RM7800E,G,L,M; RM7840E,G,L,M
7800 SERIES Relay Modules
INSTALLATION INSTRUCTIONS
Maximum Total Connected Load: 2000 VA.
APPLICATION
Fusing: 15A maximum, Type SC or equivalent Fast Blow.
The Honeywell RM7800/RM7840 Relay Modules are
microprocessor-based integrated burner controls for
automatically fired gas, oil, or combination fuel single burner
applications. The RM7800/RM7840 Relay Modules are used
for UL/CSA On/Off, UL/CSA Modulating, and FM/IRI
Modulating burner applications. The RM7800/RM7840 system
consists of a Relay Module. Keyboard Display Modules
(standard with RM7800), Dust Cover (standard with RM7840),
Subbase, Amplifier, and Purge Card. Options include DATA
CONTROLBUS MODULE™, Remote Display Mounting, First-
Out Expanded Annunciator and Communications through
Modbus™.
Environmental Ratings:
Ambient Temperature:
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.
SIL 3 Capable:
SIL 3 Capable in a properly designed Safety Instrumented
System. See form number 65-0312 for Certificate Agree-
ment.
Functions provided by the RM7800/RM7840 include
automatic burner sequencing, flame supervision, system
status indication, system or self-diagnostics and
troubleshooting. The RM7800/RM7840 is a solid state
replacement for the electromechanical R4140 Automatic
Programming Control.
Approvals:
Underwriters Laboratories Inc. Listed: File No. MP268,
Guide No. MCCZ.
Canadian Standards Association Certified: LR9S329-3.
Factory Mutual Approved: Report No. J.I.1V9A0.AF.
Swiss Re (formerly IRI): Acceptable.
Federal Communications Commission, Part 15,
Class B—Emissions.
This document provides installation and static checkout
instructions. Other applicable publications are:
65-0084:Q7800A,B 22-Terminal Wiring Subbase Product
Data.
65-0089:ST7800A Plug-In Purge Timer Installation
Instructions.
INSTALLATION
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 Sheet.
65-0101:S7830 Expanded Annunciator Product Data.
65-0109:R7824, R7847, R7848, R7849, R7851, R7852,
R7861, R7886 Flame Amplifiers for the 7800 SERIES
Product Data.
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
the application.
3. Installer must be a trained, experienced, flame
safeguard service technician.
65-0131:221818A Extension Cable Assembly Product
Data.
4. After installation is complete, check out the product
65-0229:7800 SERIES RELAY MODULES Checkout and
Troubleshooting Product Data.
operation as provided in these instructions.
65-0249:S7810M ModBus™ Module Product Data.
WARNING
Can cause property damage, severe injury,
or death.
To prevent possible hazardous burner operation, verify
safety requirements each time a control is installed on
a burner.
Fire or Explosion Hazard.
SPECIFICATIONS
Electrical Ratings, see Table 3:
Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz
(±10%).
Power Dissipation: RM7800/RM7840: 10W maximum.
SIL3
Capable
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
a. Do not run high voltage ignition transformer wires in
the same conduit with the flame detector, Data
Controlbus Module™, or Remote Reset Module
wiring.
b. Do not route flame detector, Data Controlbus
Module™, or Remote Reset Module leadwires in
conduit with line voltage circuits.
c. Remote Reset leadwires—The maximum length of
wire is 1000 feet to a Remote Reset pushbutton.
d. Data Controlbus Module™—The maximum Data
Controlbus Module™ cable length depends on the
number of system modules connected, the noise
conditions and the cable used. The maximum length
of all Data Controlbus Module™ interconnecting
wire is 1000 feet.
c. Enclose flame detector leadwires without armor
cable in metal cable or conduit.
10. Make sure loads do not exceed the terminal ratings.
Refer to the label on the RM7800/RM7840 or to the
ratings in Tables 3, 4 and 5.
d. Follow directions in flame detector, Data Controlbus
Module™, or Remote Reset Module Instructions.
8. Keyboard Display Module (KDM): Because the KDM is
powered from a low voltage, energy limited source, it
can be mounted outside of a control panel if it is
protected from mechanical damage.
Final Wiring Check
1. Check the power supply circuit. The voltage and
frequency tolerance must match those of the
RM7800/RM7840. A separate power supply circuit may
be required for the RM7800/RM7840. Add the required
disconnect means and overload protection.
2. Check all wiring circuits and complete the Static
Checkout, see Table 8, before installing the
RM7800/RM7840 on the subbase.
NOTE: A 13 Vdc power supply must be used any time more
than one Keyboard Display Module is used.
9. Maximum wire lengths follow:
a. RM7800/RM7840 leadwires—The maximum length
of leadwire is 300 feet to terminal inputs (Control,
Preignition Interlock, Running/Lockout Interlock,
High Fire Switch and Low Fire Switch).
b. Flame Detector leadwires—The maximum flame
sensor leadwire length is limited by the flame signal
strength.
3. Install all electrical connectors.
4. Restore power to the panel.
Table 1. Recommended Wire Sizes and Part Numbers.
Application
Line voltage terminals
Recommended Wire Size
Recommended Part Number(s)
14, 16 or 18 AWG copper conductor, 600 TTW60C, THW75C, THHN90C.
volt insulation, moisture-resistant wire.
Keyboard Display Module (KDM)
Data ControlBus Module™
Remote Reset Module
22 AWG two-wire twisted pair with
ground, or five wire.
Belden 8723 shielded cable or equivalent.
