Honeywell RM7824A User's Manual
Contents
1. 3 All wiring must comply with all appropriate electrical codes ordinances and regulations Wiring where required must comply with NEC Class 1 wiring 4 a Recommended wire size and type Use No 14 16 or 18 copper conductor TTW60C or THW75C or THHNOOC 600 volt insulation wire for all low voltage terminals For high temperature installations use wire selected for a temperature rating above the maximum operating temperature All leadwires must be moisture resistant CONFIGURATION JUMPERS RESET PUSHBUTTON STATUS LEDs LIMITS CONTROLLER OPTIONAL KEYBOARD DISPLAY MODULE CONTROL POWER SUPPLY POWER 7800 SERIES RM7824A RELAY MODULE b The maximum number of wires per terminal is two If more than two wires need to be connected to a terminal wire one of the wires to the terminal and use a wire nut to connect the other wires inside the subbase 5 Recommended wire routing for flame detector leadwires e Do not run high voltage ignition transformer wires in the same conduit with the flame detection wiring e Do not route scanner wires in a conduit with line voltage circuits e Enclose scanner wires without armor cable in metal cable or conduit e Follow directions given in the flame detector instructions 6 Maximum wire lengths a Forthe RM7824A the maximum length of leadwire to the control terminal input is 300 feet b Forthe flame detector leadwires the maximum flame sen2. 1 The pilot valve and ignition transformer terminals 8 and 10 are energized The RM7824A has an intermittent pilot valve terminal 8 2 Flame must be proven by the end of the 4 or 10 second PFEP to allow the sequence to continue If flame is not proven by the end of PFEP a safety shutdown occurs 3 With flame proven the ignition terminal 10 is de energized and the main valve terminal 9 is energized Run The RM7824A is now in RUN and will remain in RUN until the controller input terminal 6 opens indicating that the demand is satisfied or a limit has opened 11 Selectable Site Configurable Jumper The RM78244A has one site configurable jumper option see Fig 15 and Table 4 The site configurable jumper should be clipped with side cutters and the resistor removed from the Relay Module SELECTABLE CONFIGURATION JUMPER CONFIGURATION JUMPERS PILOT FLAME JR1 esr perio OPER AMB TEMP 40 F TO 140 F 40 C TO 60 C 97 4680 REV A FIRE OR EXPLOSION LES RISQUES DE FEU OU CAN CAUSE PROPERTY D D EXPLOSION PEUVENT CAUSER SEVERE INJURY OR DEATH DES DOMMAGES DES BLESSURES Ensure proper selection of GRAVES OU ENTRAINER LA MORT configuration jumpers belore S assurer que la configuration des cavaliers Starting the burner operation est ad quate avant d actionner le br leur M7592 Fig 15 Selectable site configurable jumpers 65 0155 1 7800 SERIES RM7824A RELAY MODULE T
3. None 24 Vdc at terminal 6 Limits Burner controller Ignition spark if ignition 1 Watch for spark or listen for transformer relay is buzz connected to terminal 10 a Ignition electrodes are clean b Ignition transformer is okay Continued 65 0155 1 12 7800 SERIES RM7824A RELAY MODULE Table 5 Static Checkout Continued RM7824A Test If Operation is Abnormal Check Test No Models Jumpers Voltmeter Normal Operation the Item Listed Below 1 Automatic pilot valve opens if connected to terminal 8 Ignition spark if ignition transformer relay is connected to terminal 8 a Watch for spark or listen for buzz Ignition electrodes are clean b Ignition transformer is okay Listen for click or feel head of valve for activation a Actuator if used b Pilot valve NOTE Refer to wiring Automatic fuel valve s opens If using direct spark ignition diagram of system being tested Same as test no 4 If using direct spark ignition check the first stage fuel valve s instead of the pilot valve check the first stage fuel valve s instead of the pilot valve N CAUTION After completing these tests open the master switch and remove all test jumpers from the subbase terminals Also remove bypass jumpers from the low fuel pressure limits if used CHECKOUT A WARNING Do not allow fuel to accumulate in the combustion chamber If fuel is allowed to enter the chamber for
4. longer than a few seconds without igniting an explosive mixture could result It is recommended that you limit the trial for pilot to ten seconds and limit the attempt to light the main burner to two seconds from the time the fuel has reached the burner nozzle In any case do not exceed the nominal lightoff time specified by the equipment manufacturer Close the manual shutoff valve s if the flame is not burning at the end of the specified time CAUTION 1 Use extreme care while testing the system Voltage is present on most terminal connections when power is on 2 Open the master switch before removing or installing the RM7824A 3 Make sure all manual fuel shutoff valve s are closed before starting the initial lightoff check and the Pilot Turndown tests 4 Do not put the system in service until you have satisfactorily completed all applicable tests in this section and any others required by the equipment manufacturer 13 N CAUTION If an RM78244A is replaced with a lower or higher functioning 7800 SERIES Relay Module the burner will not sequence unless wiring changes are made IMPORTANT 1 If the system fails to perform properly refer to 7800 SERIES System Annunciation Diagnostics and Troubleshooting form 65 01 18 2 Repeat ALL required Checkout tests after all adjustments are made ALL tests must be satisfied with the flame detector s in its FINAL position Equipment Required Volt ohmmeter 20K ohm vo
5. Check all burner adjustments If the main burner flame is not established after two attempts Check for improper pilot size Check for excess combustion air Check for inadequate fuel flow Check for proper gas supply pressure Check for proper valve operation f Check for proper pilot flame positioning Repeat steps 10 through 14 to establish the main burner flame then proceed to step 16 With the sequence in RUN make burner adjustments for flame stability and Btu input rating Shut down the system by opening the burner switch or by lowering the setpoint of the operating controller Make sure the main flame goes out There may be a delay due to gas trapped between the valve s and the burner Make sure the automatic fuel valve s closes Restart the system by closing the burner switch and or raising the setpoint of the operating controller Observe that the pilot is established during PILOT IGNITION and the main burner flame is established during RUN within the normal lightoff time Measure the flame signal Continue to check for the proper signal see Table 6 through the RUN period Run the burner through another sequence observing the flame signal for a Pilot flame alone unless using direct spark ignition b Pilot and main flame together c Main flame alone unless monitoring an intermittent pilot 929059 Also observe the time it takes to light the main flame Ignition of the main flame should be smooth 21 22 R
6. DESTROY THE UV TUBE M7594 Fig 11 Flame detector wiring The RM7824A has the following operation sequence see Figs 12 and 14 00 00 10 SAFE PrEP A INITIATE STANDBY START POWER Power 6 POWER O O O LED DISPLAY BURNER START OPERATING CONTROLLER AND LIMITS FLAME SIGNAL 4 OR 10 SEC POWER PILOT FLAME O MAIN O ALARM je fe ________ 1 L pemw 9 uA R N LL Lowewmewmor G m 8 0 8 3 h M LL 1 1 11d MEM 1 1 o uu ur el LL CIO es EOEEEEEEEEEEEIQULLLDObOJD peesmewoex mmemoms see RUN POWER PILOT FLAME main O ALARM wamvave 5 A A MAIN FUEL VALVE WILL BE ENERGIZED DURING PFEP IF FLAME IS PROVEN A RM7890A1031 PFEP IS FIXED 30 SECOND M5135B Fig 12 RM7824A sequence 65 0155 1 10 CAPTIVE 7c MOUNTING SCREW DUST COVER RELAY MODULE i FLAME a AMPLIFIER A 4 TN FLAME CURRENT 7800 SERIES RM7824A RELAY MODULE Initiate The RM7824A enters the INITIATE sequence if the Relay Module verifies voltage fluctuations of outside 22 to 28 Vdc during any part of the operating sequence The INITIATE sequence lasts for ten seconds unless the voltage tolerance is not met When the tolerance is not met a hold condition will be initiated and will be displayed on the optional Keyboard Display Module for at least five se
