RM7800E,G,L,M; RM7840E,G,L,M

7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION SPECIFICATIONS
The Honeywell RM7800/RM7840 Relay Modules are Electrical Ratings, see Table 3:
microprocessor-based integrated burner controls for Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz
automatically fired gas, oil, or combination fuel single (±10%).
burner applications. The RM7800/RM7840 Relay Power Dissipation: RM7800/RM7840: 10W maximum.
Modules are used for UL/CSA On/Off, UL/CSA
Modulating, and FM/IRI Modulating burner applications. Maximum Total Connected Load: 2000 VA.
The RM7800/RM7840 system consists of a Relay Module.
Keyboard Display Modules (standard with RM7800), Dust Fusing: 15A maximum, Type SC or equivalent Fast Blow.
Cover (standard with RM7840), Subbase, Amplifier, and Environmental Ratings:
Purge Card. Options include DATA CONTROLBUS Ambient Temperature:
MODULE™, Remote Display Mounting, First-Out Operating: -40°F to +140°F (-40°C to +60°C).
Expanded Annunciator and Communications through Storage: -40°F to +150°F (-40°C to +66°C).
Modbus™. Humidity: 85% relative humidity continuous, noncon-
Functions provided by the RM7800/RM7840 include densing.
automatic burner sequencing, flame supervision, system Vibration: 0.5G environment.
status indication, system or self-diagnostics and SIL 3 Capable:
troubleshooting. The RM7800/RM7840 is a solid state SIL 3 Capable in a properly designed Safety Instrumented
replacement for the electromechanical R4140 Automatic System. See http://www.exida.com/SAEL/Honey-
Programming Control. well_7800 for Certificate Agreement.
This document provides installation and static checkout Approvals:
instructions. Other applicable publications are: Underwriters Laboratories Inc. Listed: File No. MP268,
65-0084:Q7800A,B 22-Terminal Wiring Subbase Prod- Guide No. MCCZ.
uct Data. Factory Mutual Approved: Report No. 1V9A0.AF.
65-0089:ST7800A Plug-In Purge Timer Installation Swiss Re (formerly IRI): Acceptable.
Instructions. Federal Communications Commission, Part 15, Class B—
65-0090:S7800A Keyboard Display Module Product Emissions.
Data.
65-0091:S7810A Data ControlBus Module™ Product
Data. INSTALLATION
65-0095:S7820 Remote Reset Module Product Data.
65-0097:221729C Dust Cover Packing Sheet.
65-0101:S7830 Expanded Annunciator Product Data. When Installing this Product...
65-0109:R7824, R7847, R7848, R7849, R7851, R7852, 1. Read these instructions carefully. Failure to follow
R7861, R7886 Flame Amplifiers for the 7800 them could damage the product or cause a
SERIES Product Data. hazardous condition.
65-0131:221818A Extension Cable Assembly Product 2. Check the ratings given in the instructions and
Data. marked on the product to make sure the product is
65-0229:7800 SERIES RELAY MODULES Checkout suitable for the application.
and Troubleshooting Product Data. 3. Installer must be a trained, experienced, flame
65-0249:S7810M ModBus™ Module Product Data. safeguard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.

SIL3
Capable 32-00143-01
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Location
WARNING
Fire or Explosion Hazard. Humidity
Can cause property damage, severe injury,
or death. Install the relay module where the relative humidity never
To prevent possible hazardous burner operation, reaches the saturation point. The relay module is designed
verify safety requirements each time a control is to operate in a maximum 85 percent relative humidity
installed on a burner. continuous, noncondensing, moisture environment.
Condensing moisture may cause a safety shutdown.

WARNING Vibration
Electrical Shock Hazard. Do not install the relay module where it could be subjected
Can cause serious injury or death. to vibration in excess of 0.5G continuous maximum
Disconnect the power supply before beginning vibration.
installation. More than one power supply
disconnect may be required. Weather
IMPORTANT The relay module is not designed to be weather tight.
1. Wiring connections for the relay modules are When installed outdoors, protect the relay module using
unique; therefore, refer to Fig. 2, 3, 4, or the correct an approved weather-tight enclosure.
Specifications for proper subbase wiring, and
sequence charts. Mounting Wiring Subbase
2. Wiring must comply with all applicable codes,
ordinances and regulations. 1. Mount the subbase in any position except
3. Wiring must comply with NEC Class 1 (Line Volt- horizontally with the bifurcated contacts pointing
age) wiring. down. The standard vertical position is
4. Loads connected to the RM7800/RM7840 must recommended. Any other position decreases the
not exceed those listed on the RM7800/RM7840 maximum ambient temperature rating.
label or the Specifications, see Table 1. 2. Select a location on a wall, burner or electrical panel.
5. Limits and interlocks must be rated to simultane- The Q7800 can be mounted directly in the control
ously carry and break current to the ignition trans- cabinet. Be sure to allow adequate clearance for
former, pilot valve, and main fuel valve(s). servicing, installation, access or removal of the
6. All external timers must be listed or component RM7800/RM7840, Expanded Annunciator,
recognized by authorities who have jurisdiction for Keyboard Display Module, flame amplifier, flame
the specific purpose for which they are used. amplifier signal voltage probes, Run/Test Switch,
7. For on-off gas-fired systems, some authorities electrical signal voltage probes and electrical field
who have jurisdiction prohibit the wiring of any connections.
limit or operating contacts in series between the 3. For surface mounting, use the back of the subbase
flame safeguard control and the main fuel valve(s). as a template to mark the four screw locations. Drill
8. Two Flame Detectors can be connected in parallel the pilot holes.
with the exception of Infrared Flame Detectors 4. Securely mount the subbase using four no. 6 screws.
(C7015, C7915), Ultraviolet Flame Detectors
(C7927, C7961) or Visible Light Detector (C7962). Wiring Subbase
9. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and NOTE: There are now two different subbase models that
used in accordance with the instructions, may can be purchased. It is important to note which
cause interference to radio communications. It subbase is compatible with the relay module
has been tested and found to comply with the when purchasing repair or replacement parts.
limits for a
Class B computing device of Part 15 of FCC rules
which are designed to provide reasonable
Series 1000 Subbase
protection against such interference when All relay product codes that start with a 1 (example:
operated in a commercial environment. Operation RM7840G1014/U) needs to be used with subbase
of this equipment in a residential area may cause Q7800A1005/U.
interference; in which case, the users at their own
expense may be required to take whatever Series 2000 Subbase
measures are required to correct this interference.
All relay product codes that start with a 2 (example:
10.This digital apparatus does not exceed the Class B
RM7840G2014/U) needs to be used with subbase
limits for radio noise for digital apparatus set out
Q7800A2005/U.
in the Radio Interference Regulations of the Cana-
dian Department of Communications.

