Honeywell RM7838A Manual

ConversionWiring Diagrams

for RM7838A

B. M. • 7-92 • © Honeywell Inc. 1992 • Form Number 65-0129

The diagrams and instructions contained in this booklet are for converting the following model

semi-automatic controls to RM7838 microprocessor based integrated burner control.

TABLE OF CONTENTS Page

Product Section Matrix ..................................................................................................................................................... 3

Section I.............................................................................................................................................................................. 5

R4138A,B,C,D

Section II ............................................................................................................................................................................ 6

Honeywell W124

Section III........................................................................................................................................................................... 8

Fireye 26SJ5 6000, 6052, 6152

WARNING

Improper configuration jumper selection could cause a fire or explosion hazard that could lead to property

damage, severe injury or death.

CAUTION

1. Installer must be a trained, experienced, flame safeguard control service technician.

2. Disconnect power supply before beginning installation to prevent electrical shock and equipment damage. More

than one power supply disconnect may be involved.

3. All wiring must comply with applicable local electrical codes, ordinances, and regulations.

4. All line voltage terminal wiring shall be no. 14, 16 or 18 copper conductor TTW (60C) or THW (75C) or THHN

(90C) 600 volt insulation wire. A maximum of two conductors can be wired to each Q7800 Subbase terminal.

5. Voltage and frequency of the power supply and flame detector(s) connected to this control must agree with those

marked on the device.

6. Loads connected to the control terminals must not exceed ratings listed in the Specification, form 65-0108, or on

the RM7838A label.

7. Allexternaltimersmustbelistedorcomponentrecognizedbyauthoritieshavingjurisdictionforthespecificpurpose

for which they are used.

8. Perform all required checkout tests after installation is complete.

IMPORTANT:

1. For on-off gas-fired systems, some authorities having

jurisdiction prohibit the wiring of any limit or operat-

ing contacts in series between the flame safeguard

control and the main fuel valve(s).

2. Do not connect more than two C7012E,F or

C7076A,D Ultraviolet Flame Detectors (with self-

checking shutter) in parallel to the same terminals.

3. This equipment generates, uses and can radiate radio

frequency energy, and if not installed and used in

accordance with the instructions, may cause interfer-

ence to radio communications. It has been tested and

foundtocomplywiththelimitsforaClassBcomputing

device of Part 15 of FCC rules, which are designed to

provide reasonable protection against such interfer-

ence when operated in a commercial environment.

Operation of this equipment in a residential area may

cause interference, in which case, 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

limitsforradionoisefordigitalapparatussetoutinthe

Radio Interference Regulations of the Canadian De-

partment of Communications.

NORMAL OPERATION:

Pilot Flame

Establishing Period

Device Initiate Standby Purge (PFEP) Run

RM7838A 10 sec. * ** 4 or 10 sec. *

* STANDBY and RUN can be an infinite time period.

** PURGE will be determined by which ST7800A Purge Card is selected.

APPROVAL BODIES:

Underwriters Laboratories Inc. listed, File No. MP268,

Guide No. MCCZ.

Canadian Standards Association certified, LR9S329-3.

Factory Mutual approved, Report No. JI1V9A0.AF.

Industrial Risk Insurers acceptable.

Federal Communications Commission, Part 15, Class B.

Canadian Department of Communications, CS-03,

Certification No. 5733459A.

MOUNTING:Q7800A forpanel mountor Q7800Bfor wall

or burner mount.

REQUIRED COMPONENTS:

Q7800 Subbase

ST7800 Purge Timer

RM7847/48/49/86 Flame Amplifier

ACCESSORIES:

5-Wire Connector

—part no. 203541.

Combustion Service Manager

—part no. ZM7850A1001.

Communication Interface Base Unit

—part no. Q7700A1014.

Communication Interface ControlBus Module

—part no. QS7800A1001.

DATA CONTROLBUS MODULE™

—part no. S7810A1009.

Electrical Access Slot Cover

—part no. 203765.

Expanded Annunciator

—part no. S7830A1005

Flame Simulators

—part no. 203659 UV Flame Simulator.

—part no. 123514A Rectification Simulator.

Remote Display Mounting Bracket

—part no. 203765.

Tester

—part no. A7800A1002.

Remote Display Power Supply

—part no. 203968 Plug-in.

3 65-0129

PRODUCT SELECTION MATRIX

SEMI-AUTOMATIC ON - OFF BURNER CONTROL

SELECT A RELAY

MODULE

SELECT A

SUBBASE

1.)

2.)

SELECT A

PURGE CARD

3.)

SELECT A FLAME

AMPLIFIER

4.)

SELECT

OPTIONS

5.)

M5157A

1 120 VAC.

