Honeywell RM7840G Thermostat User Manual

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RM7800E,G,L,M; RM7840E,G,L,M  
800 SERIES Relay Modules  
7
INSTALLATION INSTRUCTIONS  
APPLICATION  
SPECIFICATIONS  
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  
Electrical Ratings, see Table 3:  
Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz  
(±10%).  
Power Dissipation: RM7800/RM7840: 10W maximum.  
Maximum Total Connected Load: 2000 VA.  
(
standard with RM7800), Dust Cover (standard with RM7840),  
Fusing: 15A maximum, Type SC or equivalent Fast Blow.  
Subbase, Amplifier, and Purge Card. Options include  
Personal Computer Interface, DATA CONTROLBUS  
MODULE™, Remote Display Mounting, First-Out Expanded  
Annunciator and Combustion System Manager™ Software.  
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.  
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.  
IRI Acceptable.  
This document provides installation and static checkout  
instructions. Other applicable publications are:  
Federal Communications Commission, Part 15,  
Class B—Emissions.  
6
5-0084:Q7800A,B 22-Terminal Wiring Subbase Product  
Data.  
6
5-0089:ST7800A Plug-In Purge Timer Installation  
Instructions.  
INSTALLATION  
6
6
6
6
6
6
5-0090:S7800A Keyboard Display Module Product Data.  
5-0091:S7810A Data ControlBus Module™ Product Data.  
5-0095:S7820 Remote Reset Module Product Data.  
5-0097:221729C Dust Cover Packing Sheet.  
5-0101:S7830 Expanded Annunciator Product Data.  
5-0109:R7824, R7847, R7848, R7849, R7851, R7861,  
R7886 Flame Amplifiers for the 7800 SERIES Product  
Data.  
5-0131:221818A Extension Cable Assembly Product  
Data.  
5-0228:7800 SERIES Multi-Drop Switch Module 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.  
6
6
6
6
5-0229:7800 SERIES RELAY MODULES Checkout and  
Troubleshooting Product Data.  
5-0249:S7810M ModBus™ Module Product Data.  
4. After installation is complete, check out the product  
operation as provided in these instructions.  
®
U.S. Registered Trademark  
Copyright © 2002 Honeywell • All Rights Reserved  
66- 1085- 3  
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
Location  
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.  
Humidity  
Install the relay module where the relative humidity never  
reaches the saturation point. The relay module is designed to  
operate in a maximum 85 percent relative humidity  
continuous, noncondensing, moisture environment.  
Condensing moisture may cause a safety shutdown.  
Vibration  
WARNING  
Can cause serious injury or death.  
Disconnect the power supply before beginning  
installation. More than one power supply disconnect  
may be required.  
Do not install the relay module where it could be subjected to  
vibration in excess of 0.5G continuous maximum vibration.  
Electrical Shock Hazard.  
Weather  
The relay module is not designed to be weather tight.  
When installed outdoors, protect the relay module using an  
approved weather-tight enclosure.  
IMPORTANT  
1
. Wiring connections for the relay modules are unique;  
therefore, refer to Fig. 2, 3, 4, or the correct  
Specifications for proper subbase wiring, and  
sequence charts.  
Mounting Wiring Subbase  
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
3
4
. Wiring must comply with all applicable codes,  
ordinances and regulations.  
. Wiring must comply with NEC Class 1 (Line Voltage)  
wiring.  
. Loads connected to the RM7800/RM7840 must not  
exceed those listed on the RM7800/RM7840 label or  
the Specifications, see Table 1.  
2. Select a location on a wall, burner or electrical panel.  
The Q7800 can be mounted directly in the control  
cabinet. Be sure to allow adequate clearance for  
servicing, installation, access or removal of the  
RM7800/RM7840, Expanded Annunciator, Keyboard  
Display Module, flame amplifier, flame amplifier signal  
voltage probes, Run/Test Switch, 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.  