7. a 24 Vdc power errors occurred see Operation section b Configuration jumper has been changed after 200 hours c Four minute INITIATE period has been exceeded 2 STANDBY PERIOD a Flame signal is present after 40 seconds b Ignition intermittent pilot valve terminal is energized c Internal system fault occurred d Main valve terminal is energized 3 SAFE START CHECK a Flame signal is present b Ignition intermittent pilot valve terminal is energized c Internal system fault occurred d Main valve terminal is energized 4 PILOT FLAME ESTABLISHING PERIOD PFEP a lgnition intermittent pilot valve terminal is not energized b Internal system fault occurred c Main valve terminal is energized d No flame present at end of PFEP 5 RUN PERIOD a Ignition terminal is energized b Internal system fault occurred c Main valve terminal is not energized d Noflame present e Pilot valve terminal is not energized SAFETY PROVISIONS Internal Hardware Status Monitoring The RM7824A analyzes the integrity of the configuration jumper and internal hardware The POWER LED will blink every four seconds signifying an internal hardware check Closed Loop Logic Test The test verifies the integrity of all safety critical loads terminals 8 9 and 10 If the loads are not energized properly i e the main valve terminal is powered during STANDBY the RM7824A will lockout on safety shutdown The RM7824A must react to input
8. abnormal sequences are in standard type INITIATE The LED indicates the burner status POWER which is a stabilization period for the RM7824A to check for any fluctuations in dc voltage inputs or control input on power up or during normal operation If the RM7824 lt A is in a HOLD status the following conditions could exist INITIATE HOLD Vdc Frequency noise INITIATE HOLD AC Line Dropout INITIATE HOLD AC Frequency INITIATE HOLD Low Line Voltage STANDBY The LED indicates the burner status POWER and that the RM7824A is waiting for excess line noise to clear up The burner sequence will not advance into STANDBY until the excess line noise which prevents sufficient read of the voltage inputs ceases The led indicates the burner status POWER and that DC Bus power has momentarily dropped out The burner sequence will not advance into STANDBY until the DC Bus voltage has stabilized throughout the INITIATE sequence The LED indicates the burner status POWER and that the internal timing functions are out of synchronization The burner sequence will not advance into STANDBY until the internal timing is synchronized The LED indicates the burner status POWER and that low DC Bus voltage has occurred The burner sequence will not advance into STANDBY until the DC Bus voltage is at a sufficient level for proper operating parameters The LED indicates the burner status POWER The burner can be placed in STANDBY by openi
9. accomplished 9 Reposition the flame scanner sight tube or use orifices until the pilot flame signal voltage is approximately 1 25 to 1 50 Vdc When the main burner lights reliably with the pilot at turndown disconnect the manometer or pressure gauge and turn the pilot gas flow up to that recommended by the equipment manufacturer If used remove the bypass jumpers from the subbase terminals limits control or switches Run the system through another cycle to check for normal operation Return the system to normal operation 10 11 12 13 Ultraviolet Sensor Ignition Spark Response Test All Ultraviolet Detectors Test to be sure that the ignition spark is not actuating the FLAME LED 1 Close the pilot and main burner manual fuel shutoff valve s 2 Start the burner and run through the PILOT IGNITION period Ignition spark should occur but the flame signal should not be more than 0 5 Vdc and the FLAME LED should not turn on 3 If the flame signal is higher than 0 5 Vdc and the FLAME LED does come on consult the equipment Operating Manual and resight the detector further out from the spark or away from possible reflection If may be necessary to construct a barrier to block the ignition spark from the detector view Continue adjustments until the flame signal due to ignition spark is less than 0 5 Vdc 17 7800 SERIES RM7824A RELAY MODULE Response to Other Ultraviolet Sources Under certain condi
10. changes but avoid the occurrence of nuisance shutdown events Signal conditioning is applied to 24 Vdc voltage inputs to verify proper operation in the presence of normal electrical line noise such as transient high voltage spikes or short periods of voltage dropout Dynamic Flame Amplifier and Shutter Check Self checking circuitry tests all electronic components in the flame detection system and amplifier twelve times per minute and shuts down the RM78244A if the detection system fails 7800 SERIES RM7824A RELAY MODULE Dynamic Input Check All system input circuits are examined to assure that the RM7824A is capable of recognizing the true status of external controls limits and interlocks If any input fails this test a safety shutdown occurs and the fault will be annunciated Dynamic Safety Relay Test Checks the ability of the dynamic safety relay contact to open and close Verifies that the safety critical loads terminals 8 9 and 10 can be de energized as required by the Dynamic Self check logic Dynamic Self Check Safety Circuit The microcomputer tests itself and related hardware and at the same time the safety relay system tests the microcomputer operation If a microcomputer or safety relay failure occurs and does not allow proper execution of the self check routine safety shutdown occurs and all safety critical loads will be de energized Expanded Safe Start Check The conventional safe start check which prevents b
11. manual fuel shutoff valve s Push the reset pushbutton and recycle the program sequence through STANDBY and SAFE START CHECK 9 Watch for the FLAME LED to help determine when the first stage burner flame is established If it is established proceed to step 15 If the first stage burner flame is not established within four seconds or within the normal lightoff time specified by the equipment manufacturer close the manual fuel shutoff valve s and open the master switch Check all burner adjustments Wait about three minutes Close the master switch open the manual fuel shutoff valve s and try again to light off the burner The first attempt may have been required to purge the lines and bring sufficient fuel to the burner If the first stage burner flame is not established within four seconds or within the normal lightoff time specified by the equipment manufacturer close the manual fuel shutoff valve s and open the master switch If necessary repeat steps 11 through 13 to establish the first stage burner flame then proceed to step 15 When the first stage burner flame is established the sequence will advance to RUN Make burner adjustments for flame stability and input rating If a second stage is used proceed to step 18 Shut down the system by opening the burner switch or by lowering the setpoint of the operating controller Make sure the burner flame goes out and make sure all automatic fuel valve s cl