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 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Subbase Compatibility 7. Recommended wire routing of leadwires:

a. Do not run high voltage ignition transformer
Any relay module in the updated 1000 series will be fully wires in the same conduit with the flame
backward compatible with any legacy subbase detector, Data Controlbus Module™, or Remote
(Q7800A1005/U) installed in the field as well as all newly Reset Module wiring.
purchased updated 1000 and 2000 series relay modules. b. Do not route flame detector, Data Controlbus
Any relay module in the new 2000 series will only be able Module™, or Remote Reset Module leadwires in
to be installed on subbase Q7800A2005/U, and will not conduit with line voltage circuits.
be backward compatible with any Q7800A1005/U legacy c. Enclose flame detector leadwires without armor
subbases already installed in the field. cable in metal cable or conduit.
d. Follow directions in flame detector, Data Control-
IMPORTANT bus Module™, or Remote Reset Module Instruc-
Make sure to check the relay model number and tions.
check the subbase compatibly prior to ordering or 8. Keyboard Display Module (KDM): Because the KDM
attempting a new installation or field upgrade. 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.
WARNING
Electrical Shock Hazard.
Can cause serious injury, death or equipment WARNING
damage. Keyboard Display Module and/or Data
Disconnect the power supply before beginning Controlbus Module is powered from internally
installation to prevent electrical shock, equipment fused low voltage source and shares the voltage
and control damage. More than one power supply supply with Relay Module. The fuse is non-
disconnect may be required. replaceable. Excessive current draw or short at
display connection may cause fuse to blow out
1. For proper subbase wiring, refer to Figs. 2, 3, 4 or 5. resulting in dead, unpowered system.
2. For proper remote wiring of the Keyboard Display
Module, through a 203541 5-wire Connector, refer NOTE: A 13 Vdc power supply must be used any time
to the Specifications for the Keyboard Display more than one Keyboard Display Module is used.
Module (65-0090), Data ControlBus Module™ (65- 9. Maximum wire lengths follow:
0091) or Extension Cable Assembly (65-0131). a. RM7800/RM7840 leadwires—The maximum
3. Disconnect the power supply from the main discon- length of leadwire is 300 feet to terminal inputs
nect before beginning installation to prevent electri- (Control, Preignition Interlock, Running/Lock-
cal shock and equipment damage. More than one out Interlock, High Fire Switch and Low Fire
disconnect may be required. Switch).
4. All wiring must comply with all applicable electrical b. Flame Detector leadwires—The maximum flame
codes, ordinances and regulations. Wiring, where sensor leadwire length is limited by the flame
required, must comply with NEC, Class 1 (Line Volt- signal strength.
age) wiring. c. Remote Reset leadwires—The maximum length
5. Recommended wire size and type: see Table 1. of wire is 1000 feet to a Remote Reset pushbut-
6. Recommended grounding practices: see Table 2. ton.
d. Data Controlbus Module™—The maximum Data
Controlbus Module™ cable length depends on
WARNING the number of system modules connected, the
The Keyboard Display Module and Data noise conditions and the cable used. The maxi-
ControlBus Module™ (for remote mounting or mum length of all Data Controlbus Module™
communications), through a 203541 5-wire interconnecting wire is 1000 feet.
Connector, must be wired in a daisy chain 10. Make sure loads do not exceed the terminal ratings.
configuration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). Refer to the label on the RM7800/RM7840 or to the
The order of interconnection of all the devices ratings in Tables 3, 4 and 5.
listed above is not important. Be aware that
modules on the closest and farthest end of the
daisy chain configuration string require a 120
Final Wiring Check
ohm (1/4 watt minimum) resistor termination 1. Check the power supply circuit. The voltage and
across terminals 1 and 2 of the electrical frequency tolerance must match those of the
connectors, for connections over RM7800/RM7840. A separate power supply circuit
100 feet. 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.
3. Install all electrical connectors.
4. Restore power to the panel.