5
6
7
. Limits and interlocks must be rated to simultaneously  
carry and break current to the ignition transformer,  
pilot valve, and main fuel valve(s).  
. All external timers must be listed or component  
recognized by authorities who have jurisdiction for  
the specific purpose for which they are used.  
. For on-off gas-fired systems, some authorities who  
have jurisdiction prohibit the wiring of any limit or  
operating contacts in series between the flame  
safeguard control and the main fuel valve(s).  
. Two Flame Detectors can be connected in parallel  
with the exception of Infrared Flame Detectors  
4. Securely mount the subbase using four no. 6 screws.  
8
9
Wiring Subbase  
(
C7015).  
. 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  
WARNING  
Electrical Shock Hazard.  
Can cause serious injury, death or equipment  
damage.  
Disconnect the power supply before beginning  
installation to prevent electrical shock, equipment  
and control damage. More than one power supply  
disconnect may be required.  
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.  
0.This digital apparatus does not exceed the Class B  
limits for radio noise for digital apparatus set out in  
the Radio Interference Regulations of the Canadian  
Department of Communications.  
1
2
.
.
For proper subbase wiring, refer to Figs. 2, 3, 4 or 5.  
For proper remote wiring of the Keyboard Display  
Module, through a 203541 5-wire Connector, refer to  
the Specifications for the Keyboard Display Module  
1
(
(
65-0090), Network Interface Unit  
63-2278), Data ControlBus Module™ (65-0091) or  
Extension Cable Assembly (65-0131).  
3
.
Disconnect the power supply from the main disconnect  
before beginning installation to prevent electrical shock  
and equipment damage. More than one disconnect may  
be required.  
6
6-1085—3  
2
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
4
.
All wiring must comply with all applicable electrical  
codes, ordinances and regulations. Wiring, where  
required, must comply with NEC, Class 1 (Line Voltage)  
wiring.  
NOTE: A 13 Vdc power supply must be used any time more  
than one Keyboard Display Module is used.  
9. Maximum wire lengths follow:  
5
6
.
.
Recommended wire size and type: see Table 1.  
Recommended grounding practices: see Table 2.  
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.  
The Keyboard Display Module, Data ControlBus Module™  
for remote mounting or communications), through a 203541  
-wire Connector, or Communication Interface ControlBus  
Module must be wired in a daisy chain configuration,  
1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order of interconnection of  
(
5
(
all the devices listed above is not important. Be aware that  
modules on the closest and farthest end of the daisy chain  
configuration string require a 120 ohm (1/4 watt minimum)  
resistor termination across terminals 1 and 2 of the electrical  
connectors, for connections over  
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.  
100 feet.  
7.  
Recommended wire routing of leadwires:  
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.  
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.  
b. Do not route flame detector, Data Controlbus  
Module™, or Remote Reset Module leadwires in  
conduit with line voltage circuits.  
c. Enclose flame detector leadwires without armor  
cable in metal cable or conduit.  
d. Follow directions in flame detector, Data Controlbus  
Module™, or Remote Reset Module Instructions.  
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.  
8
.
3. Install all electrical connectors.  
4
.
Restore power to the panel.  
Table 1. Recommended Wire Sizes and Part Numbers.  
Application  
Recommended Wire Size  
Recommended Part Number(s)  
Line voltage terminals  
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.  
Belden 8723 shielded cable or equivalent.  
22 AWG two-wire twisted pair with  
ground, or five wire.  
22 AWG two-wire twisted pair, insulated  
for low voltage.  
Communications Interface ControlBus™ 22 AWG two-wire twisted pair with  
Module ground.  
Belden 8723 shielded cable or equivalent.  
1
3 Vdc full-wave rectified transformer  
18 AWG wire insulated for voltages and TTW60C, THW75C, THHN90C.  
temperatures for given application.  
power input.  