22 AWG two-wire twisted pair with
ground, or five wire.
Belden 8723 shielded cable or equivalent.
—
22 AWG two-wire twisted pair, insulated
for low voltage.
13 Vdc full-wave rectified transformer
power input.
18 AWG wire insulated for voltages and TTW60C, THW75C, THHN90C.
temperatures for given application.
3
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
L1
(HOT) L2
1
4
L2
120 Vac,
50/60 Hz
PLUG-IN PURGE
TIMER CARD
CONFIGURATION
JUMPERS
TEST
JACK
FLAME SIGNAL
RUN/TEST
SWITCH
F
PLUG-IN
FLAME
G
MICROCOMPUTER
AMPLIFIER
TEST
RESET
PUSHBUTTON
22
2K
3K
4K
RELAY
DRIVE
5K
RELAY
6K
7K
8K
CIRCUIT
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
9K
SAFETY RELAY
CIRCUIT
1K
STATUS LEDs
CONTROL
POWER
POWER SUPPLY
20
PRE-IGNITION
INTERLOCK
RUNNING/
LOCKOUT
LIMITS CONTROLLER
INTERLOCK
1K1
2K1 5K1
7
6
10
8
IGNITION
4K1
7K1
2K2
LOW FIRE SWITCH
18
PILOT
21
9
PILOT/V2
HIGH FIRE SWITCH
19
MAIN VALVE
6K1
3K1
5
3
BLOWER
ALARM
HIGH FIRE
12
KEYBOARD
DISPLAY MODULE
8K1
8K2
9K2
DDL
COMMON
INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLT INPUTS
13
15
14
RS485
MODULATE
1
2
9K1
DDL
FIELD WIRING
INTERNAL WIRING
REMOTE
RESET
3
LOW FIRE
COMMUNICATIONS
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
M12258
Fig. 1. Internal block diagram of the RM7800L/RM7840L (See Fig. 2, 3, 4 or 5
for individual detailed wiring instructions).
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
Table 2. 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. Earth ground must be
capable of conducting enough current to blow the 20A fuse
(or breaker) in the event of an internal short circuit.
2. Use wide straps or brackets to provide minimum length,
maximum surface area ground conductors. If a leadwire
must be used, use 14 AWG copper wire.
3. Make sure that mechanically tightened joints along the
ground path are free of nonconductive coatings and pro-
tected against corrosion on mating surfaces.
Signal ground (KDM, Data ControlBus Module™
Use the shield of the signal wire to ground the device to the
signal ground terminals [3(c)] of each device. Connect the
shield at both ends of the chain to earth ground.
Table 3. Terminal Ratings.
Description
Terminal No.
Ratings
a
G
—
—
—
Flame Sensor Ground
a
Earth G
Earth Ground
L2(N)
Line Voltage Common
Alarm
3
4
120 Vac, 1A pilot duty.
b
Line Voltage Supply (L1)
120 Vac (+10%/-15%), 50 or 60 Hz (±10%)
120 Vac, 9.8 AFL, 58.8 ALR (inrush).
120 Vac, 1 mA.
5
6
7
8
Burner Motor
Burner Controller and Limits
Lockout/Running Interlock
Pilot Valve/Ignition
120 Vac, 8A run, 43A inrush.
c
120 Vac .
c
9
Main Fuel Valve
Ignition
120 Vac .
c
10
120 Vac .
F(11)
12
13
14
15
16
17
18
19
20
21
Flame Sensor
60 to 220 Vac, current limited.
120 Vac, 75 VA pilot duty.
120 Vac, 75 VA pilot duty.
120 Vac, 75 VA pilot duty.
120 Vac, 75 VA pilot duty.
—
Firing Rate High Fire
Firing Rate Common
Firing Rate Low Fire
Firing Rate Modulate
Unused
Unused
—
Low Fire Switch Input
High Fire Switch Input
Preignition Interlock Input
Interrupted/Intermittent Pilot Valve/First Stage Oil Valve
120 Vac, 1 mA.
120 Vac, 1 mA.
120 Vac, 1 mA.
c
120 Vac .
22
a
Shutter
120 Vac, 0.5A.
.
The relay module must have an earth ground providing a connection between the subbase and the control panel or the
equipment. The earth ground wire must be capable of conducting the current to blow the 15A fuse (or breaker) in event of an
internal short circuit. The relay module requires a low impedance ground connection to the equipment frame, which, in turn,
requires a low impedance connection to earth ground.
b
c
2000 VA maximum connected load to relay module assembly.
See tables 4 and 5.
5
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
Table 4. Combinations for Terminals 8, 9, 10 and 21.
Main 9 Ignition 10
Pilot Fuel 8
Intermittent Pilot Valve 21
No Load
C
B
F
F
F
F
F
F
D
D
D
No Load
No Load
No Load
No Load
F
No Load
B
A
A
A
A
A
A
No Load
No Load
D
F
No Load
No Load
D
D
No Load
D
No Load
Table 5. Explanation of Each Combination.
C
A
B
D
F
4.5A ignition.
50 VA Pilot Duty plus
4.5A ignition.
180 VA ignition plus
motor valve with:
2A Pilot Duty.
64 VA Pilot Duty plus motor
valves with:
660 VA inrush, 360 VA
open, 260 VA hold.
3850 VA inrush, 700 VA
open, 250 VA hold.