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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Number(s)
Line voltage terminals 14 or 16 AWG copper conductor, 600 THW75C, THHN90C.
volt insulation, moisture-resistant wire.
Keyboard Display Module (KDM) 22 AWG two-wire twisted pair with Belden 8723 shielded cable or
ground, or five wire. equivalent.
Data ControlBus Module™ 22 AWG two-wire twisted pair with Belden 8723 shielded cable or
ground, or five wire. equivalent.
Remote Reset Module 22 AWG two-wire twisted pair, —
insulated for low voltage.
13 Vdc full-wave rectified transformer 18 AWG wire insulated for voltages and THW75C, THHN90C.
power input. temperatures for given application.

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 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

L1
(HOT) L2

1
4 L2
120 Vac,
50/60 Hz
PLUG-IN PURGE
CONFIGURATION
TIMER CARD
JUMPERS
TEST
FLAME SIGNAL JACK
RUN/TEST F
SWITCH
PLUG-IN
MICROCOMPUTER FLAME G
TEST AMPLIFIER
RESET 22
PUSHBUTTON
2K
3K
4K
RELAY
DRIVE 5K
RELAY
CIRCUIT 6K
STATUS
7K FEEDBACK
8K AND LINE
VOLTAGE
9K INPUTS

SAFETY RELAY 1K
CIRCUIT
STATUS LEDs
CONTROL
POWER SUPPLY
POWER

20

PRE-IGNITION
INTERLOCK RUNNING/
LOCKOUT
LIMITS CONTROLLER INTERLOCK 1K1 2K1 5K1
6 7 10 IGNITION

4K1
LOW FIRE SWITCH 8 PILOT
18 7K1
21 PILOT/V2
HIGH FIRE SWITCH
2K2
19 9 MAIN VALVE
6K1
5 BLOWER
3K1
3 ALARM
HIGH FIRE
12
KEYBOARD
DDL DISPLAY MODULE 8K1
COMMON INDICATES FEEDBACK SENSING
13
RS485 OF RELAY CONTACT STATUS
8K2 MODULATE AND LINE VOLT INPUTS
1 15
9K1
DDL 2 9K2
3 REMOTE LOW FIRE FIELD WIRING
COMMUNICATIONS 14
RESET INTERNAL WIRING

1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M12258

Fig. 1. Internal block diagram of the RM7800L/RM7840L (See Fig. 2, 3, 4 or 5

for individual detailed wiring instructions).

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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 2. Recommended Grounding Practices.

Ground Type Recommended Practice
Earth ground (subbase and relay module). 1. Use to provide a connection between the subbase and
the control panel of the equipment. Earth ground must
be capable of conducting enough current to blow the
20A fuse (or breaker) in the event of an internal short
circuit.

2. Use wide straps or brackets to provide minimum

length, maximum surface area ground conductors. If a
leadwire must be used, use 14 AWG copper wire.

3. Make sure that mechanically tightened joints along

the ground path are free of nonconductive coatings and
protected against corrosion on mating surfaces.
Signal ground (KDM, Data ControlBus Module™ Use the shield of the signal wire to ground the device to the
signal ground terminals [3(c)] of each device. Connect the
shield at both ends of the chain to earth ground.

Table 3. Terminal Ratings.

Terminal No. Description Ratings
G Flame Sensor Ground a —
Earth G Earth Grounda —
L2(N) Line Voltage Common —
3 Alarm 120 Vac, 1A pilot duty.
4 Line Voltage Supply (L1) 120 Vac (+10%/-15%), 50 or 60 Hz (±10%)b
5 Burner Motor 120 Vac, 9.8 AFL, 58.8 ALR (inrush).
6 Burner Controller and Limits 120 Vac, 1 mA.
7 Lockout/Running Interlock 120 Vac, 8A run, 43A inrush.
8 Pilot Valve/Ignition 120 Vacc.
9 Main Fuel Valve 120 Vacc.
10 Ignition 120 Vacc.
F(11) Flame Sensor 60 to 220 Vac, current limited.
12 Firing Rate High Fire 120 Vac, 75 VA pilot duty.
13 Firing Rate Common 120 Vac, 75 VA pilot duty.
14 Firing Rate Low Fire 120 Vac, 75 VA pilot duty.
15 Firing Rate Modulate 120 Vac, 75 VA pilot duty.
16 Unused —
17 Unused —
18 Low Fire Switch Input 120 Vac, 1 mA.
19 High Fire Switch Input 120 Vac, 1 mA.
20 Preignition Interlock Input 120 Vac, 1 mA.
21 Interrupted/Intermittent Pilot Valve/First Stage Oil 120 Vacc.
Valve
22 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 2000 VA maximum connected load to relay module assembly.
c See tables 4 and 5.

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 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 4. Combinations for Terminals 8, 9, 10 and 21.

Pilot Fuel 8 Main 9 Ignition 10 Intermittent Pilot Valve 21
C F No Load No Load
B F No Load No Load
No Load F No Load B
F F A No Load
No Load F A F
D F A No Load
No Load D A D
D D A No Load
No Load D A D

Table 5. Explanation of Each Combination.

A B C D F
4.5A ignition. 50 VA Pilot Duty plus 180 VA ignition plus 2A Pilot Duty. 64 VA Pilot Duty plus
4.5A ignition. motor valve with: motor valves with:
660 VA inrush, 360 VA 3850 VA inrush, 700 VA
open, 260 VA hold. open, 250 VA hold.