12. retaining clasp 4 Verify the amplifier is firmly in place 5 Perform all required checkout tests Fig 7 Electrical panel installation 9 65 0155 1 7800 SERIES RM7824A RELAY MODULE Nc RECIFO FUME AMPLIFIER Fig 10 Flame signal amplifier mounting Installing Flame Detector NOTE Table 2 and Fig 11 list the flame detectors available for use with the RM7824A Make sure the correct combination of amplifier and flame detector s is used 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 wire length reducing the signal strength The maximum permissible leadwire length depends on the type of flame detector leadwire and conduit The ultimate limiting factor in the flame detector leadwire is the flame signal see Table 6 OPERATION Sequence of Operation INFRARED C7015 F WHITE BROWN SOLID STATE SELF CHECKING ULTRAVIOLET C7024E F E SHOWN A 22 YELLOW 24Vdc 3 24Vde A FLAME DETECTOR LEADS ARE COLOR CODED THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW MUST BE CONNECTED TO THE G TERMINAL THE UV SENSING TUBE IS POLARITY SENSITIVE REVERSING THE LEADS EVEN MOMENTARILY CAN DAMAGE OR
13. the RM7824A will lock out a Push the reset pushbutton and allow the RM7824A to recycle to PILOT IGNITION b Asthe control attempts to relight the pilot increase the pilot pressure immediately until the FLAME LED comes on and then slowly turn it down to obtain a pressure reading just above the dropout point or until the flame signal increases to approximately 1 25 Vdc This step must be completed within four or ten seconds depending on the selected PFEP or lockout will occur c Turn the pilot back down slightly but not enough to cause the FLAME LED to go out Keep the pilot gas pressure just above the reading noted in step 6 above NOTE Step d requires two people to complete one person to open the manual main fuel valve s and one to watch for ignition d With the sequence in the normal burner run mode make sure that the automatic main fuel valve s is open Smoothly open the manual main fuel shutoff valve s and watch for main burner lightoff e If the main flame is not established within five seconds or the normal lightoff period specified by the burner manufacturer close the manual main fuel shutoff valve s and open the master switch Then return to step 6 a If the burner flame is established in the normal lightoff period proceed to step 10 7 Recycle the burner and let the sequence advance to the PILOT IGNITION period 8 Increase the pilot flame size by increasing its fuel flow until a smooth main flame is
14. write or phone 1 Your local Honeywell Home and Building Control Sales Office check white pages of phone directory 2 Home and Building Control Customer Logistics Honeywell Inc 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 In Canada Honeywell Limited Honeywell Limit e 35 Dynamic Drive Scarborough Ontario M1V 4Z9 International Sales and Service Offices in all principal cities of the world Manufacturing in Australia Canada Finland France Germany Japan Mexico Netherlands Spain Taiwan United Kingdom U S A 65 0155 1 2 7800 SERIES RM7824A RELAY MODULE Weight RM7824A with Dust Cover 1 pound 12 ounces unpacked N CAUTION IMPORTANT To prevent the control from sequencing on power up Flame Detection System available for use with RM7824 Relay Modules with software revision 2424 RM7824A To select your Plug in Flame Signal or less should not be used with R7848 Infrared Amplifier and applicable Flame Detector see Table 2 Amplifiers and C7015 Infrared Flame Detectors and Fig 3 unless a ten second delay is provided Table 2 Flame Detection Systems Plug in Flame Signal Amplifiers Applicable Flame Detectors Flame Failure Type Color Self Checking Response Time Type Rectification Green Dynamic R7824C 3 sec Gas oil coal Ultraviolet C7024E F Self Check Purple Peeper Infrared pr pe 3 sec Gas oil coal Infrared C7015 Lead Sulfide a R7848B 3 sec Gas oil coal Infrared C7015 AMPLI CH
15. 8 or 3 to 10 of the subbase k Check for adequate bleeding of the fuel line l Reinstall the RM7824A on the subbase and close the master switch m Return to step 4 10 11 12 13 14 15 16 17 18 19 20 7800 SERIES RM7824A RELAY MODULE 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 sighting to provide a maximum and steady flame signal Recycle the system to recheck lightoff and pilot flame signal When the RUN period is displayed by the MAIN LED make sure the automatic main fuel valve is open then smoothly open the manual main fuel shutoff valve s and watch for main burner flame ignition When the main burner flame is established proceed to step 16 If the main burner flame is not established within five seconds or the normal lightoff time specified by the equipment manufacturer close the manual main fuel shutoff valve s Recycle the system to recheck lightoff and pilot flame signal Let the RM7824A recycle to the RUN period Smoothly open the manual fuel shutoff valve s and try lightoff again The first attempt may have been required to purge the lines and bring sufficient fuel to the burner If the main burner flame is not established within five seconds or the normal lightoff time specified by the equipment manufacturer close the manual main fuel shutoff valve s
16. AVIOLET SWITCH FLAME DETECTOR A 24 VDC POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS A FOR A CONTINUOUS OR STANDING PILOT INSTALL AN EXTERNAL RELAY TO SWITCH THE F LEAD THE RELAY MUST HAVE GOLD CLAD OR GOLD FLASH CONTACTS AND A 120 VAC COIL POWER THE RELAY COIL FROM THE Q7800 SUBBASE TERMINAL 8 CONNECT THE RELAY CONTACTS BETWEEN THE F LEAD OF THE DETECTOR AND THE F TERMINAL OF THE Q7800 SUBBASE A 24 VDC RELAY IS ACCEPTABLE TO USE IN THIS TYPE OF APPLICATION USE THE N O PILOT DUTY CONTACTS M5820A Fig 6 Wiring the RM7824A 65 0155 1 8 ASSEMBLY Mounting RM7824A NOTE For installation dimensions see Fig 1 or 2 Relay Module Mounting 1 7800 SERIES RM7824A RELAY MODULE Mount the RM7824A vertically see Figs 7 or 8 or mount horizontally with the knife blade terminals pointing downward When mounted on the Q7800A the RM7824A must be in an electrical enclosure Select the location in the electrical enclosure Be sure to allow adequate clearance for servicing installation and removal of the RM7824A dust cover flame amplifier flame amplifier signal voltage probes electrical signal voltage probes and electrical connections a Allow an additional two inches below the RM7824A for the flame amplifier mounting b Allow an optional three inch minimum to both Fig 8 Wall or burner installation sides of the RM7824A for electrical signal v
17. Adda shield or screen to reflect radiated heat Add cooling refer to sight pipe ventilation in the detector instructions 5 Make sure that the flame adjustment is not too lean 6 Make sure that the detector is properly sighting the flame 7 If necessary resight or reposition the detector Initial Lightoff Check for Proved Pilot Perform this check on all installations that use a pilot It should immediately follow the preliminary inspection NOTE Low fuel pressure limits if used could be open If so bypass them with jumpers during this check 1 Open the master switch 2 Make sure that the manual main fuel shutoff valve s is closed Open the manual pilot shutoff valve If the pilot takeoff is downstream from the manual main fuel shutoff valve s slightly open the manual main valve to supply pilot gas flow Make sure the main fuel is shut off just upstream from the burner inlet or disconnect power from the automatic main fuel valve s 3 Close the master switch and start the system with a call for heat by raising the setpoint of the operating controller see Fig 12 or RM7824A sequence The primary sequence should start the SAFE START CHECK sequence 4 Letthe sequence advance through STANDBY and SAFE START CHECK Ignition spark should occur and the pilot should light If the pilot ignites the FLAME LED will be energized Proceed to step 7 5 If the pilot flame is not established in four or ten seconds safety shutd