3. Make sure no subbase wiring is projecting beyond the
terminal blocks. Tuck in wiring against the back of the
subbase so it does not interfere with the knife blade
terminals or bifurcated contacts.
Mounting RM7800/RM7840
Relay Module (Fig. 5)
1. Mount the RM7800/RM7840 vertically on the Q7800
Subbase, or mount horizontally with the knife blade
terminals pointing downward. When mounted on the
Q7800A, the RM7800/RM7840 must be in an electrical
enclosure.
IMPORTANT
The RM7800/RM7840 must be installed with a
plug-in motion rather than a hinge action.
2. When mounting in an electrical enclosure, provide
adequate clearance for servicing, installation and
removal of the RM7800/RM7840, Keyboard Display
Module, flame amplifier, flame amplifier signal voltage
probes, electrical signal voltage probes, and electrical
connections.
4. Mount the RM7800/RM7840 by aligning the four
L-shaped corner guides and knife blade terminals with
the bifurcated contacts on the wiring subbase and
securely tighten the two screws without deforming the
plastic.
a. Allow an additional two inches below the
RM7800/RM7840 for the flame amplifier mounting.
b. Allow an optional three-inch minimum to both sides
of the RM7800/RM7840 for electrical signal voltage
probes.
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
Q7800
HIGH FIRE
COMMON
LOW FIRE
MODULATE
12
13
14
G
B
R
B
R
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
L2
IGNITION
TRANSFORMER
10
W
3
4
5
W
120V ALARM
8
9
L2
15
16
(L1)
2ND STAGE
FUEL VALVE
(OPTIONAL)
BURNER MOTOR
(BLOWER)
BURNER
CONTROLLER/LIMITS
17
6
4
LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)
LOW FIRE
7
8
18
19
20
21
22
START SWITCH
1
2
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS REQUIRED.
10 SEC. INTERRUPTED
PILOT/IGNITION
HIGH FIRE
PURGE SWITCH
RM7800/7840E ONLY: HIGH FIRE PURGE SWITCH
2
5
CONNECTED TO
(L1), NOT
.
4
5
MAIN FUEL VALVE(S)
9
10
F
PREIGNITION
INTERLOCK
3
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
15 SEC.
INTERRUPTED
PILOT VALVE
4
5
DO NOT WIRE TO ANY UNUSED TERMINALS.
RM7840L1026, RM7800L1053 HAVE INTERMITTENT
PILOT VALVE FUNCTIONS.
FLAME DETECTOR
3
L1
(HOT)
1
L2
M12261C
MASTER
SWITCH
RM7800/RM7840E,L
INITIATE
(INITIAL
POWERUP
PREPURGE
HOLD
DRIVE TO
HIGH FIRE
PREPURGE PFEP
HOLD
DRIVE TO
10 SEC.
00
(4 SEC. IF
00
00
00
10
20 25
MFEP
00
POSTPURGE STANDBY
POWER POWER
15
TIMED
PREPURGE
ONLY)
LOW FIRE JR1 CLIPPED
STANDBY
POWER
RUN
POWER
POWER
POWER
POWER
POWER
POWER
PILOT
POWER
PILOT
LED
DISPLAY
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
MAIN
ALARM
ALARM
ALARM
ALARM
ALARM
BURNER/BLOWER MOTOR
10 IGN.
5
BURNER
1
5 SEC.
10 SEC. IGN./PILOT
15 SEC. PILOT
8
21
2
9
MAIN VALVE
OPERATING
CONTROLS
AND
TO
TO
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
L1
6
6
7
INTERLOCK. CHECK
IC
INTERLOCKS
PREIGNITION INTERLOCK CLOSED
TO 19 HIGH FIRE SW.
4
TO 20
PII
18
5
5
LOW FIRE SW.
TO
FLAME PROVING
13
1
FLAME
SIGNAL
SSC
SAFE START CHECK
SWITCHING
15
TO
TO
14
13
14
13
TO
13
12
TO
FIRING
RATE
MOTOR ACTION
MOTOR
1
2
FOR THE R7800/R7840E: THE HIGH FIRE SWITCH MUST BE WIRED CORRECTLY TO PERFORM ENERGY SAVING PURGE
FUNCTIONS. THE BURNER/BLOWER MOTOR DOES NOT START UNTIL THE HIGH FIRE SWITCH MAKES.
RM7800L1053, RM7840L1026: TERMINAL 21 PROVIDES INTERMITTENT PILOT FUNCTION.
M12263D
Fig. 2. Wiring subbase and sequence for RM7800E,L/RM7840E,L.
7
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
Q7800
HIGH FIRE
COMMON
LOW FIRE
G
12
13
14
B
B
R
L2
R
W
3
4
5
W
120V ALARM
MODULATE
(L1)
15
16
FOR DIRECT SPARK IGNITION
(OIL OR GAS)
BURNER MOTOR
(BLOWER)
3
IGNITION
TRANSFORMER
10
BURNER
CONTROLLER/LIMITS
17
6
4
1ST STAGE
FUEL VALVE
21
L2
RUNNING INTERLOCKS
(INC. AIR FLOW SWITCH)
LOW FIRE
START SWITCH
7
8
18
19
20
21
22
2ND STAGE
9
FUEL VALVE
(OPTIONAL)
10 SEC. INTERRUPTED
PILOT/IGNITION
2
JUMPER WIRE FOR 30s MFEP
MAIN FUEL VALVE(S)
9
10
F
PREIGNITION
INTERLOCK
1
2
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS REQUIRED.