Mounting RM7800/RM7840 3. Make sure no subbase wiring is projecting beyond

the terminal blocks. Tuck in wiring against the back
Relay Module (Fig. 5) of the subbase so it does not interfere with the knife
blade terminals or bifurcated contacts.
1. Mount the RM7800/RM7840 vertically on the
Q7800 Subbase, or mount horizontally with the knife IMPORTANT
blade terminals pointing downward. When mounted The RM7800/RM7840 must be installed with a
on the Q7800A, the RM7800/RM7840 must be in an plug-in motion rather than a hinge action.
electrical enclosure.
2. When mounting in an electrical enclosure, provide 4. Mount the RM7800/RM7840 by aligning the four
adequate clearance for servicing, installation and L-shaped corner guides and knife blade terminals
removal of the RM7800/RM7840, Keyboard Display with the bifurcated contacts on the wiring subbase
Module, flame amplifier, flame amplifier signal and securely tighten the two screws without deform-
voltage probes, electrical signal voltage probes, and ing the plastic.
electrical connections.
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 sig-
nal voltage probes.

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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
G 12 B B
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
COMMON
L2 13 R R
IGNITION
10 TRANSFORMER
LOW FIRE
120V ALARM 3 14 W W
8 L2
MODULATE
4 (L1) 15
9 2ND STAGE
FUEL VALVE
BURNER MOTOR (OPTIONAL)
(BLOWER) 5 16

BURNER 6 17
CONTROLLER/LIMITS
4

LOCKOUT INTERLOCKS LOW FIRE

(INC. AIR FLOW SWITCH) 7 18
START SWITCH
1 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
10 SEC. INTERRUPTED 8 19 HIGH FIRE MEANS AND OVERLOAD PROTECTION AS REQUIRED.
PILOT/IGNITION PURGE SWITCH
2 2 RM7800/7840E ONLY: HIGH FIRE PURGE SWITCH
MAIN FUEL VALVE(S) 9 20 PREIGNITION CONNECTED TO 4 (L1), NOT 5 .
INTERLOCK
3 SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
5 FOR CORRECT WIRING.
5 SECOND IGNITION
(EARLY SPARK 10 21
15 SEC.
TERMINATION) INTERRUPTED 4 DO NOT WIRE TO ANY UNUSED TERMINALS.
PILOT VALVE
F 22 5 RM7840L1026, RM7800L1053 HAVE INTERMITTENT
FLAME DETECTOR PILOT VALVE FUNCTIONS.
L1
(HOT)
3 1
L2
MASTER M12261C
SWITCH

RM7800/RM7840E,L
INITIATE PREPURGE PREPURGE PFEP
(INITIAL HOLD HOLD 10 SEC.
POWERUP 00 DRIVE TO 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY HIGH FIRE PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER
LED PILOT PILOT PILOT PILOT PILOT
DISPLAY
FLAME FLAME FLAME FLAME FLAME
MAIN MAIN MAIN MAIN MAIN
ALARM ALARM ALARM ALARM ALARM

BURNER 1 BURNER/BLOWER MOTOR 5

10 IGN. 5 SEC.

10 SEC. IGN./PILOT 8

15 SEC. PILOT 21 2

MAIN VALVE 9

OPERATING
LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6
CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK LOCKOUT INTERLOCKS CLOSED 6 TO 7 IC

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

1 5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18

FLAME
SAFE START CHECK FLAME PROVING SSC
SIGNAL
SWITCHING 13 TO 15

13 TO 12 13 TO 14 13 TO 14
FIRING
RATE MOTOR ACTION
MOTOR

1 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.

2 RM7800L1053, RM7840L1026: TERMINAL 21 PROVIDES INTERMITTENT PILOT FUNCTION. M12263D

Fig. 2. Wiring subbase and sequence for RM7800E,L/RM7840E,L.

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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
G 12 B B

COMMON
L2 13 R R

LOW FIRE
120V ALARM 3 14 W W

MODULATE
4 (L1) 15

BURNER MOTOR FOR DIRECT SPARK IGNITION

5 16 3 (OIL OR GAS)
(BLOWER)
IGNITION
10 TRANSFORMER
BURNER 6 17
CONTROLLER/LIMITS
4
1ST STAGE
21 FUEL VALVE L2
RUNNING INTERLOCKS LOW FIRE
(INC. AIR FLOW SWITCH) 7 18
START SWITCH
9 2ND STAGE
FUEL VALVE
10 SEC. INTERRUPTED 8 19 2 (OPTIONAL)
PILOT/IGNITION JUMPER WIRE FOR 30s MFEP

MAIN FUEL VALVE(S) 9 20 PREIGNITION

INTERLOCK
1 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT
5 SECOND IGNITION MEANS AND OVERLOAD PROTECTION AS REQUIRED.
(EARLY SPARK 10 21 15 OR 30 SEC.
TERMINATION) INTERRUPTED/
INTERMITTENT 2 ADD JUMPER FOR 30 SECOND MAIN FLAME
PILOT VALVE ESTABLISHING PERIOD (MFEP).
F 22
FLAME DETECTOR 3 DO NOT WIRE TO ANY UNUSED TERMINALS.
L1
4 (HOT) 4 SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
L2 FOR CORRECT WIRING.
MASTER M12260B
SWITCH 1

RM7800G/RM7840G
INITIATE PREPURGE PFEP
(INITIAL HOLD 10 SEC.
POWERUP 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER
LED PILOT PILOT PILOT PILOT PILOT
DISPLAY
FLAME FLAME FLAME FLAME FLAME
MAIN MAIN MAIN MAIN MAIN
ALARM ALARM ALARM ALARM ALARM