18. ECK Lead Sulfide Circuitry tests all electronic components in the flame detection system amplifier and detector 12 times a minute during burner operation and shuts down the burner if the detection system fails Table 3 Sequence Timing For Normal Operation STANDBY and RUN can be an infinite time period Approval Bodies Mounting Underwriters Laboratories Inc Component Recognized Q7800A for panel mount or Q7800B for wall or burner mount File no MP268 guide no MCCZ Canadian Standards Association certified LR9S329 3 Required Components Federal Communications Commission Part 15 Plug in Flame Signal Amplifier see Fig 2 Class B Emissions Q7800A or Q7800B I Honeywell BURNER CONTROL lt lt 5 1 4 188 A REMOVE ONLY FOR TERMINAL TEST ACCESS M5872 5 127 Fig 1 Mounting dimensions of RM7824A Relay Module and Q7800A Subbase in in mm 3 65 0155 1 7800 SERIES RM7824A RELAY MODULE Honeywell BURNER CONTROL 6 3 32 155 em 5 127 A REMOVE ONLY FOR TERMINAL TEST ACCESS eara Fig 2 Mounting dimensions of RM7824A Relay Module and Q7800B Subbase in in mm Dust Cover is part number 221729A Accessories MOUNTING FLANGE 3 4 14 NPT Optional 7 7 32 183 e COMBUSTION SYSTEM MANAGER Part number ZM7850A1001 Communication Interface Base Unit Part number Q7700A1014 C
19. Honeywell 7800 SERIES RM7824A Relay Module GENERAL The Honeywell RM7824A Relay Module is a 24 Vdc microprocessor based integrated burner control for automatically fired gas oil or combination fuel single burner applications The RM7824A consists of the Relay Module Subbase and Amplifier are required to complete the system Options include Keyboard Display Module Personal Computer Interface DATA CONTROL BUS MODULE Remote Display Module and COMBUSTION SYSTEM MANAGER Software The RM7824A is programmed to provide a level of safety functional capability and features beyond the capacity of conventional controls Functions provided by the RM7824A include automatic burner sequencing flame supervision system status indication system or self diagnostics and troubleshooting FEATURES Safety features Closed loop logic test Dynamic input check Dynamic safety relay check Dynamic self check logic Expanded safe start check internal hardware status monitoring Tamper resistant timing and logic Access for external electrical voltage checks Application flexibility Communications interface capability Dependable long term operation provided by microcomputer technology Copyright 1995 Honeywell Inc All Rights Reserved PRODUCT DATA First out annunciation and system diagnostics are provided by a 2 row by 20 column Vacuum Fluorescent Display VFD located on th
20. able 4 Site Configurable Jumper Options Equipment Recommended Jumper 1 Voltmeter 20K ohm volt minimum sensitivity set on the Number Description Clipped 0 30 Vdc scale gt 2 Two jumper wires No 14 wire insulated 12 in 305 mm JRI Pilot Flame 10 seconds 4 seconds long with insulated alligator clips at both ends Establishing Period General Instructions IMPORTANT i 1 Perform all applicable tests listed in Static Checkout After 200 hours of operation the configuration Table 5 in the order listed jumper cannot be changed If it is changed after 2 MAKE SURE THAT ALL MANUAL FUEL SHUTOFF 200 hours of operation the RM7824 lt A locks out The VALVE S ARE CLOSED HM7824A cannot be reset and has to be replaced 3 Perform only those tests designated for the specific ut RM7824A model being tested SERVICE NOTE Clipping and removing a site configurable 4 Raise the set point of the operating controller to jumper enhances the level of safety simulate a call for heat 5 For each test open the master switch and install the jumper wire s between the subbase wiring terminals STATIC CHECKOUT listed in the Test Jumpers column of Table 5 6 Close the master switch before observing operation 7 Read the voltage between the subbase wiring terminals A CAUTION listed in the Voltmeter column of Table 5 4 U t hile testing th t Volt 8 If there is no voltage or the operation is abnormal poem ee NE Care WE Seong NE Sy ote o
21. air 6 Combustion chamber and flues are clear of fuel and fuel vapor 7 Power is connected to the system disconnect switch master switch 8 Lockout switch is reset push in reset pushbutton only if the RM7824A is powered See Fig 1 and 2 9 System is in the STANDBY condition POWER LED is energized 10 All limits and interlocks are reset Table 6 Flame Signal See Fig 15 Minimum Acceptable Maximum Expected Flame Signal Amplifier Steady dc Voltage dc Voltage Flame Detector C7015A 5 0 Vdc at a 20K ohm volt voltmeter C7024E F R7824C 1 25 Vdc 5 0 Vdc at the Keyboard Display Module or R7848A B This minimum or a stronger signal should be easily obtained if the detector is correctly installed and positioned to properly sense the flame This voltage must be obtained before completing checkout b The flame signal amplifier circuitry is tested one half second every five seconds during burner operation and shuts down the burner if the amplifier fails all installations The amplifier is an AMPLI CHECK type Flame Signal Measurement Measure the flame signal at the appropriate times defined in the following checkout tests Read the flame signal volts dc at the flame amplifier test jacks and Com 1 Use a 20K ohm per volt voltmeter with a 0 to 30 Vdc capability 2 Set the voltmeter to the 0 to 10 Vdc range 3 Insert the positive red probe into the jack of the flame amplifier and the nega
22. ave been completed reset all switches to original states TROUBLESHOOTING RM7824A System Diagnostics Troubleshooting control system equipment failures is easier with the RM7824A self diagnostics and first out annunciation In addition to an isolated spst alarm relay audible annunciation the RM7824A provides visual annunciation by displaying the ALARM LED Self diagnostics of the RM7824A enable it to detect and annunciate both external and internal system problems External faults such as flame failures and false flame signals are annunciated by a lockout of the RM7824A that energizes the ALARM LEDs by using the optional Keyboard Display Module or 7800 SERIES System Annunciation Diagnostics and Troubleshooting form 65 0118 The RM7824A provides diagnostic information to aid the service mechanic to obtain information when troubleshooting the system see Table 7 and Table 8 The optional Keyboard Display Module displays sequence status messages indicating INITIATE STANDBY SAFE START CHECK PILOT IGN and RUN The selectable messages also provide visual indication current status and historical status of the equipment such as Flame Signal Total Cycles Total Hours Fault History and Diagnostic Information 65 0155 1 18 The Expanded Annunciator Terminal Status is not available with the RM7824A With this information most problems can be diagnosed without extensive trial and error testing Information available in the Diagn
