Product Overview

ManualsBrandsHoneywell ManualsHeating SuppliesOn-Off Primary Control, 4 or 10 sec Fixed Pilot

Table Of Contents

PRODUCT DATA

66-1195-01

RM7890; RM7895 100 Vac

7800 SERIES Relay Modules

APPLICATION

The Honeywell RM7890B; RM7895A Relay Modules are

microprocessor based integrated burner controls for

automatically 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.

The RM7890; RM7895 provides on/off automatic burner

sequencing, flame supervision, system status indication,

system or self-diagnostics and troubleshooting. The RM7895

includes an output for the blower motor to provide purging.

This document provides installation and static checkout

instructions. Other applicable publications are:

FEATURES

• Safety features:

— Closed loop logic test.

— Dynamic AMPLI-CHECK™ circuitry.

— Dynamic input check.

— Dynamic safety relay test.

— Dynamic self-check logic.

Form

Number Description

65-0249 S7810M Modbus Module

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 Sheet

65-0109 R7824, R7847, R7848, R7849, R7851, R7852,

R7861, R7886 Flame Amplifiers for the 7800

SERIES Product Data

65-0131 221818A Extension Cable Assembly Product

Data

65-0229 7800 SERIES Relay Modules Checkout and

Troubleshooting

Contents

Application ........................................................................ 1

Features ........................................................................... 1

Specifications ................................................................... 2

Principal Technical Features ............................................. 6

Installation ........................................................................ 7

Wiring ............................................................................... 10

Assembly .......................................................................... 13

Troubleshooting ................................................................ 24

Summary of content (28 pages)