BURNER BURNER/BLOWER MOTOR 5

10 IGN. 5 SEC.

10 SEC. IGN./PILOT 8

15/30 SEC. INTERRUPTED/INTERMITTENT PILOT VALVE 21

MAIN VALVE 9

OPERATING
LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6
CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK RUNNING INTERLOCKS CLOSED 6 TO 7 IC

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

LOW FIRE SW. 5 TO 18

FLAME FLAME PROVING

SAFE START CHECK SSC
SIGNAL

RM7800/7840G SWITCHING 13 TO 15

13 TO 12 13 TO 14 13 TO 14
FIRING
RATE MOTOR ACTION
MOTOR

M12264A

Fig. 3. Wiring subbase and sequence for RM7800G/RM7840G.

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RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Q7800

G 12

COMMON
L2 13
FOR DIRECT SPARK IGNITION
(OIL OR GAS)

120V ALARM 3 14 IGNITION

2 10 TRANSFORMER
MODULATE DAMPER
4 (L1) 15 MOTOR 1ST STAGE
21 FUEL VALVE L2

BURNER MOTOR
(BLOWER) 5 16
9 2ND STAGE
FUEL VALVE
(OPTIONAL)
BURNER 6 17
CONTROLLER/LIMITS 2
2

RUNNING INTERLOCKS 7 18 LOW FIRE

(INC. AIR FLOW SWITCH) START SWITCH

10 SEC. INTERRUPTED 8 19
PILOT/IGNITION 3 1 120V, 50/60 Hz POWER SUPPLY. PROVIDE
DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
MAIN FUEL VALVE(S) 9 20 PREIGNITION
INTERLOCK 2 WHEN NO DAMPER MOTOR OR LOWFIRE
SWITCH IS USED, JUMPER TERMINAL 14
5 SECOND IGNITION
(EARLY SPARK 10 21 INTERMITTENT TO TERMINAL 18. DO NOT WIRE TERMINAL 15.
TERMINATION) PILOT
3 DO NOT WIRE TO ANY UNUSED TERMINALS.
F 22 4 SEE FLAME DETECTOR INSTALLATION
FLAME DETECTOR
INSTRUCTIONS FOR CORRECT WIRING.
L1
4 (HOT)
1
L2
MASTER M12262A
SWITCH

RM7800M/RM7840M
INITIATE PREPURGE PFEP
(INITIAL HOLD 10 SEC.
POWERUP 00 TIMED 00 DRIVE TO 00(4 SEC. IF 10 20 25 00 15
ONLY) STANDBY PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER
LED PILOT PILOT PILOT PILOT PILOT
DISPLAY
FLAME FLAME FLAME FLAME FLAME
MAIN MAIN MAIN MAIN MAIN
ALARM ALARM ALARM ALARM ALARM

BURNER BURNER/BLOWER MOTOR 5

10 IGN. 5 SEC.

10 SEC. IGN./PILOT 8

INTERMITTENT PILOT VALVE 21

MAIN VALVE 9

OPERATING LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6

CONTROLS
AND
INTERLOCKS INTERLOCK. CHECK RUNNING INTERLOCKS CLOSED 6 TO 7 IC

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

LOW FIRE SW. 5 TO 18

FLAME FLAME PROVING

SAFE START CHECK SSC
SIGNAL

RM7800M/7840M SWITCHING 13 TO 15

13 TO 15

MOTOR ACTION
DAMPER
MOTOR

M12265A

Fig. 4. Wiring subbase and sequence for RM7800M/RM7840M.

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 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

WIRING
SUBBASE

RUN/TEST DIN RAIL MOUNT BASE:

SWITCH SHOWN Q7800XX
RELAY
MODULE

CONFIGURATION
JUMPERS

PURGE
TIMER

BASE SECURITY PIN

RESET
BUTTON
CAPTIVE
MOUNTING
SCREW

BURNER CONTRO
L

SCROLL
MODE

- SAVE -

2-LINE VFD
KEYBOARD
DISPLAY
MODULE FLAME
(STANDARD ON AMPLIFIER
RM7800E,G,L,M)

4-LINE LCD
KEYBOARD DISPLAY MODULE
(SOLD AS AN OPTIONAL
ACCESSORY, SEE PG. 14)

Fig. 5. RM7800/RM7840 Relay Module exploded view.

SAFETY SHUTDOWN g. Purge card is not installed or is removed.

h. Purge card is bad.
3. PREPURGE Period:
Safety Shutdown (Lockout) occurs a. Preignition Interlock opens anytime during PRE-
if any of the following occur during PURGE period (RM7840E,L).
b. Flame signal is detected after first ten seconds
the indicated period: during PREPURGE (RM7840E,L).
1. INITIATE Period: c. High Fire Switch fails to close within four min-
a. Purge card is not installed or is removed. utes and fifteen seconds after the firing rate
b. Purge card is bad. motor is commanded to drive to the high fire
c. Configuration jumpers are changed (after 200 position at the start of PREPURGE (RM7840E,L).
hours of operation). d. Low Fire Switch fails to close within four minutes
d. Ac line power errors occurred, see Operation and fifteen seconds after the firing rate motor is
section. commanded to drive to the low fire position at
e. Four minute INITIATE period has been exceeded. the end of PREPURGE.
2. STANDBY Period: e. Running Interlock does not close within 30 sec-
a. Flame signal is present after 240 seconds. onds (RM7840G,M).
b. Preignition Interlock is open an accumulative f. Lockout Interlock does not close within 10 sec-
time onds (RM7840E,L).
of 30 seconds. g. Lockout Interlock opens during PREPURGE
c. Interlock check feature is enabled and the (RM7840E,L).
Interlock String (including airflow switch) is h. Ignition/pilot valve/intermittent pilot valve ter-
closed for 120 seconds with controller closed. minal is energized.
d. Ignition/pilot valve/intermittent pilot valve ter- i. Main valve terminal is energized.
minal is energized. j. Internal system fault occurred.
e. Main valve terminal is energized. k. Purge card is removed.
f. Internal system fault occurred. l. Purge card is bad.