23. conds When the tolerance is met the INITIATE sequence will restart If the condition is not corrected and the hold condition exists for four minutes the RM7824 lt A will lock out Causes for hold conditions in the INITIATE sequence are e Vdc dropout is detected Internal timing functions are not synchronized The noise that can prevent a sufficient reading of the low voltage inputs e Brownouts caused by low input voltage RESET ALARM TEST PILOT IGNITION RUN e POWER o PILOT Fave O MAIN ALARM M3362 Fig 14 LED sequence status display information see Fig 13 PUSH FLAME BUTTON SEQUENCE sIMULATORINPUT CK STATUS LEDS M7593 Fig 13 Sequence status LEDs STANDBY HOLD F G SAFE FLAME START INITIATE STANDBY DETECTED CHECK Power PILOT Q FLAME MAIN QO ALARM The RM7824A is ready to start an operating sequence when the operating control input determines a call for heat is present The burner switch limits operating limit control and all microcomputer monitored circuits must be in the correct state for the RM7824A to continue into the SAFE START CHECK Normal Start Up Safe Start Check The RM7824A verifies that a flame does not exist and proceeds into the ignition trial If a flame is present the RM7824A will recycle to the STANDBY period If the critical loads are not in the correct state a safety shutdown occurs Ignition Trials Pilot Flame Establishing Period PFEP
24. e ge check the circuits and external devices as described in is present on most terminal connections when the last column Power IS On 9 Check all wiring for correct connections tight terminal 2 Open ihe master switch before installing or screws correct wire and proper wiring techniques removing a jumper on the s bbase Replace all damaged or incorrectly sized wires 3 Before continuing to the next test be sure to 10 Replace faulty controllers limits interlocks actuators remove the test jumper s used in the previous valves transformers motors and other devices as tests 2 required 4 Replace all limits and interlocks not operating 11 Obtain normal operation for each required test before properly Do not bypass limits and interlocks continuing the checkout 5 Close all manual fuel shutoff valve s before 12 After completing each test be sure to remove the test starting these tests jumper s Table 5 Static Checkout RM7824A Test If Operation is Abnormal Check Test No Models Jumpers Voltmeter Normal Operation the Item Listed Below A WARNING Make sure 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 All None 3 L2 24 Vdc at terminal 3 1 Master switch 2 Power connected to the master switch 3 Overload protection fuse circuit breaker has not opened the power line
25. e optional Keyboard Display Module Five light emitting diodes LEDs for sequence information Flame signal strength Local or remote annunciation of RM7824A operation and fault information optional e Nonvolatile memory RM7824A retains history files and sequencing status after loss of power Plug in flame amplifier Remote reset optional Report generation optional Shutter drive output Burner controller data optional Hold status Lockout Alarm status Sequence status Sequence time Total cycles of operation Total hours of operation Fault history providing the six most recent faults Cycles of operation 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 Software revision and version of RM7824A and optional Keyboard Display Module Status of configuration jumper Contents General 1 Features 1 Specifications 2 Ordering Information 2 Principal Technical Features Wave D Safety Provisions 5 INSIEME 6 iugo m MEN Hn EPI Assembly Operation Static Ch
26. eck the ratings given in the instructions and marked on the product to make sure the product is suitable for your application 3 Installer must be a trained experienced flame safeguard service technician 4 After installation is complete check out the product operation as provided in these instructions N CAUTION To prevent electrical shock and equipment damage disconnect the power supply before beginning installation More than one power supply disconnect may be involved 1 To prevent electrical shock and equipment damage disconnect the power supply before beginning installation More than one power supply disconnect may be involved 2 Wiring connections for the RM78244 are unique therefore refer to Fig 6 or the correct specifications for proper subbase wiring 3 Wiring must comply with all applicable codes ordinances and regulations 4 Wiring where required must comply with NEC Class 1 wiring 5 Loads connected to the RM7824A must not exceed those listed on the RM78244 label or the specifications see Table 1 6 Limits and interlocks must be rated to carry and break current simultaneously to the ignition transformer pilot valve and main fuel valve s 65 0155 1 7 All external timers must be listed or component recognized by authorities who have jurisdiction for the specific purpose for which they are used IMPORTANT 1 For on off gas fired systems some authorities who have jurisdiction prohibi
27. eckout Checkout Troubleshooting 65 0155 1 7800 SERIES RM7824A RELAY MODULE SPECIFICATIONS Model Environmental Ratings RM7824A Relay Module for the 7800 SERIES Ambient Temperature Operating 40 F to 140 F 40 C to 50 C Electrical Ratings See Table 1 Storage 60 F to 150 F 49 C to 66 C Voltage 24 Vdc 22 28 Vdc Humidity 85 relative humidity noncondensing Power Dissipation 10W maximum Vibration 0 5G environment Maximum Total Connected Load 500 VA Fusing Total Connected Load 20A maximum type FRN or Dimensions equivalent See Fig 1 through 4 Table 1 Terminal Ratings TemmaNo Description Rem O 6 mesmo 1 24 Vac Common Ee e eee s quus LL 6 emerce aveo 3 qum 70 8 Pirvawelgnio 24V sSATmsh TAConmuxs 9 wamruevawe 24 Vd 10 Trush 2A Continuous or 60 VA motorized vale Fi Famese LL 2 Uwe LL 38 uus I a quum LL 38 quus UL 39 quum LL o quus I Pte quum LL 39 uus UL 39 Uwe C 2 uus I 500 VA maximum connected load to RM7824A assembly ORDERING INFORMATION When purchasing replacement and modernization products from your 7800 SERIES distributor refer to the TRADELINE Catalog or price sheets for complete ordering number If you have additional questions need further information or would like to comment on our products or services please
28. eturn the system to normal operation Make sure all readings are in the required ranges before proceeding NOTE Upon completing these tests open the master 15 switch and remove all test jumpers from the subbase terminals limits controls or switches 65 0155 1 7800 SERIES RM7824A RELAY MODULE Initial Lightoff Check for Direct Spark Ignition This check applies for gas and oil burners that do not use a pilot and it should immediately follow the preliminary inspection Refer to the appropriate sample block diagram of field wiring for the ignition transformer and fuel valve s hookup NOTE Low pressure fuel limits if used could be open If so bypass them with jumpers during this check 1 Open the master switch 2 Complete the normal checkout of the fuel supply and equipment as recommended by the equipment manufacturer 3 Close all manual main fuel shutoff valve s Check that the automatic fuel valve s are closed Make sure fuel is not entering the combustion chamber 4 Close the master switch and start the system with a call for heat by raising the setpoint of the operating controller see Fig 11 or RM7824A sequencing The primary sequence should start with the SAFE START sequence 5 Let the sequence advance through STANDBY and SAFE START CHECK to Ignition Trial Ignition spark should occur Listen for the click of the first stage fuel solenoid valve s Let the program sequence complete its cycle Open the