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
15 OR 30 SEC.
INTERRUPTED/
INTERMITTENT
PILOT VALVE
ADD JUMPER FOR 30 SECOND MAIN FLAME
ESTABLISHING PERIOD (MFEP).
FLAME DETECTOR
4
3
4
DO NOT WIRE TO ANY UNUSED TERMINALS.
L1
(HOT)
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
L2
MASTER
SWITCH
M12260B
1
RM7800G/RM7840G
INITIATE
(INITIAL
POWERUP
ONLY)
PREPURGE PFEP
10 SEC.
00
HOLD
DRIVE TO
00
00
10
20 25
MFEP
00
POSTPURGE STANDBY
POWER POWER
15
TIMED
PREPURGE
(4 SEC. IF
LOW FIRE JR1 CLIPPED
STANDBY
POWER
RUN
POWER
POWER
POWER
POWER
POWER
PILOT
POWER
PILOT
LED
DISPLAY
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
MAIN
ALARM
ALARM
ALARM
ALARM
ALARM
BURNER/BLOWER MOTOR
10 IGN.
10 SEC. IGN./PILOT
15/30 SEC. INTERRUPTED/INTERMITTENT PILOT VALVE 21
MAIN VALVE
5
BURNER
5 SEC.
8
9
OPERATING
CONTROLS
AND
TO
TO
LIMITS AND BURNER CONTROLLER CLOSED L1
6
7
6
INTERLOCK. CHECK
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
RUNNING INTERLOCKS CLOSED
IC
INTERLOCKS
4
TO 20
PII
18
5
TO
FLAME PROVING
13
FLAME
SIGNAL
SSC
SAFE START CHECK
15
TO
RM7800/7840G SWITCHING
13
TO
14
14
13
TO
13
12
TO
FIRING
RATE
MOTOR ACTION
MOTOR
M12264A
Fig. 3. Wiring subbase and sequence for RM7800G/RM7840G.
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
Q7800
G
12
13
14
COMMON
L2
FOR DIRECT SPARK IGNITION
(OIL OR GAS)
3
4
5
120V ALARM
IGNITION
TRANSFORMER
10
2
MODULATE
DAMPER
MOTOR
(L1)
15
16
1ST STAGE
FUEL VALVE
21
L2
BURNER MOTOR
(BLOWER)
2ND STAGE
9
FUEL VALVE
(OPTIONAL)
BURNER
CONTROLLER/LIMITS
17
6
2
2
LOW FIRE
START SWITCH
RUNNING INTERLOCKS
(INC. AIR FLOW SWITCH)
7
8
18
19
20
21
22
10 SEC. INTERRUPTED
PILOT/IGNITION
3
1
2
120V, 50/60 Hz POWER SUPPLY. PROVIDE
DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
MAIN FUEL VALVE(S)
9
10
F
PREIGNITION
INTERLOCK
WHEN NO DAMPER MOTOR OR LOWFIRE
SWITCH IS USED, JUMPER TERMINAL 14
TO TERMINAL 18. DO NOT WIRE TERMINAL 15.
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
INTERMITTENT
PILOT
3
4
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION
INSTRUCTIONS FOR CORRECT WIRING.
FLAME DETECTOR
4
L1
(HOT)
1
L2
M12262A
MASTER
SWITCH
RM7800M/RM7840M
INITIATE
(INITIAL
POWERUP
ONLY)
PREPURGE PFEP
HOLD
10 SEC.
00
00
00
10
20 25
00
POSTPURGE STANDBY
POWER POWER
15
TIMED
PREPURGE
DRIVE TO
LOW FIRE
(4 SEC. IF
JR1 CLIPPED
POWER
STANDBY
MFEP
RUN
POWER
POWER
POWER
POWER
POWER
PILOT
POWER
PILOT
LED
DISPLAY
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
PILOT
FLAME
MAIN
FLAME
MAIN
FLAME
MAIN
ALARM
ALARM
ALARM
ALARM
ALARM
BURNER/BLOWER MOTOR
10 IGN.
10 SEC. IGN./PILOT
5
BURNER
5 SEC.
8
INTERMITTENT PILOT VALVE 21
MAIN VALVE
9
OPERATING
CONTROLS
AND
TO
TO
LIMITS AND BURNER CONTROLLER CLOSED L1
6
7
6
INTERLOCK. CHECK
RUNNING INTERLOCKS CLOSED
TO 20
LOW FIRE SW.
IC
INTERLOCKS
PREIGNITION INTERLOCK CLOSED
4
PII
18
5
TO
FLAME PROVING
13
FLAME
SIGNAL
SSC
SAFE START CHECK
RM7800M/7840M SWITCHING
13 15
15
TO
TO
MOTOR ACTION
DAMPER
MOTOR
M12265A
Fig. 4. Wiring subbase and sequence for RM7800M/RM7840M.
9
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
WIRING
SUBBASE
RUN/TEST
SWITCH
HONEYWELL
RELAY
MODULE
CONFIGURATION
JUMPERS
PURGE
TIMER
SEQUENCE
STATUS
LED PANEL
POWER
RESET
BUTTON
PILOT
FLAM
E
MAIN
ALARM
RE
KEYBOARD
DISPLAY
MODULE
CAPTIVE
MOUNTING
SCREW
SET
(STANDARD ON
RM7800E,G,L,M)
BUR
NE
R
CONTROL
FLAME
AMPLIFIER
S
CROLL
MODE
- S
A
V
E
-
M16353
Fig. 5. RM7800/RM7840 Relay Module exploded view.
d. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
e. Main valve terminal is energized.
f. Internal system fault occurred.
g. Purge card is not installed or is removed.
h. Purge card is bad.