2 FFRT = FLAME FAILURE RESPONSE TIME.

3 ONE Q7700 WILL SUPPORT ANY COMBINATION OF UP TO SIX (6) QS7700s/QS7800s.

EXPANDED ANNUNCIATION

S7830A1005 EXPANDED ANNUNCIATOR

REMOTE DISPLAY MOUNTING

203765 REMOTE MOUNTING BRACKET

221818A SIX FEET EXTENSION CABLE ASSEMBLY

13 VDC POWER SUPPLY

• 203968A PLUG-IN

RM7838A1006 WITH DISPLAY 50 HZ

RM7838A1014 WITH DISPLAY 60 HZ

Q7800A1005 PANEL MOUNT OR

Q7800B1003 BURNER/WALL

MOUNT

ST7800A1005 2 SEC.

ST7800A1013 7 SEC.

ST7800A1021 10 SEC.

ST7800A1039 30 SEC.

ST7800A1047 40 SEC.

ST7800A1054 60 SEC.

ST7800A1062 90 SEC.

ST7800A1070 2.5 MIN.

ST7800A1088 4 MIN.

ST7800A1096 6 MIN.

ST7800A1104 9 MIN.

ST7800A1112 12 MIN.

ST7800A1120 15 MIN.

ST7800A1138 22 MIN.

ST7800A1146 30 MIN.

R7847A1025 0.8 Sec. FFRT (RECTIFICATION). USE

 W/FLAME RODS OR PHOTOCELLS.

R7847A1033 3.0 Sec. FFRT (RECTIFICATION). USE

 W/FLAME RODS, PHOTOCELLS OR 

 C7012A,C.

R7847B1023 0.8 Sec. FFRT (RECTICATION). USE 

 W/FLAME RODS OR PHOTOCELLS.

R7847B1031 3.0 Sec. FFRT (RECTICATION). USE 

 W/FLAME RODS, PHOTOCELLS OR 

 C7012A,C.

R7847C1005 3.0 Sec. FFRT (C7012E,F)

R7848A1008 3.0 Sec. FFRT (C7015)

R7848B1006 3.0 Sec. FFRT (C7015)

R7849A1015 0.8 Sec. FFRT (C7027/C7035/C7044)

R7849A1023 3.0 Sec. FFRT (C7027/C7035/C7044)

R7849B1013 0.8 Sec. FFRT (C7027/C7035/C7044)

R7849B1021 3.0 Sec. FFRT (C7027/C7035/C7044)

R7886A1001 3.0 Sec. FFRT (C7076A,D)

COMMUNICATIONS

Q7700A1014 BASE UNIT

QS7800A1001 CONTROLBUS MODULE

ZM7850A1001 COMBUSTION SYSTEM MANAGER™

REMOTE DISPLAY MODULE

S7800A1001 DISPLAY MODULE

DIRECTIONS:

1. Disconnect all power to control being replaced. Note

that more than one power supply disconnect may be

involved.

2. Remove old control from subbase.

3. Mark all wires on subbase; i.e., wires connected to

terminal 1 should be marked 1.

4. Disconnect wires from subbase.

5. Remove old subbase.

6. Mount Q7800 Subbase.

7. Connect wires to subbase according to wiring conver-

sion for control being replaced. Pay close attention to

footnotes.Thetrianglesymbol

withanumberorletter

inside designates a footnote.

8. Install the RM7838A control. Make sure the proper

ST7800 purge card and flame detector have been se-

lected for the application.

9. TheRM7838Ahasone siteconfigurablejumperoption

thatisusedtoselectthePilotFlameEstablishingPeriod.

Refer to the RM7838A instructions, form 60-0108, for

assistance and proper selection.

10. Refer to the RM7838A instructions, form 60-0108, for

checkout and start-up.

GENERAL FOOTNOTES:

1 Be sure system is modernized to 120 Vac. The

replacement 7800 SERIES control is 120 Vac.

2 Select subbase.

3 TheRM7838Acannotbewiredforredundantappli-

cations without external relay logic to isolate the

safety critical loads test of the RM7838.

4 Select proper prepurge card based on the purge

timing of the control being replaced or the external

purge timer.

5 Select proper flame amplifier according to the

cross reference table or to meet the needs of the

application.

6 Selectproperflamedetectorwhenconvertingfroma

competitive control to Honeywell or if a different

flame detection system is desired; i.e., the old flame

amplifier was flame rectification and the new flame

amplifier is to be ultraviolet. Refer to the product

selection matrix on page 3 to select proper flame

detector.

7 Proper grounding of the green subbase terminal

screw to an electrical earth ground is a MUST for

proper operation of the 7800 SERIES control.

8 NOTE: UL allows only two electrical wires to each

subbase terminal. Wiring information may show

more than two wires to a particular terminal, which

mayrequireanexternalconnectiontoaccomplishthe

termination.