29. ime during PILOT IGNITION As an additional troubleshooting aid it provides sequence timing diagnostic information and historical information during normal operation or when a safety shutdown or hold occurs 65 0155 1 7800 SERIES RM7824A RELAY MODULE First out Annunciation reports the cause of a safety shutdown or identifies the cause of a failure to start or continue the burner control sequence with an English text and numbered code via the optional Keyboard Display Module It monitors all field input circuits including the flame signal amplifier The system distinguishes 39 modes of failure and detects and annunciates difficult to find intermittent failures Self diagnostics add to the First out Annunciation by allowing the RM7824A to distinguish between field external device and internal system related problems Faults associated within the flame detection subsystem or RM7824A are isolated and reported by the optional Keyboard Display Module See the 7800 SERIES System Annunciation Diagnostics and Troubleshooting form 65 01 18 INSTALLATION A WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH To prevent possible hazardous burner operation perform verification of safety requirements each time a control is installed on a burner When Installing this Product 1 Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condition 2 Ch
30. lt minimum sensitivity e 0 6000 ohm capability e 0 30 Vdc capability Checkout Summary Preliminary inspection all installations Flame signal measurement all installations Initial lightoff check for proved pilot all installations using a pilot Initial lightoff check for direct spark ignition of oil all burners using DSI Pilot turndown test all installations using a pilot 65 0155 1 7800 SERIES RM7824A RELAY MODULE Hot refractory hold in test all installations Ignition spark pickup all installations using Ultraviolet Flame Detectors Response to other ultraviolet sources all installations using Ultraviolet Flame Detectors Flame signal with hot combustion chamber all installations Safety shutdown tests all installations See Fig 13 for location of component parts and see Fig 6 or Q7800 Specifications for terminal locations Preliminary Inspection Perform the following inspections to avoid common problems Make certain that 1 Wiring connections are correct and all terminal screws are tight 2 Flame detector s is clean installed and positioned properly Consult the applicable instructions 3 Correct combination of amplifier and flame detector s is used See Table 2 in the Specifications section 4 Plug in amplifier is securely in place 5 Burner is completely installed and ready to fire consult equipment manufacturer instructions Fuel lines are purged of
31. ng the burner switch or if the operating controller indicates its setpoint has been satisfied If a demand is present for burner operation the burner sequence will not advance from STANDBY to SAFE START CHECK until the recycle limits close If the RM7824 lt A is in a HOLD status the following conditions could exist STANDBY HOLD F G Flame Detected SAFE START CHECK PILOT IGN RESET ALARM TEST The LEDs indicate the burner status POWER and FLAME and that a flame is detected A demand is present for burner operation The burner sequence will not advance to SAFE START CHECK because a flame is detected as being present The sequence will not advance to SAFE START CHECK until the flame signal clears If the flame signal does not clear within 40 seconds the RM78244A will lockout The LED indicates the burner status POWER which is the period of time after STANDBY The RM7824A is verifying that a flame is not present before the start of Ignition Trials If a flame is present the RM7824A will recycle to STANDBY The LEDs indicate the burner status POWER PILOT and FLAME which is the period of time the RM7824A permits the pilot valve and ignition to be energized and the pilot flame to be established The LEDs indicate the burner status POWER PILOT FLAME and MAIN which is the period of time after the Ignition Trials and before the operating controller setpoint is reached During this time the burner is firing under the control of
32. oltage probes Make sure no subbase wiring is projecting beyond the terminal blocks Tuck in wiring against the back of the mounting Dust Cover subbase so it does not interfere with the knife blade Align the two interlocking ears of the Dust Cover with terminals or bifurcated contacts the two mating slots on the RM7824A see Fig 9 2 Insert the two interlocking ears into the two mating IMPORTANT slots and with a hinge action push on the upper 4 Mount the RM78244A by aligning the four L shaped The RM7824A must be installed with a plug in corners of the Dust Cover to secure it to the RM7824A motion rather than a hinge action 3 Be sure the Dust Cover is firmly in place corner guides and knife blade terminals with the bifurcated contacts on the wiring subbase and securely tightening the two screws Do not tighten the screws to the point where they deform the plastic of the RM7824A case Fig 9 Dust Cover mounting Installing Plug In Flame Signal Amplifier 1 Disconnect the power supply before beginning installation to prevent electrical shock and equipment damage More than one disconnect may be involved 2 Align the amplifier circuit board edge connector with the keyed receptacle on the RM7824A Verify that the amplifier nameplate faces away from the Relay Module see Fig 10 3 Push in the amplifier until the circuit board is fully inserted into the receptacle and then push the amplifier toward the RM7824A
33. ommunication Interface ControlBus Module Part number QS7800A1001 ControlBus 5 Wire Electrical Connector Part number 203544 DATA CONTROLBUS MODULE Part cR TD AN a 5 1 4 133 gt number S7810A1009 LEADWIRES Flush Mounting Kit for S7800 Keyboard Display Module FACEPLATE Part number 205321B C7024E Keyboard Display Module 878004 English Spanish French German Italian NEMA 4 and NEMA 1 Weatherproofing Kit for 57800 Keyboard Display Module Part number 204718A B Remote Display Mounting Bracket Part number 203765 Remote Reset Module Part number S7820A1007 Sixty inch Extension Cable Assembly Part number 2218184 1 11 1 2 NPT Os D 27 7 t 5 16 18 UNC 2B BY 9 229 1 5 8 41 2 3 4 ps 3 7 16 11 DEEP i 70 1 1 16 27 MOUNTING HOLES 2 gt EN C7024F 1 1 4 m M5818 32 j age E P4 Fig 4 Rectification detectors in in mm APERTURE 3 4 14 3 4 14 NPSM NPSM INTERNAL COLLAR 3 4 14 NPSM THREADS INTERNAL THREADS M1982A CELL MOUNT HEAT BLOCK LEADWIRES AW 2 LEADS IN A 48 INCH 1 2 METER FLEXIBLE CONDUIT BUSHING WITH MAGNIFYING LENS Fig 3 Infrared detector dimensions in in mm 65 0155 1 4 PRINCIPAL TECHNICAL FEATURES The RM78244A provides all customary flame safeguard functions while providing significant advancements in the areas of safety annunciation and system diagnostics Safety Shutdown Lockout Occurs If 1 INITIATE PERIOD
34. ose If used remove the bypass jumpers from the low fuel pressure limit and subbase If a second stage is used make sure the automatic second stage fuel valve s has opened check the lightoff as follows Otherwise proceed to step 19 a Open the manual second stage fuel valve s ouo 10 11 12 13 14 15 16 17 18 65 0155 1 16 b Restart the system by raising the setpoint of the operating controller c When the first stage burner flame is established watch for the automatic second stage fuel valve s to open Observe that the second stage lights off properly d Make burner adjustments for flame stability and input rating e Shutdown the system by lowering the setpoint of the operating controller Make sure the burner flame goes out and all automatic fuel valve s close Restart the system by closing the burner switch and or raising the setpoint of the operating controller Observe that the burner flame is established during PILOT IGNITION within the normal lightoff time specified by the equipment manufacturer Measure the flame signal Continue to check for the proper signal see Table 6 through the RUN period Any pulsating or unsteady readings will require further attention Make sure all readings are within the required ranges before proceeding 19 20 21 NOTE Upon completing these tests open the master switch and remove all test jumpers from the subbase terminal