SAFETY SHUTDOWN
Safety Shutdown (Lockout) occurs if
any of the following occur during the
indicated period:
3. PREPURGE Period:
a. Preignition Interlock opens anytime during
1. INITIATE Period:
PREPURGE period (RM7840E,L).
a. Purge card is not installed or is removed.
b. Purge card is bad.
c. Configuration jumpers are changed (after 200 hours
of operation).
d. Ac line power errors occurred, see Operation
section.
b. Flame signal is detected after first ten seconds
during PREPURGE (RM7840E,L).
c. High Fire Switch fails to close within four minutes
and fifteen seconds after the firing rate motor is
commanded to drive to the high fire position at the
start of PREPURGE (RM7840E,L).
e. Four minute INITIATE period has been exceeded.
2. STANDBY Period:
d. Low Fire Switch fails to close within four minutes
and fifteen seconds after the firing rate motor is
commanded to drive to the low fire position at the
end of PREPURGE.
e. Running Interlock does not close within 30 seconds
(RM7840G,M).
a. Flame signal is present after 240 seconds.
b. Preignition Interlock is open an accumulative time
of 30 seconds.
c. Interlock check feature is enabled and the
Interlock String (including airflow switch) is closed
for 120 seconds with controller closed.
f. Lockout Interlock does not close within 10 seconds
(RM7840E,L).
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g. Lockout Interlock opens during PREPURGE
(RM7840E,L).
h. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
i. Main valve terminal is energized.
j. Internal system fault occurred.
k. Purge card is removed.
unless the voltage or frequency tolerances are not met. When
the tolerances are not met, a hold condition is initiated and
displayed on the VFD for at least five seconds. When the
tolerances are met, the INITIATE sequence restarts. If the
condition is not corrected and the hold condition exists for four
minutes, the RM7800/RM7840 locks out. Causes for hold
conditions in the INITIATE sequence:
l. Purge card is bad.
4. PILOT FLAME ESTABLISHING Period (PFEP):
a. Low Fire Switch opens.
a. AC line dropout is detected.
b. AC line noise prevents a sufficient reading of the
line voltage inputs.
c. Low line voltage brownouts occur.
b. Lockout Interlock opens (RM7840E,L).
c. Ignition/pilot valve/intermittent pilot valve terminal is
not energized.
The INITIATE sequence also delays the burner motor starter
from being energized and de-energized from an intermittent
AC line input or control input.
d. Early spark termination terminal is energized after
five seconds.
e. No flame is present at the end of PFEP.
f. Main valve terminal is energized (RM7800G,M).
g. Internal system fault occurred.
h. Purge card is removed.
Standby
The RM7800/RM7840 remains in standby, ready to start. The
operating control determines a call for heat is present and
provides input to terminal 6. The burner switch, limits,
operating control and all microcomputer monitored circuits
must be in the correct state for the RM7800/RM7840 to
advance into the PREPURGE sequence.
i. Purge card is bad.
5. MAIN FLAME ESTABLISHING Period (MFEP):
a. Low Fire Switch Opens.
b. Lockout Interlock opens (RM7840E,L).
c. Ignition/pilot valve/intermittent pilot valve terminal is
not energized.
d. Main valve terminal is not energized.
e. No flame is present at the end of MFEP.
f. Internal system fault occurred.
g. Purge card is removed.
Prepurge
The RM7800/RM7840 provides a prepurge timing selectable
from two seconds to 30 minutes with power applied and the
RM7800 operating control indicating a call for heat:
h. Purge card is bad.
6. RUN Period:
a. Running Interlocks, Preignition Interlocks, Burner
Switch, Run/Test Switch, Lockout Interlocks and all
microcomputer monitored circuits must be in the
correct operating state.
b. The blower motor output, terminal 5, is powered to
start the PREPURGE sequence, except for the
RM7800E/RM7840E. The firing rate motor is driven
to the high fire position. The PREPURGE timing for
the RM7800/RM7840E,L does not begin until the
Lockout Interlock String and High Fire Switch are
both closed. The blower motor output for the
RM7800E is not energized until the High Fire Switch
is closed.
a. No flame is present.
b. Lockout Interlock opens (RM7840E,L).
c. Interrupted pilot valve terminal is energized
(RM7840G,M).
d. Main valve terminal is not energized.
e. Internal system fault occurred.
f. Purge card is removed.
g. Purge card is bad.
7. POSTPURGE Period:
a. Preignition Interlock does not close in five seconds
and opens after five-second time period.
b. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
c. Main valve terminal is energized.
d. Internal system fault occurred.
e. Purge card is removed.
c. The Preignition Interlock input must remain closed
throughout PREPURGE; otherwise, control returns
to the STANDBY state and holds (30 seconds) for
the RM7800/RM7840G,M or safety shutdown for the
RM7800/RM7840E,L occurs.
f. Purge card is bad.
d. The Lockout Interlock or Running Interlock inputs
(interlock circuit including Airflow Switch) must close
by ten seconds into PREPURGE; otherwise, a
recycle to the beginning of PREPURGE for the
RM7800/RM7840G,M will happen or a safety
shutdown for the RM7800/RM7840E,L occurs.
e. When PREPURGE timing is complete, the firing rate
motor drives to the low fire position,
OPERATION
Sequence of Operation
The RM7800/RM7840 has the following operating sequences,
see Fig. 2, 3, 4, and Table 6. The RM7800/RM7840 LED
provide positive visual indication of the program sequence:
POWER, PILOT, FLAME, MAIN and ALARM.