PAGE 1
RM7890; RM7895 100 Vac 7800 SERIES Relay Modules PRODUCT DATA The RM7890; RM7895 provides on/off automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics and troubleshooting. The RM7895 includes an output for the blower motor to provide purging. This document provides installation and static checkout instructions.
PAGE 2
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES — — — Expanded safe-start check. Internal hardware status monitoring. Tamper resistant timing and logic. — — Total hours of operation. Fault history providing the six most recent faults: • Cycles of operation at the time of the fault. • Access for external electrical voltage checks. • Fault message and code. • Application flexibility. • Hours of operation at the time of the fault.
PAGE 3
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Terminal No. G Earth G Table 1. RM7890, RM7895 Terminal Ratings.
PAGE 4
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES BURNER CONTROL 5 (127) 1 POWER PILOT FLAME MAIN ALARM RESET 5-1/4 (133) 5 (127) 1 M5148A OPTIONAL TERMINAL TEST ACCESS SLOT COVER. Fig. 1. Mounting dimensions of RM7890, RM7895 Relay Module and Q7800A Subbase in in. (mm). BURNER CONTROL 5 (127) POWER PILOT 1 FLAME MAIN ALARM RESET 6-3/32 (155) 5 (127) 1 REMOVE ONLY FOR TERMINAL TEST ACCESS. M5149 Fig. 2. Mounting dimensions of RM7890, RM7895 Relay Module and Q7800B Subbase in in. (mm).
PAGE 5
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES 50023821-001 Keyboard Display Module Cover, NEMA 4, clear. 50023821-002 Keyboard Display Module Cover, NEMA 4, clear with reset button. 205321B Flush Display Mounting Kit. 221818A Extension Cable, display, 5 ft (1.52 m). 221818C Extension Cable, display, 10 ft (3.05 m). 123514A Rectification Flame Simulator. 203569 Ultraviolet Flame Simulator IMPORTANT A flame detection system is required for operation and must be ordered separately.
PAGE 6
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Table 5. Sequence Timing for Normal Operation. Device Initiate Standbya Purgeb Runa Pilot Flame Establishing Period RM7890 10 sec. — N/A 4 or 10 sec. — RM7895 10 sec. — — 4 or 10 sec. — a b Standby and Run can be an infinite time period. Purge is determined by the ST7800 Purge Timing Card selected (RM7895 only).
PAGE 7
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Dynamic Input Check The optional multi-functional KDM shows elapsed time during PILOT IGN. As an additional troubleshooting aid, it provides sequence timing, diagnostic information, historical information and expanded annunciator information during normal operation or when a safety shutdown or hold occurs.
PAGE 8
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Location IMPORTANT 1. Wiring connections for the relay modules are unique; refer to Fig. 6 and 7 or the correct Specifications for proper subbase wiring. 2. Wiring must comply with all applicable codes, ordinances and regulations. 3. Wiring must comply with NEC Class 1 (Line Voltage) wiring. 4. Loads connected to the relay module must not exceed those listed on the relay module label or the Specifications; see Table 1. 5.
PAGE 9
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES L1 L2 (HOT) 1 3 100 Vac CONFIGURATION JUMPERS TEST JACK FLAME SIGNAL L2 F MICROCOMPUTER RESET PUSHBUTTON TEST RELAY DRIVE CIRCUIT SAFETY RELAY CIRCUIT STATUS LEDs 6 3K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS 4K 1K 1K1 2K1 4K2 4K1 2K2 3K1 DDL OPTIONAL KEYBOARD DISPLAY MODULE 1 1 2 3 CONTROL POWER 10 IGNITION 8 PILOT 9 MAIN VALVE 4 ALARM INDICATES FEEDBACK SENSING TO RELAY STATUS FEEDBACK AND LINE VOLT INPUTS RS485 DDL C
PAGE 10
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES L1 (HOT) L2 1 5 L2 100 Vac PLUG-IN PURGE TIMER CARD CONFIGURATION JUMPERS TEST JACK FLAME SIGNAL F MICROCOMPUTER TEST RESET PUSHBUTTON RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS 6K 7K SAFETY RELAY CIRCUIT STATUS LEDs 1K POWER SUPPLY LOCKOUT INTERLOCK LIMITS CONTROLLER 6 1K1 7 2K1 5K1 4K1 2K2 6K1 3K1 OPTIONAL KEYBOARD DISPLAY MODULE 1 2 3 CONTROL POWER 10 IGNITION 8 PILOT 9 MAIN VALVE 4 BLOWER 3 ALARM INDICATES FEEDBACK
PAGE 11
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Q7800 120V ALARM BURNER CONTROLLER/LIMITS INTERMITTENT PILOT/IGNITION G 12 L2 13 3 (L1) 14 4 15 5 16 6 17 7 18 8 19 MAIN FUEL VALVE(S) 9 20 IGNITION 10 21 F 22 2 FOR DIRECT SPARK IGNITION (OIL OR GAS) 10 IGNITION TRANSFORMER 8 MAIN VALVE L2 9 RECTIFYING FLAME ROD L1 (HOT) 1 100V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
PAGE 12
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Q7800 G 12 L2 13 120V ALARM 3 14 BURNER MOTOR (BLOWER) 4 15 5 BURNER CONTROLLER/LIMITS AIRFLOW INTERLOCK (L1) 2 16 6 17 7 18 8 19 FOR DIRECT SPARK IGNITION (OIL OR GAS) 10 INTERMITTENT PILOT/IGNITION IGNITION TRANSFORMER L2 8 MAIN FUEL VALVE(S) 9 20 IGNITION 10 21 F 22 MAIN VALVE RECTIFYING FLAME ROD 1 100V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
PAGE 13
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES c. KDM: The KDM is powered from a low voltage, energy-limited source, so it can be mounted outside of the control panel if it is protected from mechanical damage. NOTE: Use a separate 13 Vdc power supply any time more than two Data ControlBus™ Modules or KDM are used or when placed more than 100 feet (30 meters) from the relay module. 8. 9. 10. 11. 12. 13. 3. d.
PAGE 14
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES 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 manufacturer instructions. Keep the flame signal leadwires as short as possible from the flame detector to the wiring subbase. Capacitance increases with leadwire length, reducing the signal strength.
PAGE 15