11 32-00143—01
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

4. PILOT FLAME ESTABLISHING Period (PFEP): five seconds. When the tolerances are met, the INITIATE
a. Low Fire Switch opens. sequence restarts. If the condition is not corrected and the
b. Lockout Interlock opens (RM7840E,L). hold condition exists for four minutes, the
c. Ignition/pilot valve/intermittent pilot valve ter- RM7800/RM7840 locks out. Causes for hold conditions in
minal is not energized. the INITIATE sequence:
d. Early spark termination terminal is energized
after five seconds. a. AC line dropout is detected.
e. No flame is present at the end of PFEP. b. AC line noise prevents a sufficient reading of the
f. Main valve terminal is energized (RM7800G,M). line voltage inputs.
g. Internal system fault occurred. c. Low line voltage brownouts occur.
h. Purge card is removed. The INITIATE sequence also delays the burner motor
i. Purge card is bad. starter from being energized and de-energized from an
5. MAIN FLAME ESTABLISHING Period (MFEP): intermittent AC line input or control input.
a. Low Fire Switch Opens.
b. Lockout Interlock opens (RM7840E,L). Standby
c. Ignition/pilot valve/intermittent pilot valve ter- The RM7800/RM7840 remains in standby, ready to start.
minal is not energized. The operating control determines a call for heat is present
d. Main valve terminal is not energized. and provides input to terminal 6. The burner switch, limits,
e. No flame is present at the end of MFEP. operating control and all microcomputer monitored
f. Internal system fault occurred. circuits must be in the correct state for the
g. Purge card is removed. RM7800/RM7840 to advance into the PREPURGE
h. Purge card is bad. sequence.
6. RUN Period:
a. No flame is present.
b. Lockout Interlock opens (RM7840E,L). Prepurge
c. Interrupted pilot valve terminal is energized The RM7800/RM7840 provides a prepurge timing
(RM7840G,M). selectable from two seconds to 30 minutes with power
d. Main valve terminal is not energized. applied and the RM7800 operating control indicating a
e. Internal system fault occurred. call for heat:
f. Purge card is removed.
g. Purge card is bad. a. Running Interlocks, Preignition Interlocks,
7. POSTPURGE Period: Burner Switch, Run/Test Switch, Lockout Inter-
a. Preignition Interlock does not close in five sec- locks and all microcomputer monitored circuits
onds and opens after five-second time period. must be in the correct operating state.
b. Ignition/pilot valve/intermittent pilot valve ter- b. The blower motor output, terminal 5, is powered
minal is energized. to start the PREPURGE sequence, except for the
c. Main valve terminal is energized. RM7800E/RM7840E. The firing rate motor is
d. Internal system fault occurred. driven to the high fire position. The PREPURGE
e. Purge card is removed. timing for the RM7800/RM7840E,L does not
f. Purge card is bad. begin until the Lockout Interlock String and High
Fire Switch are both closed. The blower motor
output for the RM7800E is not energized until
OPERATION the High Fire Switch is closed.
c. The Preignition Interlock input must remain
closed throughout PREPURGE; otherwise, con-
Sequence of Operation trol returns to the STANDBY state and holds (30
seconds) for the RM7800/RM7840G,M or safety
The RM7800/RM7840 has the following operating shutdown for the RM7800/RM7840E,L occurs.
sequences, see Fig. 2, 3, 4, and Table 6. The d. The Lockout Interlock or Running Interlock
RM7800/RM7840 LED provide positive visual indication inputs (interlock circuit including Airflow Switch)
of the program sequence: POWER, PILOT, FLAME, MAIN must close by ten seconds into PREPURGE;
and ALARM. otherwise, a recycle to the beginning of
PREPURGE for the RM7800/RM7840G,M will
Initiate happen or a safety shutdown for the
The RM7800/RM7840 enters the INITIATE sequence RM7800/RM7840E,L occurs.
when the Relay Module is powered. The RM7800/RM7840 e. When PREPURGE timing is complete, the firing
can also enter the INITIATE sequence if the Relay Module rate motor drives to the low fire position,
verifies voltage fluctuations of +10/-15 percent or RM7800/RM7840E,G,L.
frequency fluctuations of +/-10 percent during any part of f. When the firing rate motor reaches low fire posi-
the operating sequence. The INITIATE sequence lasts for tion, the Low Fire Switch, terminal 18, input must
ten seconds unless the voltage or frequency tolerances be energized before entering the Ignition Trial
are not met. When the tolerances are not met, a hold state.
condition is initiated and displayed on the VFD for at least

32-00143—01 12
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Ignition Trials Run