3
66-1085—3  
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
L1  
(HOT) L2  
1
4
L2  
1
5
20 Vac,  
0/60 Hz  
PLUG-IN PURGE  
TIMER CARD  
CONFIGURATION  
JUMPERS  
TEST  
JACK  
FLAME SIGNAL  
RUN/TEST  
SWITCH  
F
PLUG-IN  
FLAME  
MICROCOMPUTER  
G
AMPLIFIER  
TEST  
RESET  
PUSHBUTTON  
22  
2
3
4
K
K
K
RELAY  
DRIVE  
5K  
RELAY  
CIRCUIT 6K  
STATUS  
FEEDBACK  
AND LINE  
VOLTAGE  
INPUTS  
7
K
K
8
9K  
SAFETY RELAY  
CIRCUIT  
1K  
STATUS LEDs  
CONTROL  
POWER  
POWER SUPPLY  
20  
PRE-IGNITION  
INTERLOCK  
RUNNING/  
LOCKOUT  
INTERLOCK  
LIMITS CONTROLLER  
1K1  
2K1 5K1  
6
7
10  
8
IGNITION  
4
K1  
LOW FIRE SWITCH  
8
HIGH FIRE SWITCH  
PILOT  
1
7
K1  
K2  
21  
PILOT/V2  
2
19  
9
MAIN VALVE  
6K1  
5
3
BLOWER  
ALARM  
3K1  
HIGH FIRE  
1
2
3
KEYBOARD  
DISPLAY MODULE  
8
K1  
K2  
9K2  
DDL  
COMMON  
INDICATES FEEDBACK SENSING  
OF RELAY CONTACT STATUS  
AND LINE VOLT INPUTS  
1
RS485  
8
MODULATE  
1
2
15  
9K1  
DDL  
REMOTE  
RESET  
FIELD WIRING  
INTERNAL WIRING  
3
LOW FIRE  
COMMUNICATIONS  
14  
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).  
6
6-1085—3  
4
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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™,  
Communications Interface 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  
G
Flame Sensor Grounda  
Earth Grounda  
Earth G  
L2(N)  
Line Voltage Common  
Alarm  
3
4
120 Vac, 1A pilot duty.  
Line Voltage Supply (L1)  
20 Vac (+10%/-15%), 50 or 60 Hz (±10%)b,d  
1
5
6
7
8
Burner Motor  
120 Vac, 9.8 AFL, 58.8 ALR (inrush).  
120 Vac, 1 mA.  
Burner Controller and Limits  
Lockout/Running Interlock  
Pilot Valve/Ignition  
120 Vac, 8A run, 43A inrush.  
20 Vacc.  
20 Vacc.  
20 Vacc.  
1
1
1
9
Main Fuel Valve  
Ignition  
1
0
F(11)  
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.  
1
1
1
1
1
1
1
1
2
2
2
3
4
5
6
7
8
9
0
1
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.  
20 Vacc.  
1
2
2
Shutter  
120 Vac, 0.5A.  
.aThe 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
2
000 VA maximum connected load to relay module assembly.  
c
See tables 4 and 5.  
d
RM7800G,M/RM7840G,M operating frequency determined by relay module selection.  
5
66-1085—3  
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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.  
Pilot Fuel 8 Main 9 Ignition 10  
No Load  
Combination No.  
Intermittent Pilot Valve 21  
No Load  
1
2
3
4
5
6
7
8
9
C
B
F
F
F
F
F
F
D
D
D
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  
.5A ignition.  
180 VA ignition plus  
motor valve with:  
2A Pilot Duty.  
64 VA Pilot Duty plus motor  
valves with:  
3850 VA inrush, 700 VA  
open, 250 VA hold.  
4
6
60 VA inrush, 360 VA  
open, 260 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.  