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES 00 10 PFEP RUN 4 or 10 SEC 00 INITIATE LED DISPLAY STANDBY POWER POWER SAFESTART POWER POWER PILOT PILOT FLAME FLAME MAIN MAIN ALARM ALARM IGNITION BURNER START STANDBY POWER POWER 10 INTERMITTENT PILOT 8 MAIN VALVE OPERATING CONTROLLER AND LIMITS 1 9 LIMITS AND BURNER CONTROL CLOSED L1 TO 6 FLAME SIGNAL SAFE START CHECK FLAME PROVING SSC 1 MAIN FUEL VALVE WILL BE ENERGIZED DURING PFEP IF FLAME IS PROVEN. M32664 Fig. 12.
PAGE 16
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES sequence restarts. If the condition is not corrected and the hold condition exists for four minutes, the relay module locks out. Causes for hold conditions in the INITIATE sequence are: 1. 2. 3. 4. 3. Ac line dropout is detected. Ac line frequency error. Ac line noise occurred that prevents a sufficient reading of the line voltage inputs. Brownout occurred caused by a low line voltage. shutdown occurs.
PAGE 17
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Table 9. Site-Configurable Jumper Options (RM7895). Jumper Number Description Intact Clipped JR1 Pilot Flame Establishing Period 10 seconds 4 seconds JR2 Flame Failure Action Recycle Lockout JR3 Airflow Switch (ILK) Failure Recycle Lockout STATIC CHECKOUT Equipment Recommended 1. WARNING 2. Electrical Shock Hazard. Can cause severe injury, death or property damage.
PAGE 18
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Table 10. RM7890 Static Checkout. Test Number Test Jumpers Voltmeter Normal Operation If Operation is Abnormal, Check the Items 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. Bypass them with jumpers for the remaining static tests, if required. 1 None 3 to L2 Line voltage at terminal 3. 1.
PAGE 19
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Table 11. RM7895 Static Checkout. Test Number Test Jumpers Voltmeter Normal Operation If Operation is Abnormal, Check the Items 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. Bypass them with jumpers for the remaining static tests, if required. 1 None 5 to L2 Line voltage at terminal 3. 1.
PAGE 20
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Checkout Summary WARNING 1. 2. 3. Electrical Shock Hazard. Can cause severe injury, death or property damage. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on. 1. 2. 3. 4. 5. 6. 7. Open the master switch before removing or installing the relay module. Make sure all manual fuel shutoff valve(s) are closed before starting the initial lightoff check and the Pilot Turndown tests.
PAGE 21
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES NOTE: Low fuel pressure limits, if used, could be open; if so, bypass with jumpers during this check. POSITIVE (+) METER LEAD NEGATIVE (-) METER LEAD 1. 2. ONE MEGOHM/VOLT METER 3. 4. 5. M7382 Fig. 16. Flame signal measurement. 6. 1. Use a one megohm per volt meter with a 0 to 10 Vdc capability. 2. Set the one megohm per volt meter to the 0 to 10 Vdc range. 3.
PAGE 22
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Initial Lightoff Check for Direct Spark Ignition (DSI) When the pilot ignites, measure the flame signal. If the pilot flame signal is unsteady or approaching the 1.25 Vdc minimum value, adjust the pilot flame size or detector position to provide a maximum and steady flame signal. Recycle the system to recheck lightoff and pilot flame signal.
PAGE 23
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES 19. 20. 21. PREPURGE. If the Flame Failure Action jumper is clipped: push the reset pushbutton and allow the RM7890D to recycle to PILOT IGNITION or the RM7895E,F to recycle through PREPURGE. b. As the control attempts to relight the pilot, increase the pilot pressure immediately until the FLAME LED comes on, and then turn it down slowly to obtain a pressure reading just above the dropout point or until the flame signal increases to approximately 1.
PAGE 24
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES To Eliminate Ignition Interference 1. 2. 3. 4. 5. Make sure there is enough ground area. Be sure the ignition electrode and the flame rod are on opposite sides of the ground area. Check for correct spacing on the ignition electrode: a. 6,000V systems 1/16 in. to 3/32 in. (1.6 mm to 2.4 mm). b. 10,000V systems 1/8 in. (3.2 mm). Make sure the leadwires from the flame rod and ignition electrode are not too close together. Replace any deteriorated leadwires.
PAGE 25
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Diagnostic Information Index Historical Information Index The relay module with the optional KDM can monitor input/ output terminals and can display the status of the terminal on the KDM display (for example, Pilot Valve T8 1<); see S7800 Keyboard Display Module specification, form 65-0090. A complete terminal description and terminal number are provided. The display shows the actual status of the terminal.
PAGE 26
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES SERVICE NOTE: SERVICE NOTE: Remove the access slot covers on the sides of the Q7800 Wiring Subbase to check voltages. A lockout condition or restart of a relay module can be accomplished by pressing the reset pushbutton on the relay module or by pressing a remote reset pushbutton wired through an optional KDM, Data ControlBus™ Module, extension cable assembly, or remote reset module.
PAGE 27
RM7890; RM7895 100 VAC 7800 SERIES RELAY MODULES Table 13. 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 7800 SERIES RELAY MODULES Automation and Control Solutions Honeywell International Inc. 1985 Douglas Drive North Golden Valley, MN 55422 customer.honeywell.com ® U.S. Registered Trademark © 2011 Honeywell International Inc. 66-1195—01 M.S.