9 Selectpropersiteconfigurablejumperconfiguration

as required by the application. Refer to the cross

reference table and to Specifications, form 65-0108.

NOTE: Jumper number 1 selects Pilot Flame

Establishing Period.

10 Donotuse anyunusedsubbaseterminals asawiring

junction or termination point.

5 65-0129

7800 SERIES CONVERSION WIRING DIAGRAM

FROM R4138A, B, C, D

(DEVICE TO BE MODERNIZED)

M3307

RM7838A

(O.S. NUMBER OF RELAY MODULE TO BE USED)

Q7800

1253 784

GENERAL FOOTNOTES, SEE PAGE 4.

(L1)

7, 17

R4138B,D DEVICES PROVIDED CIRCUITRY TO

WITHSTAND UP TO A ONE SECOND POWER

INTERRUPTION WITHOUT SYSTEM SHUTDOWN.

THE REPLACEMENT 7800 SERIES CONTROL WILL

RETURN TO INITIATE AND THE SYSTEM WILL NEED

TO BE RESTARTED BEGINNING WITH PURGE.

DISREGARD R4138 SUBBASE JUMPERS (IF USED);

13–14, 12–F, AND L1–6. THESE JUMPERS ARE NOT

REQUIRED FOR THE RM7838 CONTROL.

IF THE R4138 HAS AN ALARM SILENCING

RELAY, CONNECT THE R4138 SUBBASE

TERMINAL 15 TO Q7800 TERMINAL 3.

LOCATE L1 CONNECTION TO ALARM

SILENCING RELAY AND WIRE NUT THIS

LEADWIRTE WITH THE ALARM LEADWIRE

THAT IS CONNECTED TO THE R4138

SUBBASE TERMINAL 16.

IF THERE IS NO SILENCING RELAY,

CONNECT THE R4138 SUBBASE TERMINAL

16 TO THE Q7800 SUBBASE TERMINAL 3

AND IGNORE THE JUMPER FROM THE

R4138 SUBBASE TERMINALS 11–15.

IF A JUMPER WAS INSTALLED BETWEEN

THE R4138 SUBBASE TERMINALS 7–13,

REMOVE AND DISCARD THIS JUMPER.

THE R4138 SUBBASE TERMINAL L1 WAS

POWERED FROM THE MASTER SWITCH

THROUGH LIMITS AND RUNNING

INTERLOCKS. THE RM7838 SUBBASE L1

TERMINAL (4) MUST BE POWERED

DIRECTLY FROM THE MASTER SWITCH.

CONNECT THE SERIES STRING OF THE

BURNER SWITCH, LIMITS AND RUNNING

INTERLOCKS (IF USED) BETWEEN THE

MASTER SWITCH AND TERMINAL 7.

7800 SERIES CONVERSION WIRING DIAGRAM

FROM___________________ TO ________________________

(DEVICE TO BE MODERNIZED) (O.S. NUMBER OF RELAY MODULE TO BE USED)

Q7800

W124 RM7838A

M2669

12568

347

GENERAL FOOTNOTES, SEE PAGE 4.

210

(L1)

(Specific Instructions on page 7)

765-0129

Specific instructions and footnotes for converting from

the Honeywell W124 Protectoglo Flame Safeguard to the

RM7838A. The footnotes will be designated with a letter in

a triangle (i.e.,

) for specific footnotes or a number in a

triangle (i.e.,

) for general footnotes from page 4.

1. Thefollowingcomponentswillbeneededinaddition

to the 7800 SERIES control.

• S445A Start-Stop Switch.

• Doublepole/singlethrowswitch(ifalarmsilenc-

ing is desired).

2. Wires that can be moved from the W124 subbase

terminals to the RM7838A subbase terminals are

shown in the tabs.

3. Locate, label and disconnect the hot supply wire

for the:

• alarm

• ignition transformer.

4. Remove and discard the following:

• Start/stop Switch (if it is not a S445A Start-Stop

Switch).

• Temperaturecontroller(ifused).Noteiftherewas

a temperature controller, a line voltage tempera-

ture controller will have to be installed in series

with the burner control switch.

• Jumper wires (if used) that are between W124

terminals 2-11, 3-8, 4-9, L1-11, R-W-B, or

W-10.

• Any external purge timer (if used).

5. Connect the hot supply wire of the ignition trans-

former to terminal C of the S445 Start-

Stop Switch.

6. Note General Footnotes.

SPECIFIC FOOTNOTES:

A Install the High Fire Purge switch between Q7800

Subbase terminals 7 and 19. If no High Fire

Purge Switch is used then install a jumper wire

between Q7800 subbase terminals 7 and 14. Note

installing the jumper will add 30 seconds to the

purge timing.