1. Pilot Flame Establishing Period (PFEP): 1. A ten-second stabilization period occurs at the
a. With the firing rate motor at the low fire position: beginning of the RUN period.
(1) The pilot valve and ignition transformer, 2. The firing rate motor releases to modulation
terminals 8, 10 and 21, are energized. The (RM7800/RM7840E,G,L). Damper motor is ener-
RM7800M has an intermittent pilot valve, gized (RM7800/RM7840M).
terminal 21. The RM7800/RM7840G has an 3. The RM7800/RM7840 is now in RUN and remains in
interrupted or intermittent pilot valve, RUN until the controller input, terminal 6, opens,
terminal 21, depending on the selection of indicating that the demand is satisfied or a limit
configuration jumper 2. The opened.
RM7800/RM7840E,L has a fifteen-second
interrupted pilot valve, terminal 21. All of the Postpurge
RM7800/RM7840s have a
ten-second interrupted pilot valve/ignition, The RM7800/RM7840 provides a fifteen-second
terminal 8. POSTPURGE following the completion of the RUN period.
(2) During PFEP, the Low Fire Switch must The blower motor output is powered to drive all products
remain closed. If it opens, a safety shutdown of combustion and any unburned fuel from the
occurs. combustion chamber. It also supplies combustion air to
(3) The Preignition Interlock input is ignored burn fuel being purged from the fuel line downstream of
throughout the Ignition Trial state. the fuel shutoff valve.
b. Flame must be proven by the end of the ten-sec- 1. The main fuel valve and intermittent pilot valve,
ond PFEP (four if JR1 is clipped) to allow the Terminals 9 and 21, are de-energized and the firing
sequence to continue. If flame is not proven by rate motor is commanded to the low fire position to
the end of PFEP, a safety shutdown occurs. begin the POSTPURGE period.
c. After five seconds, the ignition, terminal 10, is 2. The Preignition Interlock closes within the first five
de-energized for early spark termination. seconds of POSTPURGE.
2. Main Flame Establishing Period (MFEP): 3. After the fifteen-second POSTPURGE period is
a. Terminal 9 is energized when the presence of completed, the RM7800/RM7840 reenters Standby.
flame is verified at the end of a 10-second Pilot
Flame Establishing Period (PFEP) (four seconds
if JR1 is clipped).
b. Terminal 8 is turned off 10 seconds after Termi-
nal 9 is energized.
c. Terminal 21 action:
(1) RM7800E,L/RM7840E,L: De-energized
15 seconds after Terminal 9 is energized.
(2) RM7840G:
(a) Not turned off, or
(b)15 seconds after Terminal 9 is energized
and JR2 is clipped, or
(c)30 seconds after Terminal 9 is energized
and Terminals 5 and 19 are jumpered and
jumper JR2 is clipped.
(3) RM7800L1053, RM7840L1026,
RM7800M/RM7840M: Remain energized as
long as call for heat is present.

13 32-00143—01
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 6. Sequence Timing for Normal Operation.

Flame Establishing
Period Post- Energy
Purge Interlock Firing Rate Saving Approval
Device Initiate Standby Purge Pilot Maina Run Timing Circuits Circuit Prepurge Code Bodies
RM7800E/ 10 sec. * ** 4 or 10 10 or 15 sec. * 15 sec. Preignition, 4-wire Yes FM/IRI
RM7840E sec. Lockout, High modulating Modulating
and Low Fire
RM7800G/ 10, 15 sec. or Preignition, No UL/CSA
RM7840G intermittent Running, Low Modulating
Fire
RM7800L/ 10 or 15 sec.b Preignition, FM/IRI
RM7840L Lockout, High Modulating
and Low Fire
RM7800M/ 10 sec. or Preignition, 2-wire isolated UL/CSA On-
RM7840M intermittent Running, Low On-Off-On Off
Fire contacts
* STANDBY and RUN can be an infinite time period.
**PURGE determined by which ST7800A purge card is selected.
a
The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.
See Fig. 2, 3, 4, 5 and 6.
b
RM7800L1053, RM7840L1026: 10 second or intermittent.

Keyboard Display Module Options purchased separately. This display offers more lines of text
displaying the trouble-shooting guide. (It is important to
note that this display's lower end temperature rating is
2-Line Vacuum Fluorescent Display (VFD) 0 °F)
The Keyboard Display Module (see Fig. 5) is provided with
the RM7800 Relay Module (but is not required for The first line of the Home and Lockout pages on the LCD
operation) and is an option for the RM7840 Relay Module. display use a larger font size than all other pages so that
The first line of the Vacuum Fluorescent Display (VFD) information on them can be more easily viewed from
provides: distances farther away from the display module (refer to
document number 32-00110 for full details on operation).
• Current status of the burner sequence (STANDBY,
PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE). Up to 4 lines of text are displayed at a time on the page.
• Timing information (PURGE, PILOT IGN, MAIN IGN and When the page has more than 4 lines of text to display a
POSTPURGE) in minutes and seconds. scroll bar is present on the right-hand side of the page to
• Hold information (PURGE HOLD: T19). indicate this situation. The “Up arrow” and “Down arrow”
• Lockout information (Lockout, Fault Code, Message buttons are used to scroll up and down the lines of the
and Sequence). page. Each line is highlighted with a white background to
The extreme right side of the first line is either blank or indicate that it currently has input focus for any button
shows a small arrow pointing to the second line followed actions. The scroll bar adjusts to give a relative position of
by a two-letter code (DI-Diagnostic Information, Hn-Fault the current view with respect to all lines that the page can
History Information, and EA-Expanded Annunciator). display.
When the arrow and two-letter code are displayed, it When a line has a right arrow symbol positioned on the
indicates the second line is showing a selectable message right hand side it indicates that this line can navigate to
submenu. The second line displays selectable or another page, “Next page”, related to the subject of the line
preemptive messages. when that line has input focus. A “Right arrow” or “OK”
A selectable message supplies information for flame button can be pressed when the focus is on this line to
strength, system status indication, system or self- navigate to the next page.
diagnostics and troubleshooting.