6
6-1085—3  
6
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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
SERIES 90  
FIRING RATE SERIES 90  
Q7800  
MOTOR  
CONTROLLER  
HIGH FIRE  
COMMON  
LOW FIRE  
MODULATE  
G
12  
13  
14  
B
B
FOR DIRECT SPARK IGNITION (OIL  
OR GAS)  
L2  
R
R
IGNITION  
TRANSFORMER  
10  
1
20V ALARM  
3
4
5
W
W
8
L2  
(L1)  
15  
16  
9
2ND STAGE  
FUEL VALVE  
(OPTIONAL)  
BURNER MOTOR  
(
BLOWER)  
BURNER  
CONTROLLER/LIMITS  
6
17  
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.  
1
0 SEC. INTERRUPTED  
HIGH FIRE  
PURGE SWITCH  
PILOT/IGNITION  
2
5
RM7800/7840E ONLY: HIGH FIRE PURGE SWITCH  
CONNECTED TO  
4 5  
(L1), NOT .  
MAIN FUEL VALVE(S)  
9
PREIGNITION  
INTERLOCK  
3
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS  
FOR CORRECT WIRING.  
5
SECOND IGNITION  
10  
(
EARLY SPARK  
15 SEC.  
INTERRUPTED  
PILOT VALVE  
TERMINATION)  
4
5
DO NOT WIRE TO ANY UNUSED TERMINALS.  
F
RM7840L1026, RM7800L1053 HAVE INTERMITTENT  
PILOT VALVE FUNCTIONS.  
FLAME DETECTOR  
3
L1  
(
HOT)  
1
L2  
MASTER  
SWITCH  
M12261C  
RM7800/RM7840E,L  
INITIATE  
PREPURGE  
HOLD  
DRIVE TO  
HIGH FIRE  
PREPURGE PFEP  
(INITIAL  
HOLD  
DRIVE TO  
10 SEC.  
00  
(4 SEC. IF  
0
0
00  
00  
10  
20 25  
MFEP  
00  
15  
POWERUP  
ONLY)  
TIMED  
STANDBY  
POWER  
PREPURGE LOW FIRE JR1 CLIPPED  
RUN  
POSTPURGE STANDBY  
POWER  
POWER  
POWER  
POWER  
POWER  
POWER  
PILOT  
POWER  
PILOT  
POWER  
POWER  
LED  
DISPLAY  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
FLAME  
FLAME  
MAIN  
MAIN  
ALARM  
ALARM  
ALARM  
ALARM  
ALARM  
BURNER  
1
BURNER/BLOWER MOTOR  
IGN.  
0 SEC. IGN./PILOT  
5 SEC. PILOT  
5
10  
5 SEC.  
1
8
1
21  
2
MAIN VALVE  
9
OPERATING  
CONTROLS  
AND  
LIMITS AND BURNER CONTROLLER CLOSED  
LOCKOUT INTERLOCKS CLOSED  
L1 TO  
TO  
6
7
INTERLOCK. CHECK  
6
IC  
INTERLOCKS  
PREIGNITION INTERLOCK CLOSED  
TO 19 HIGH FIRE SW.  
4
TO 20  
PII  
1
5
LOW FIRE SW.  
5
TO 18  
FLAME PROVING  
13 TO 15  
FLAME  
SIGNAL  
SAFE START CHECK  
SSC  
SWITCHING  
1
13  
TO 14  
13 TO 14  
3
TO 12  
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
66-1085—3  
href="
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
SERIES 90  
FIRING RATE SERIES 90  
CONTROLLER  
Q7800  
MOTOR  
HIGH FIRE  
COMMON  
LOW FIRE  
MODULATE  
G
12  
13  
14  
B
B
L2  
R
R
1
20V ALARM  
3
4
5
W
W
(L1) 15  
16  
BURNER MOTOR  
(
FOR DIRECT SPARK IGNITION  
(OIL OR GAS)  
3
BLOWER)  
IGNITION  
TRANSFORMER  
10  
BURNER  
CONTROLLER/LIMITS  
6
17  
4
1
ST STAGE  
21  
L2  
FUEL VALVE  
RUNNING INTERLOCKS  
INC. AIR FLOW SWITCH)  
LOW FIRE  
START SWITCH  
7
8
18  
19  
20  
21  
22  
(
9
2ND STAGE  
FUEL VALVE  
(OPTIONAL)  
1
0 SEC. INTERRUPTED  
2
PILOT/IGNITION  
JUMPER WIRE FOR 30s MFEP  
MAIN FUEL VALVE(S)  
9
PREIGNITION  
INTERLOCK  
1
2
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT  
MEANS AND OVERLOAD PROTECTION AS REQUIRED.  