RM7800/RM7840E,G,L.
f. When the firing rate motor reaches low fire position,
the Low Fire Switch, terminal 18, input must be
energized before entering the Ignition Trial state.
Initiate
The RM7800/RM7840 enters the INITIATE sequence when
the Relay Module is powered. The RM7800/RM7840 can also
enter the INITIATE sequence if the Relay Module verifies
voltage fluctuations of +10/-15 percent or frequency
Ignition Trials
1. Pilot Flame Establishing Period (PFEP):
a. With the firing rate motor at the low fire position:
(1) The pilot valve and ignition transformer,
terminals 8, 10 and 21, are energized. The
RM7800M has an intermittent pilot valve,
fluctuations of +/-10 percent during any part of the operating
sequence. The INITIATE sequence lasts for ten seconds
11
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
terminal 21. The RM7800/RM7840G has an
interrupted or intermittent pilot valve, terminal
21, depending on the selection of configuration
jumper 2. The RM7800/RM7840E,L has a
fifteen-second interrupted pilot valve, terminal
21. All of the RM7800/RM7840s have a
ten-second interrupted pilot valve/ignition,
terminal 8.
(a) Not turned off, or
(b)15 seconds after Terminal 9 is energized and
JR2 is clipped, or
(c)30 seconds after Terminal 9 is energized and
Terminals 5 and 19 are jumpered and jumper
JR2 is clipped.
(3) RM7800L1053, RM7840L1026,
RM7800M/RM7840M: Remain energized as
long as call for heat is present.
(2) During PFEP, the Low Fire Switch must remain
closed. If it opens, a safety shutdown occurs.
(3) The Preignition Interlock input is ignored
Run
throughout the Ignition Trial state.
b. Flame must be proven by the end of the ten-second
PFEP (four if JR1 is clipped) to allow the sequence
to continue. If flame is not proven by the end of
PFEP, a safety shutdown occurs.
1. A ten-second stabilization period occurs at the
beginning of the RUN period.
2. The firing rate motor releases to modulation
(RM7800/RM7840E,G,L). Damper motor is energized
(RM7800/RM7840M).
3. The RM7800/RM7840 is now in RUN and remains in
RUN until the controller input, terminal 6, opens,
indicating that the demand is satisfied or a limit opened.
c. After five seconds, the ignition, terminal 10, is
de-energized for early spark termination.
2. Main Flame Establishing Period (MFEP):
a. Terminal 9 is energized when the presence of flame
is verified at the end of a 10-second Pilot Flame
Establishing Period (PFEP) (four seconds if JR1 is
clipped).
Postpurge
The RM7800/RM7840 provides a fifteen-second
POSTPURGE following the completion of the RUN period.
The blower motor output is powered to drive all products of
combustion and any unburned fuel from the combustion
chamber. It also supplies combustion air to burn fuel being
purged from the fuel line downstream of the fuel shutoff valve.
b. Terminal 8 is turned off 10 seconds after Terminal 9
is energized.
c. Terminal 21 action:
(1) RM7800E,L/RM7840E,L: De-energized
15 seconds after Terminal 9 is energized.
(2) RM7840G:
Table 6. Sequence Timing for Normal Operation.
Flame Establishing
Period
Post-
Firing
Rate
Energy Approval
Saving Code
Purge Interlock
Run Timing Circuits
a
Device
Initiate Standby Purge Pilot
Main
Circuit Prepurge Bodies
RM7800E/ 10 sec.. *
RM7840E
**
4 or 10 10 or 15
*
15 sec. Preignition, 4-wire
Yes
FM/IRI
Modulating
sec.
sec.
Lockout,
High and
Low Fire
modulating
RM7800G/
RM7840G
10, 15 sec.
or
intermittent
Preignition,
Running,
Low Fire
No
UL/CSA
Modulating
RM7800L/
RM7840L
10 or 15
Preignition,
Lockout,
High and
Low Fire
FM/IRI
Modulating
b
sec.
RM7800M/
RM7840M
10 sec. or
intermittent
Preignition, 2-wire
Running, isolated
UL/CSA
On-Off
Low Fire
On-Off-On
contacts
*
STANDBY and RUN can be an infinite time period.
** PURGE determined by which ST7800A purge card is selected.
a
The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.
See Fig. 2, 3, 4, 5 and 6.
b
RM7800L1053, RM7840L1026: 10 second or intermittent.
Keyboard Display Module (VFD)
The Keyboard Display Module (see Fig. 5) is provided with the
RM7800 Relay Module (but is not required for operation) and
is an option for the RM7840 Relay Module. The first line of the
Vacuum Fluorescent Display (VFD) provides:
•
•
•
Current status of the burner sequence (STANDBY,
PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE).
Timing information (PURGE, PILOT IGN, MAIN IGN and
POSTPURGE) in minutes and seconds.
Hold information (PURGE HOLD: T19).
66-1085—04
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
•
Lockout information (Lockout, Fault Code, Message and
Sequence).
allowing pilot-turn-down test and other burner
adjustments to be made. This activates a fifteen second
flameout timer that permits pilot flame adjustment
without nuisance safety shutdowns. The Run/Test
Switch is ignored during PFEP for the RM7800/
RM7840E,L if Terminals 8 and 9 or 9 and 21 are
jumpered.