B Connectthehotsupplywireofthealarmthroughone

pole of the double pole/single throw alarm silencing

switch (if used) to Q7800 Subbase terminal 3.

C ConnectterminalBofthe S445A Start-Stop Switch

through the other pole of the double pole/single

throw alarm silencing switch (if used) to Q7800

Subbase terminal 6.

D Connectthelimitsofrunninginterlocks(HighLimit,

Pressure Switch, Combustion Air Switch and etc.)

in series with the burner switch and temperature

controller (if used). Connect this series string be-

tween L1 of the master switch and Q7800 Subbase

terminal 7.

F ConnecttheLowFirePurgeSwitch and any starting

interlocksinseriesbetweenQ7800Subbaseterminal

10 and terminal D of the S445 Start-Stop Switch.

G ConnectQ7800Subbaseterminal21toterminalAof

the S445 Start-Stop Switch.

H If Dynamic Self Check has been selected for the

flameamplifier,thenconnectoneoftheshutterleads

(white)oftheC7012E,ForC7076A,DFlameDetec-

tor to Q7800 Subbase terminal 22.

7800 SERIES CONVERSION WIRING DIAGRAM

FROM FIREYE 26SJ5 6000, 6052,6152

(DEVICE TO BE MODERNIZED)

M3306

RM7838A

(O.S. NUMBER OF RELAY MODULE TO BE USED)

Q7800

1253 784

GENERAL FOOTNOTES, SEE PAGE 4.

(L1)

1314

(Specific Instructions on page 9)

SPECIFIC FOOTNOTES:

AIf the neutral wire is on terminal 1 of the 26SJ5

control, then the system is 208 Vac or 240 Vac. The

systemwillhavetoberecontrolledto120 Vactouse

the 7800 SERIES control.

BInstall the High Fire Purge switch between Q7800

Subbase terminals 7 and 19. If no High Fire Purge

switch is used, then install a jumper between Q7800

Subbase terminals 7 and 19. Note that installing a

jumper will add 30 seconds to the purge timing.

CConnectthehotsupplywireofthealarmthroughone

pole of the double pole/single throw alarm silencing

switch (if used) to Q7800 Subbase terminal 3.

D Connect terminal B of the S445A Start-Stop Switch

through the other pole of the double pole/single

throw alarm silencing switch (if used) to Q7800

Subbase terminal 6.

EConnect the hot supply wire of the Pilot Fuel Valve

to Q7800 Subbase terminal 8.

FConnect the hot supply wire of the Main Fuel Valve

to Q7800 Subbase terminal 9.

GConnect the starting interlocks and Low Fire Purge

SwitchinseriesbetweenQ7800Subbaseterminal10

and terminal D of the S445 Start-Stop Switch.

HConnectQ7800Subbaseterminal21toterminalAof

the S445 Start-Stop Switch.

J If Dynamic Self Check has been selected for the

flameamplifier,thenconnectoneoftheshutterleads

(white)oftheC7012E,ForC7076A,DFlameDetec-

tor to Q7800 Subbase terminal 22.

Specific instructions and footnotes for converting from

the Fireye 26SJ56000, 6052, 6152 to the RM7838A. The

footnotes will be designated with a letter in a triangle

(i.e.,

) for specific footnotes or a number in a triangle

(i.e.,

) for general footnotes from page 4.

1. Thefollowingcomponentswillbeneededinaddition

to the 7800 SERIES control.

• S445A Start-Stop Switch.

• Double pole/single throw switch (if alarm

silencing is desired).

2. Locate, label and disconnect the hot supply (120 V

supply) wire for the:

• Alarm

• Ignition Transformer

• Main Fuel Valve

• Pilot Valve

3. Remove and discard the following:

• Alarm Silencing Switch (if used).

• Start Switch.

• Purge Timer (TA).

• Main Flame Timer (TB).

• Pilot Timer (TC).

• Purging Indicator Lamp.

• Flame OFF Indicator Lamp.

• Flame ON Indicator Lamp.

• Leadwires that are on terminals 5, 7, 8, 9, 10, 11,

12, A, C and L.

4. Note General Footnotes.

5. Wires that can be moved from the Fireye 26SJ5

terminals to the RM7838A terminals are shown in

the tabs.

6. Connect the hot supply wire of the ignition trans-

former to terminal C of the S445 Start-Stop Switch.

7. If there was an auxiliary load on terminal 6 of the

26SJ5device,then connectthisloadto terminalBof

theS445Start-StopSwitch.Notethatifthecombined

loadoftheignitiontransformerandtheauxiliaryload

is greater than 4.5A, then an external relay will have

to be used to switch the auxiliary load. Connect the

relay coil (120 Vac) to terminal B of the S445 Start-

Stop Switch.

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