5
SECOND IGNITION  
10  
15 OR 30 SEC.  
INTERRUPTED/  
INTERMITTENT  
PILOT VALVE  
(
EARLY SPARK  
TERMINATION)  
ADD JUMPER FOR 30 SECOND MAIN FLAME  
ESTABLISHING PERIOD (MFEP).  
F
FLAME DETECTOR  
4
3
4
DO NOT WIRE TO ANY UNUSED TERMINALS.  
L1  
(
HOT)  
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS  
FOR CORRECT WIRING.  
L2  
1
MASTER  
SWITCH  
M12260B  
RM7800G/RM7840G  
PREPURGE PFEP  
INITIATE  
INITIAL  
POWERUP  
ONLY)  
(
HOLD  
DRIVE TO  
PREPURGE LOW FIRE JR1 CLIPPED  
10 SEC.  
00  
(4 SEC. IF  
00  
00  
10  
20 25  
MFEP  
00  
15  
TIMED  
STANDBY  
POWER  
RUN  
POSTPURGE STANDBY  
POWER  
POWER  
POWER  
POWER  
POWER  
PILOT  
POWER  
PILOT  
POWER  
POWER  
LED  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
DISPLAY  
FLAME  
FLAME  
MAIN  
MAIN  
ALARM  
ALARM  
ALARM  
ALARM  
ALARM  
BURNER  
BURNER/BLOWER MOTOR  
IGN.  
0 SEC. IGN./PILOT  
5/30 SEC. INTERRUPTED/INTERMITTENT PILOT VALVE 21  
MAIN VALVE  
5
10  
5 SEC.  
1
8
1
9
OPERATING  
CONTROLS  
AND  
LIMITS AND BURNER CONTROLLER CLOSED L1 TO  
RUNNING INTERLOCKS CLOSED TO  
PREIGNITION INTERLOCK CLOSED TO 20  
LOW FIRE SW.  
6
7
INTERLOCK. CHECK  
6
IC  
INTERLOCKS  
4
PII  
5
TO 18  
FLAME PROVING  
13 TO 15  
FLAME  
SIGNAL  
SAFE START CHECK  
RM7800/7840G SWITCHING  
SSC  
13  
TO 14  
13 TO 14  
13  
TO 12  
FIRING  
RATE  
MOTOR ACTION  
MOTOR  
M12264A  
Fig. 3. Wiring subbase and sequence for RM7800G/RM7840G.  
6
6-1085—3  
8
href="
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)  
(
1
20V ALARM  
3
4
5
IGNITION  
TRANSFORMER  
2
10  
MODULATE  
DAMPER  
MOTOR  
(L1)  
15  
16  
1ST STAGE  
FUEL VALVE  
21  
L2  
BURNER MOTOR  
(
BLOWER)  
2ND STAGE  
FUEL VALVE  
9
(
OPTIONAL)  
BURNER  
CONTROLLER/LIMITS  
6
17  
2
2
RUNNING INTERLOCKS  
LOW FIRE  
7
8
18  
19  
20  
21  
22  
(
INC. AIR FLOW SWITCH)  
START SWITCH  
1
0 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
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  
10  
INTERMITTENT  
PILOT  
(
EARLY SPARK  
TERMINATION)  
3
4
DO NOT WIRE TO ANY UNUSED TERMINALS.  
F
SEE FLAME DETECTOR INSTALLATION  
INSTRUCTIONS FOR CORRECT WIRING.  