The extreme right side of the first line is either blank or shows
a small arrow pointing to the second line followed by a
two-letter code (DI-Diagnostic Information, Hn-Fault History
Information, and EA-Expanded Annunciator). When the arrow
and two-letter code are displayed, it indicates the second line
is showing a selectable message submenu. The second line
displays selectable or preemptive messages.
5. During Run, the Run/Test Switch, when placed in the
TEST position, drives the firing rate motor to the Low
Fire position.
A selectable message supplies information for flame strength,
system status indication, system or self-diagnostics and
troubleshooting.
NOTE: When RM7800/RM7840 is switched to the Test
mode, it stops and holds at the next Run/Test Switch
point in the operating sequence. Make sure that the
Run/Test Switch is in the RUN position before
leaving the installation.
A preemptive message has parentheses around the message
and supplies a detailed message to support the sequence
status information. A preemptive message can also be a
lockout message. A preemptive message replaces a
selectable message to support the sequence status
information. It also replaces a selectable message after 60
seconds if it or a lockout message is available.
SETTINGS AND ADJUSTMENTS
Selectable Site-Configurable
Jumpers
Run/Test Switch
The RM7800/RM7840 has three site-configurable jumper
options, see Fig. 6 and Table 7. If necessary, clip the
site-configurable jumpers with side cutters and remove the
resistors from the Relay Module.
WARNING
Explosion Hazard.
Can cause serious injury or death.
Do not use the Run/Test switch during the Pilot Flame
Establishing Period for the RM7800/RM7840G,M
when using Direct Spark Function, because it turns on
the main gas valve, causing an accumulation of fuel in
the burner.
SELECTABLE CONFIGURATION JUMPERS
RUN/TEST SWITCH
The Run/Test Switch is located on the top side of the
RM7800/RM7840, see Fig. 6. The Run/Test Switch allows the
burner sequence to be altered as follows:
1. In Prepurge Drive To High Fire Position, the Run/Test
Switch, when placed in the TEST position, holds in
PREPURGE with the firing rate motor in the High Fire
position.
2. In the measured PREPURGE sequence, the Run/Test
Switch, when placed in the TEST position, causes the
PREPURGE timing to stop. The firing rate motor is in
the High Fire position.
3. In Prepurge Drive to Low Fire position, the Run/Test
Switch, when placed in the TEST position, holds the
burner sequence in PREPURGE with the firing rate
motor in the Low Fire position.
4. In PFEP, the Run/Test Switch, when placed in the TEST
position, stops the timer during the first eight seconds
when a ten second PFEP is selected or during the first
three seconds when a four second PFEP is selected,
NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.
M12301
Fig. 6. Selectable site-configurable jumpers.
13
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
Table 7. Site Configurable Jumper Options.
Description Intact Clipped
10 seconds
Jumper Number
JR1
RM7800/RM7840 Type
Pilot Flame Establishing
Period (PFEP)
4 seconds
All
a
b
JR2
10 seconds
Intermittent
RM7800G/RM7840G
All
Pilot Valve /Main Flame
15 or 30 seconds Interrupted
Establishing Period (MFEP)
JR3
Start-up Interlock Check
Disabled
Enabled
a
b
Pilot Valve /First Stage Oil Valve (Valve/Start) Terminal 21.
A 30 second MFEP can be accomplished by adding a jumper wire between Terminals 19 and 5.
SERVICE NOTE:Clipping and removing a site-configurable jumper enhances the level of safety. Removal after 200 hours of
main valve operation will result in a hard lockout, Code 110.
Equipment Recommended
STATIC CHECKOUT
1. Voltmeter (1M ohm/volt minimum sensitivity) set on the
0-300 Vac scale.
After checking all wiring, perform this checkout before
installing the RM7800/RM7840 on the subbase. These tests
verify the Q7800 Wiring Subbase is wired correctly, and the
external controllers, limits, interlocks, actuators, valves,
transformers, motors and other devices are operating
properly.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
(304.8 mm) long with insulated alligator clips at both
ends. An ammeter may be used in place of a jumper
wire to check the amp usage when testing the blower
motor, ignition, pilot and main valve operation.
General Instructions
WARNING
1. Perform all applicable tests listed in Static Checkout,
Table 8, in the order listed.
Explosion and Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
2. Make sure all manual fuel shutoff valve(s) are closed.
3. Perform only those tests designated for the specific
RM7800/RM7840 model being tested.
4. Raise the setpoint of the operating controller to simulate
a call for heat.
5. For each test, open the master switch and install the
jumper wire(s) between the subbase wiring terminals
listed in the Test Jumpers column.
6. Close the master switch before observing operation.
7. Read the voltage between the subbase wiring terminals
listed in the Voltmeter column.
1. Close all manual fuel shutoff valve(s) before starting
these tests.
2. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
3. Open the master switch before installing or
removing a jumper on the subbase.
4. Before continuing to the next test, be sure to
remove test jumper(s) used in the previous test.
5. Replace all limits and interlocks that are not
operating properly. Do not bypass limits and
interlocks.
8. If there is no voltage or the operation is abnormal, check
the circuits and external devices as described in the last
column.
9. Check all wiring for correct connections, tight terminal
screws, correct wire, and proper wiring techniques.
Replace all damaged or incorrectly sized wires.