35. ostic Information file includes Device Type Device Suffix Software Revision Manufacturing Code Flame Amplifier Type Flame Failure Response Time Selectable Jumper Configuration Status and Terminal Status Diagnostic Information Index The RM7824A with the optional Keyboard Display Module can monitor input output terminals and can display the status of the terminal at the VFD eg Pilot Valve T9 ON lt see S7800A Keyboard Display Module Specifications A complete terminal description and terminal number are provided The display will show the actual status of the terminal If voltage is detected at the terminal ON is displayed but if voltage is not present at the terminal OFF is displayed Historical Information The RM7824A has nonvolatile memory that allows the Relay Module to retain historical information for the six most recent lockouts Each of the six lockout files retains the cycle when the fault occurred the hour of operation when the fault occurred and the fault message and burner status when the fault occurred The historical information can be viewed by the optional S7800A Keyboard Display Module SERVICE NOTE To check voltages remove the access slot covers on the sides of the Q7800A B N CAUTION Reinstall access slot covers on the Q7800A B Subbase after performing voltage checks 7800 SERIES RM7824A RELAY MODULE Table 7 Sequence And Status Hold Information NOTE Normal sequences are in bold type while
36. own occurs Let the sequence complete its cycle Consult the equipment operating manual for further information 6 Push the reset pushbutton and let the system recycle once If the pilot still does not ignite make the following ignition pilot adjustments a Open the master switch and remove the RM7824A from the subbase b Onthe subbase jumper terminal 3 to ignition terminal 8 or 10 refer to the appropriate subbase wiring diagram to determine the proper terminal Disconnect the leadwire to the pilot valve if it is connected to the same terminal c Close the master switch to energize only the ignition transformer d If the ignition spark is not strong and continuous open the master switch and adjust the ignition electrode spark gap setting to the manufacturer recommendation e Make sure the ignition electrodes are clean f Close the master switch and observe the spark g After a continuous spark is obtained open the master switch and add a jumper on the subbase from terminal 3 to the pilot terminal 8 Reconnect the leadwire from the pilot valve if it was disconnected in step b h Close the master switch to energize both the ignition transformer and the pilot valve i If the pilot does not ignite and if the ignition spark is still continuous adjust the pressure regulator until a pilot is established j When the pilot ignites properly and stays ignited open the master switch and remove the jumper s from terminals 3 to
37. s limits controls or switches 22 Return the system to normal operation Pilot Turndown Test All Installations Using a Pilot Perform this check on all installations that use a pilot The purpose of this test is to verify that the main burner can be lit by the smallest pilot flame that will hold in the flame amplifier and energize the FLAME LED Clean the flame detector s to make sure that it will detect the smallest acceptable pilot flame When using Self checking Amplifier and 20K ohm volt voltmeter the flame signal will fluctuate every time the amplifier does a self check or a shutter check NOTE Low fuel pressure limits if used could be open If so bypass them with jumpers during this test 1 Open the master switch 2 Close the main fuel shutoff valve s 3 Connect a manometer or pressure gauge to measure pilot gas pressure during the turndown test 4 Open the manual pilot shutoff valve s 5 Close the master switch and start the system with a call for heat by raising the setpoint of the operating controller The primary sequence should start and PILOT IGNITION should begin 6 After the sequence has entered the normal burner run period very slowly turn the pilot gas pressure down reading the manometer or pressure gauge as the pressure drops Stop immediately when the FLAME LED goes out Note the pressure at this point NOTE If there is not flame present for the selected Flame Failure Response Test FFRT
38. s have been completed If used the external alarm should turn on Press the RM7824A reset pushbutton to restart the system 1 Detect flame 40 seconds after entry to STANDBY a Simulate a flame to cause the flame signal voltage level to be at least 1 25 Vdc for 30 sec onds after the initial 40 second entry into STANDBY b Safety shutdown will occur 2 Failure to ignite pilot a Close the pilot and main fuel manual shutoff valve s b Depress the reset pushbutton c Startthe system d Automatic pilot valve s should be energized but the pilot cannot ignite e Safety shutdown will occur 3 Loss of flame during RUN a Openthe main fuel manual shutoff valve s The manual pilot shutoff valve s must also be opened b Depress the reset pushbutton c Startthe system Startup should be normal and the main burner should light normally d After the sequence is in the normal RUN period for at least ten seconds with the main burner firing close the manual main and pilot fuel shutoff valve s to extinguish the main burner flame e The flame signal should drop below 1 25 Vdc within three seconds after the main flame goes out f Safety shutdown will occur 65 0155 1 7800 SERIES RM7824A RELAY MODULE IMPORTANT 1 If the RM7824A fails to shut down on any of these tests take corrective action refer to Troubleshooting RM7824A diagnostics and return to the beginning of all Checkout tests When all Checkout tests h
39. sor leadwire length is limited by the flame signal strength FLAME SIGNAL PLUG IN FLAME AMPLIFIER AND LINE VOLTAGE INPUTS IGNITION MAIN VALVE t INDICATES FEEDBACK SENSING RS485 TO RELAY STATUS FEEDBACK AND LINE VOLT INPUTS al A i DDL 2 FIELD WIRING COMMUNICATIONS REMOTE INTERNAL WIRING RESET IN PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED M5821 Fig 5 Internal block diagram of the RM7824A see Fig 6 for detailed wiring instructions 7 65 0155 1 7800 SERIES RM7824A RELAY MODULE 7 Make sure loads do not exceed the terminal ratings 9 Check all wiring circuits and complete the Static Refer to the label on the RM78244A or to the ratings in Checkout section before installing the RM78244A on the the specifications see Table 1 subbase see Table 5 8 Check the power supply circuit The voltage tolerance 10 Install all electrical connectors must match those of the RM7824A A separate power 11 Restore power to the panel supply circuit may be required for the RM78244A with the required disconnect means and overload protection added Q7800 24 VDC ALARM BURNER n CONTROLLER LIMITS amp amp eo INTERMITTENT PILOT IGNITION MAIN FUEL VALVE S IGNITION l l l l l l l l l l l l l l l l l l l l l l l l l l BROWN C7015 INFRARED LEAD SULFIDE DETECTOR 24 VDC OR l OA C7024E F MASTER YELLOW ULTR