FLAME DETECTOR  
4
L1  
(
HOT)  
1
L2  
M12262A  
MASTER  
SWITCH  
RM7800M/RM7840M  
PREPURGE PFEP  
INITIATE  
INITIAL  
POWERUP  
ONLY)  
(
HOLD  
DRIVE TO  
PREPURGE LOW FIRE JR1 CLIPPED  
10 SEC.  
00  
(4 SEC. IF  
00  
00  
10  
20 25  
MFEP  
00  
POSTPURGE STANDBY  
POWER POWER  
15  
TIMED  
STANDBY  
POWER  
RUN  
POWER  
POWER  
POWER  
POWER  
POWER  
PILOT  
POWER  
PILOT  
ED  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
ISPLAY  
FLAME  
FLAME  
MAIN  
MAIN  
ALARM  
ALARM  
ALARM  
ALARM  
ALARM  
URNER  
BURNER/BLOWER MOTOR  
IGN.  
0 SEC. IGN./PILOT  
5
10  
5 SEC.  
1
8
INTERMITTENT PILOT VALVE 21  
MAIN VALVE  
9
PERATING  
ONTROLS  
ND  
LIMITS AND BURNER CONTROLLER CLOSED L1 TO  
RUNNING INTERLOCKS CLOSED TO  
PREIGNITION INTERLOCK CLOSED TO 20  
LOW FIRE SW.  
6
7
INTERLOCK. CHECK  
6
IC  
NTERLOCKS  
4
PII  
5
TO 18  
FLAME PROVING  
13 TO 15  
LAME  
IGNAL  
SAFE START CHECK  
SSC  
RM7800M/7840M SWITCHING  
TO 15  
MOTOR ACTION  
13  
AMPER  
OTOR  
M12265A  
Fig. 4. Wiring subbase and sequence for RM7800M/RM7840M.  
9
66-1085—3  
href="
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  
FLAME  
MAIN  
ALARM  
KEYBOARD  
DISPLAY  
MODULE  
CAPTIVE  
MOUNTING  
SCREW  
RESET  
(STANDARD ON  
RM7800E,G,L,M)  
BURNER CONTROL  
FLAME  
AMPLIFIER  
SCROLL  
MODE  
-
SAVE -  
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.  
PREPURGE Period:  
SAFETY SHUTDOWN  
Safety Shutdown (Lockout) occurs if any of  
the following occur during the indicated  
period:  
3
.
a. Preignition Interlock opens anytime during  
PREPURGE period (RM7840E,L).  
1
.
INITIATE Period:  
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.  
e. Four minute INITIATE period has been exceeded.  
STANDBY Period:  
a. Flame signal is present after 40 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.  
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).  
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).  
f. Lockout Interlock does not close within 10 seconds  
(RM7840E,L).  
2
.
6
6-1085—3  
10  
href="
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
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.  
l. Purge card is bad.  
PILOT FLAME ESTABLISHING Period (PFEP):  
a. Low Fire Switch opens.  
b. Lockout Interlock opens (RM7840E,L).  
c. Ignition/pilot valve/intermittent pilot valve terminal is  
not energized.  
d. Early spark termination terminal is energized after  
five seconds.  
fluctuations of +/-10 percent during any part of the operating  
sequence. The INITIATE sequence lasts for ten seconds  
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:  
(
4
.
a. AC line dropout is detected.  
b. AC line frequency error occurs caused by using a  
60 Hz device on a 50 Hz line, or vice versa.  
c. AC line noise prevents a sufficient reading of the  
line voltage inputs.  
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.  
d. Low line voltage brownouts occur.  
The INITIATE sequence also delays the burner motor starter  
from being energized and de-energized from an intermittent  
AC line input or control input.  
i. Purge card is bad.  
5
.
MAIN FLAME ESTABLISHING Period (MFEP):  
a. Low Fire Switch Opens.  