10. Replace faulty controllers, limits, interlocks, actuators,
valves, transformers, motors and other devices as
required.
11. Make sure normal operation is obtained for each
required test before continuing the checkout.
12. After completing each test, be sure to remove the test
jumper(s).
CAUTION
Equipment Damage Hazard.
Improper testing can damage equipment.
Internal surge protectors can break down and conduct
a current, causing the RM7800/RM7840 to fail the
dielectric test or possibly destroy the internal lightning
and high current protection. Do not perform a dielectric
test with the RM7800/RM7840 installed.
WARNING
Explosion Hazard.
Can cause serious injury or death.
Make sure all manual fuel shutoff valves are closed
before performing static checkout.
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
Table 8. Static Checkout.
RM7800/
RM7840
Models
Test
No.
Test
If Operation is Abnormal,
Check the Items Listed Below
Jumpers Voltmeter
Normal Operation
1
2
All
None
4-L2
Line voltage at Terminal 4.
1. Master Switch.
2. Power connected to the Master Switch.
3. Overload protection (fuse, circuit breaker,
etc.) has not opened the power line.
6-L2
Line voltage at Terminal 6.
Line voltage at Terminal 20.
1. Limits.
2. Burner Controller.
3
4
20-L2
7-L2
1. Preignition interlocks.
4-5
1. Burner motor (fan or
blower) starts.
2. Line voltage at Terminal
7 within 10 seconds.
1. Burner motor circuit.
a. Manual switch of burner motor.
b. Burner motor power supply, overload
protection, and starter.
c. Burner motor.
2. Running or Lockout Interlocks (including
Airflow Switch).
5
6
4-10
4-8
—
—
Ignition spark (if ignition
transformer is connected to
Terminal 10)
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
All
1. Ignition spark (if ignition
transformer is connected to
Terminal 8).
2. Automatic pilot valve opens (if
connected to Terminal 8).
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
2. Listen for click or feel head of valve for
activation.
a. Actuator if used.
b. Pilot valve.
NOTE: Refer to wiring diagram of
system being tested.
7
8
4-21
4-9
—
—
Same as test no. 6 for connections Same as test no. 6. If using direct spark
to Terminal 8. If using direct spark ignition, check the first stage fuel valve(s)
ignition, check the first stage fuel
valve(s) instead of the pilot valve.
instead of the pilot valve.
Automatic main fuel valve(s) open. 1. Listen for and observe operation of the
If using direct spark ignition on a
model with intermittent pilot on
Terminal 21, check the optional
second stage fuel valve, if used.
main
fuel valve(s) and actuator(s).
2. Valve(s) and actuator(s).
1. Alarm.
9
4-3
—
Alarm (if used) turns on.
10
11
12
13
14
RM7800E,G,L; 4-5
RM7840E,G,L and
18-L2
Firing rate motor drives open; zero 1. Low Fire Start Switch.
volts at Terminal 18 after motor
starts driving open.
2. Firing rate motor and transformer.
12-13
RM7800E,G,L; 4-5
RM7840E,G,L and
18-L2
19-L2
19-L2
—
Firing rate motor drives closed; line 1. Low Fire Start Switch.
voltage at Terminal 18 after motor 2. Firing rate motor and transformer.
is in Low Fire position.
14-13
RM7800E,L;
RM7840E,L
4-5
and
12-13
Firing rate motor drives open; line 1. High Fire Purge Switch.
voltage at Terminal 19 after motor 2. Firing rate motor and transformer.
is in High Fire position.
RM7800E,L;
RM7840E,L
4-5
and
14-13
Firing rate motor drives closed;
zero volts at Terminal 19 after
motor starts driving closed.
1. Low Fire Start Switch.
2. Firing rate motor and transformer.
RM7800E,G,L; 15-13
RM7840E,G,L
1. Raise setpoint of Series 90
controller—firing rate motor
should drive toward open.
2. Lower setpoint of Series 90
controller—firing rate motor
should drive toward closed.
1. Series 90 Controller.
2. Firing rate motor and transformer.
15
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Table 8. Static Checkout. (Continued)
RM7800/
RM7840
Models
Test
No.
Test
If Operation is Abnormal,
Check the Items Listed Below
Jumpers Voltmeter
Normal Operation
15
RM7800M;
14-13
—
If damper motor is used, motor
drives damper open.
Damper motor.
RM7840M with
open damper
contacts..
16
17
RM7800M;
4-5
18-L2
18-L2
If damper motor is used, motor
drives open; line voltage at
Terminal 18 after motor is in Low
Fire position.
1. Low Fire Start Switch.
2. Damper motor.
RM7840M with
open damper
contacts..
RM7800M;
4-5
If damper motor is used, motor
drives open; zero volts at
Terminal 18.
1. Low Fire Start Switch.
2. Damper motor.
RM7840M with and
open damper 4-13
contacts..
Final All
CAUTION
Equipment Damage Hazard.
Improper wiring can damage equipment.
On completing these tests, open the master switch and remove all test jumpers from the
subbase terminal. Also remove bypass jumpers from the low fuel pressure limits (if used) to
prevent equipment damage.
Automation and Control Solutions
Honeywell International Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
Honeywell Limited-Honeywell Limitée
35 Dynamic Drive
® U.S. Registered Trademark
© 2010 Honeywell International Inc.
66-1085—04 M.S. Rev. 09-10
Printed in U.S.A.
Toronto, Ontario M1V 4Z9
customer.honeywell.com
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