40. t the wiring of any limit or operating contacts in series between the flame safeguard control and the main fuel valve s 2 Two C7024E F Detectors can be connected in parallel 3 This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause interference to radio communications It has been tested and found to comply with the limits for a Class B computing device of part 15 of FCC rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Operation of this equipment in a residential area may cause interference in which case the users at their own expense may be required to take whatever measures are required to correct this interference 4 This digital apparatus does not exceed the Class B limits for radio noise of digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Humidity Install the RM7824A where the relative humidity never reaches the saturation point The RM7824A is designed to operate in a maximum 85 percent relative humidity continuous noncondensing moisture environment Condensing moisture can cause a shutdown Vibration Do not install the RM7824A where it could be subjected to vibration in excess of 0 5G continuous maximum vibration Weather The RM7824A is not designed to be weather tight If installed o
41. the operating controller The LED indicates the burner status POWER and ALARM This condition indicates that the reset pushbutton is pressed If it is held for more than four seconds the alarm output is energized The alarm output will be de energized after the reset pushbutton is released 19 65 0155 1 7800 SERIES RM7824A RELAY MODULE Table 8 Hold And Fault Message Summary Fault Number Annunciation Message Fault number Annunciation Message Fault 98 108 P ranno T Fanen Fat Fault 255727 Fault 19 Main Flame Ign Fault 94 108 Call Service Honeywell Home and Building Control Home and Building Control Helping You Control Your World Honeywell Inc Honeywell Limited Honeywell Limit e 1985 Douglas Drive North 740 Ellesmere Road Golden Valley MN 55422 Scarborough Ontario MIP 2V9 65 0155 1 Rev 6 95 G R Printed in U S A www honeywerll com bbc
42. tions an ultraviolet detector will respond to other ultraviolet sources as if it is sensing a flame These ultraviolet sources include artificial light such as incandescent or fluorescent bulbs mercury and sodium vapor lamps or daylight To check for proper detector operation check the Flame Failure Response Time FFRT and conduct Safety Shutdown tests under all operating conditions Flame Signal with Hot Combustion Chambers All Installations After all initial start up tests and burner adjustments are completed operate the burner until the combustion chamber is at the maximum expected temperature Observe the equipment manufacturer warm up instructions Recycle the burner under these hot conditions and measure the flame signal Check the pilot alone for non DSI applications or the main burner flame for DSI applications Check the FFRT of the Flame Amplifier Lower the setpoint of the operating controller and observe the time it takes for the burner flame to go out This should be within three seconds maximum If the flame signal is too low or unsteady check the flame detector temperature Relocate the detector if the temperature is too high If necessary realign the sighting to obtain the proper signal and response time Then if the response time continues to be too slow replace the Plug in Flame Signal Amplifier Safety Shutdown Tests All Installations Perform these tests at the end of Checkout section after all other test
43. tive black probe into the Com jack of the flame amplifier see Fig 16 METER LEAD POSITIVE ONE MEGOHM VOLT NEGATIVE METER LEAD d METER Fig 16 Flame signal measurement 65 0155 1 Allow a few seconds for the meter reading to stabilize When using a shutter check amplifier read the average stable voltage disregarding the peaks and valleys caused by the self checking program 6 The meter reading must be as specified in Table 6 after all tests are completed and all adjustments are made or As an option the flame signal can be checked by using the optional Keyboard Display Module If the signal is unstable or less than the minimum acceptable voltage check the flame detector installation and circuitry 1 Check the supply voltages at terminals 3 and L2 N Make sure the master switch is closed connections are correct and the power supply voltage is correct 2 Check the detector wiring for defects including e Deteriorated wire e ncorrect connections e Leakage paths caused by moisture soot or accumulated dirt e Open circuits e Short circuits e Wrong wire type 3 For all optical detectors clean the detector viewing window and inside the sight pipe as applicable 4 With the burner running check the temperature at the detector If it exceeds the detector maximum rated temperature e Add a heat block to stop conducted heat traveling up the sight pipe e
44. urner start up if flame is indicated at start up is expanded to include a flame signal check during STANDBY and a safety critical load check Off Cycle Standby Flame Signal Check The flame detection subsystem flame detector and amplifier is monitored during STANDBY If a flame simulating condition or an actual flame exists for 40 seconds in STANDBY a safety shutdown occurs and startup is prevented If the flame signal exists at any time after the 40 seconds during STANDBY a safety shutdown occurs and is annunciated The self checking detector is energized for the first 40 seconds during STANDBY and the last two seconds before exiting STANDBY If a flame exists after the first 40 seconds during STANDBY the self checking detector is energized during the last ten seconds of the 40 second flame detection period If a flame exists a safety shutdown occurs Safety and logic timings are inaccessible and cannot be altered or defeated Verified Spark Termination The ignition terminal is monitored to assure early spark termination ten seconds ignition and pilot and ten seconds pilot and main only First Out Annunciation and Self Diagnostics Sequence Status Lights LEDs provide positive visual indication of the program sequence POWER PILOT FLAME MAIN and ALARM The green POWER LED blinks every four seconds signifying that the RM7824A hardware is running correctly Optional multi function Keyboard Display Module shows elapsed t
45. utdoors the RM7824A must be protected by an approved weather tight enclosure Mounting Wiring Subbase NOTE Forinstallation dimensions see Fig 1 or 2 1 Mount the subbase in any position except horizontally with the bifurcated contacts pointing down The standard vertical position is recommended Any other position decreases the maximum ambient temperature rating 2 Select a location on a wall burner or in an electrical panel The Q7800 can be mounted directly in the control cabinet Be sure to allow adequate clearance for servicing installation access and removal of the RM7824A dust cover flame amplifier flame amplifier signal voltage probes electrical signal voltage probes and electrical field connections 3 For surface mounting use the back of the subbase as a template to mark the four screw locations Drill the pilot holes 4 Mount the subbase securely using four No 6 screws WIRING 1 a Forthe internal block diagram of the RM7824A see Fig 5 b For proper subbase wiring refer to Fig 6 c For proper remote wiring of the Keyboard Display Module refer to the Specifications for the Keyboard Display Module 65 0090 Communication Interface Base Unit 63 2278 DATA CONTROLBUS MODULE 65 0091 or Extension Cable Assembly 65 0131 2 Disconnect the power supply from the main disconnect before beginning installation to prevent electrical shock and equipment damage More than one disconnect may be involved
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