Standby  
The RM7800/RM7840 is ready to start an operating sequence  
when the operating control determines a call for heat is  
present. The burner switch, limits, operating control and all  
microcomputer monitored circuits must be in the correct state  
for the RM7800/RM7840 to continue into the PREPURGE  
sequence.  
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.  
h. Purge card is bad.  
Normal Start-Up 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:  
6
7
.
.
RUN Period:  
a. No flame is present.  
b. Lockout Interlock opens (RM7840E,L).  
c. Interrupted pilot valve terminal is energized  
(
RM7840G,M).  
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/RM7840. 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.  
d. Main valve terminal is not energized.  
e. Internal system fault occurred.  
f. Purge card is removed.  
g. Purge card is bad.  
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.  
f. Purge card is bad.  
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.  
OPERATION  
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,  
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.  
Initiate  
RM7800/RM7840E,G,L.  
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  
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.  
11  
66-1085—3  
href="
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
(
(
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.  
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,  
terminal 21. The RM7800/RM7840G has an  
interrupted or intermittent pilot valve, terminal  
(
3) RM7800L1053, RM7840L1026,  
RM7800M/RM7840M: Remain energized as  
long as call for heat is present.  
21, depending on the selection of configuration  
jumper 2. The RM7800/RM7840E,L has a  
fifteen-second interrupted pilot valve, terminal  
Run  
2
1. All of the RM7800/RM7840s have a  
1
.
A ten-second stabilization period occurs at the  
beginning of the RUN period.  
ten-second interrupted pilot valve/ignition,  
terminal 8.  
2) During PFEP, the Low Fire Switch must remain  
closed. If it opens, a safety shutdown occurs.  
3) The Preignition Interlock input is ignored  
throughout the Ignition Trial state.  
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.  
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.  
c. After five seconds, the ignition, terminal 10, is  
de-energized for early spark termination.  
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.  
2
.
1
.
The main fuel valve and intermittent pilot valve,  
Terminals 9 and 21, are de-energized and the firing rate  
motor is commanded to the low fire position to begin the  
POSTPURGE period.  
The Preignition Interlock closes within the first five  
seconds of POSTPURGE.  
b. Terminal 8 is turned off 10 seconds after Terminal 9  
is energized.  
c. Terminal 21 action:  
(
1) RM7800E,L/RM7840E,L: De-energized  
5 seconds after Terminal 9 is energized.  
2) RM7840G:  
2
.
1
(
Table 6. Sequence Timing for Normal Operation.  
Flame Establishing  
Post-  
Firing Energy Approval  
Rate Saving Code  
Circuit Prepurge Bodies  
Period  
Purge Interlock  
Device  
Initiate Standby Purge Pilot  
Maina  
Run Timing Circuits  
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  
sec.  
Preignition,  
Lockout,  
High and  
Low Fire  
FM/IRI  
Modulating  
b
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.  
The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.  
See Fig. 2, 3, 4, 5 and 6.  
*
a
b
RM7800L1053, RM7840L1026: 10 second or intermittent.  
6
6-1085—3  
12  
href="
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
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:  
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,  
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.  
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).  
Lockout information (Lockout, Fault Code, Message and  
Sequence).  
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.  
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 selectable message supplies information for flame strength,  
system status indication, system or self-diagnostics and  
troubleshooting.  
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  
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.  
Run/Test Switch  
WARNING  
SELECTABLE CONFIGURATION JUMPERS  
RUN/TEST SWITCH  
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.  
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.  
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.  
2
.
NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.  
M12301  
Fig. 6. Selectable site-configurable jumpers.  
1
3
66-1085—3  
href="
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  
JR2  
a
10 seconds  
Intermittent  
15 or 30 seconds Interruptedb  
RM7800G/RM7840G  
All  
Pilot Valve /Main Flame  
Establishing Period (MFEP)  
JR3  
Start-up Interlock Check  
Disabled  
Enabled  
a
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.  
b
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.  
STATIC CHECKOUT  
Equipment Recommended  
1
.
Voltmeter (1M ohm/volt minimum sensitivity) set on the  
-300 Vac scale.  
Two jumper wires; no. 14 wire, insulated, 12 inches  
304.8 mm) long with insulated alligator clips at both  
ends.  
0
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
.
(
General Instructions  
1
.
Perform all applicable tests listed in Static Checkout,  
Table 8, in the order listed.  
WARNING  
2
3
.
.
Make sure all manual fuel shutoff valve(s) are closed.  
Perform only those tests designated for the specific  
RM7800/RM7840 model being tested.  
Explosion and Electrical Shock Hazard.  
Can cause serious injury, death or equipment  
damage.  
4
5
.
.
Raise the setpoint of the operating controller to simulate  
a call for heat.  
For each test, open the master switch and install the  
jumper wire(s) between the subbase wiring terminals  
listed in the Test Jumpers 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.  
6
7
.
.
Close the master switch before observing operation.  
Read the voltage between the subbase wiring terminals  
listed in the Voltmeter column.  
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.  
1
0. Replace faulty controllers, limits, interlocks, actuators,  
valves, transformers, motors and other devices as  
required.  
1. Make sure normal operation is obtained for each  
required test before continuing the checkout.  
2. After completing each test, be sure to remove the test  
jumper(s).  
CAUTION  
Equipment Damage Hazard.  
1
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.  
1
WARNING  
Explosion Hazard.  
Can cause serious injury or death.  
Make sure all manual fuel shutoff valves are closed  
before performing static checkout.  
6
6-1085—3  
14  
href="
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
3
. Power connected to the Master Switch.  
. 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.  
. Burner Controller.  
2
3
4
20-L2  
7-L2  
1. Preignition interlocks.  
4-5  
1. Burner motor (fan or  
blower) starts.  
1. Burner motor circuit.  
a. Manual switch of burner motor.  
b. Burner motor power supply, overload  
protection, and starter.  
2
. Line voltage at Terminal  
7
within 10 seconds.  
c. Burner motor.  
. Running or Lockout Interlocks (including  
2
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).  
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.  
2
. Automatic pilot valve opens (if  
connected to Terminal 8).  
a. Actuator if used.  
NOTE: Refer to wiring diagram of  
system being tested.  
b. Pilot valve.  
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).  
9
1
4-3  
Alarm (if used) turns on.  
1. Alarm.  
0
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 2. Firing rate motor and transformer.  
starts driving open.  
1
2-13  
1
1
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.  
1
4-13  
1
1
1
2
3
4
RM7800E,L;  
RM7840E,L  
4-5  
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.  
and  
1
2-13  
RM7800E,L;  
RM7840E,L  
4-5  
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.  
and  
1
4-13  
RM7800E,G,L; 15-13  
RM7840E,G,L  
1. Raise setpoint of Series 90  
controller—firing rate motor  
should drive toward open.  
. Lower setpoint of Series 90  
controller—firing rate motor  
should drive toward closed.  
1. Series 90 Controller.  
2. Firing rate motor and transformer.  
2
1
5
66-1085—3  
href="
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES  
Table 8. Static Checkout. (Continued)  
RM7800/  
RM7840  
Models  
Test  
No.  
Test  
If Operation is Abnormal,  
Check the Items Listed Below  
Jumpers Voltmeter  
Normal Operation  
1
1
1
5
6
7
RM7800M;  
14-13  
If damper motor is used, motor  
drives damper open.  
Damper motor.  
RM7840M with  
open damper  
contacts..  
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  
985 Douglas Drive North  
Golden Valley, MN 55422  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Scarborough, Ontario  
M1V 4Z9  
1
Printed in U.S.A. on recycled  
paper containing at least 10%  
post-consumer paper fibers.  
6
6-1085—3 G.R. Rev. 02-02  
www.honeywell.com  

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