A preemptive message has parentheses around the

Run/Test Switch
message and supplies a detailed message to support the
sequence status information. A preemptive message can
also be a lockout message. A preemptive message WARNING
replaces a selectable message to support the sequence Explosion Hazard.
status information. It also replaces a selectable message Can cause serious injury or death.
after 60 seconds if it or a lockout message is available. Do not use the Run/Test switch during the Pilot
Flame Establishing Period for the
4-Line LCD Display RM7800/RM7840G,M when using Direct Spark
Function, because it turns on the main gas valve,
The 4-line LCD Keyboard Display Module (See Fig. 5) causing an accumulation of fuel in the burner.
S7800A2142/U is available as an option for the RM7800
and RM7840 Relay Modules. This display must be

32-00143—01 14
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

The Run/Test Switch is located on the top side of the during the first three seconds when a four second
RM7800/RM7840, see Fig. 6. The Run/Test Switch allows PFEP is selected, allowing pilot-turn-down test and
the burner sequence to be altered as follows: other burner adjustments to be made. This activates
a fifteen second flameout timer that permits pilot
1. In Prepurge Drive To High Fire Position, the flame adjustment without nuisance safety
Run/Test Switch, when placed in the TEST position, shutdowns. The Run/Test Switch is ignored during
holds in PREPURGE with the firing rate motor in the PFEP for the RM7800/RM7840E,L if Terminals 8
High Fire position. and 9 or 9 and 21 are jumpered.
2. In the measured PREPURGE sequence, the 5. During Run, the Run/Test Switch, when placed in the
Run/Test Switch, when placed in the TEST position, TEST position, drives the firing rate motor to the Low
causes the PREPURGE timing to stop. The firing rate Fire position.
motor is in the High Fire position.
3. In Prepurge Drive to Low Fire position, the Run/Test NOTE: When RM7800/RM7840 is switched to the Test
Switch, when placed in the TEST position, holds the mode, it stops and holds at the next Run/Test
burner sequence in PREPURGE with the firing rate Switch point in the operating sequence. Make
motor in the Low Fire position. sure that the Run/Test Switch is in the RUN
4. In PFEP, the Run/Test Switch, when placed in the position before leaving the installation.
TEST position, stops the timer during the first eight
seconds when a ten second PFEP is selected or

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.

SELECTABLE CONFIGURATION JUMPERS

RUN/TEST SWITCH

NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.

M12301

Fig. 6. Selectable site-configurable jumpers.

Table 7. Site Configurable Jumper Options.

RM7800/RM7840
Jumper Number Description Intact Clipped Type
JR1 Pilot Flame Establishing 10 seconds 4 seconds All
Period (PFEP)
JR2 Pilot Valvea/Main Flame 10 seconds 15 or 30 seconds Interruptedb RM7800G/RM7840G
Establishing Period (MFEP) Intermittent
JR3 Start-up Interlock Check Disabled Enabled All
a Pilot Valve /First Stage Oil Valve (Valve/Start) Terminal 21.
b A 30 second MFEP can be accomplished by adding a jumper wire between Terminals 19 and 5.

15 32-00143—01
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

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 jumper wire to check the amp usage when testing
the blower motor, ignition, pilot and main valve oper-
ation.
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, General Instructions
and the external controllers, limits, interlocks, actuators,
1. Perform all applicable tests listed in Static Checkout,
valves, transformers, motors and other devices are
Table 8, in the order listed.
operating properly.
2. Make sure all manual fuel shutoff valve(s) are
closed.
3. Perform only those tests designated for the specific
WARNING RM7800/RM7840 model being tested.
Explosion and Electrical Shock Hazard. 4. Raise the setpoint of the operating controller to sim-
Can cause serious injury, death or equipment ulate a call for heat.
damage. 5. For each test, open the master switch and install the
1. Close all manual fuel shutoff valve(s) before jumper wire(s) between the subbase wiring termi-
starting these tests. nals listed in the Test Jumpers column.
2. Use extreme care while testing the system. Line 6. Close the master switch before observing operation.
voltage is present on most terminal connections 7. Read the voltage between the subbase wiring termi-
when power is on. nals listed in the Voltmeter column.
3. Open the master switch before installing or 8. If there is no voltage or the operation is abnormal,
removing a jumper on the subbase. check the circuits and external devices as described
4. Before continuing to the next test, be sure to in the last column.
remove test jumper(s) used in the previous test. 9. Check all wiring for correct connections, tight termi-
5. Replace all limits and interlocks that are not nal screws, correct wire, and proper wiring tech-
operating properly. Do not bypass limits and niques. Replace all damaged or incorrectly sized
interlocks. wires.
10. Replace faulty controllers, limits, interlocks, actua-
tors, valves, transformers, motors and other devices
CAUTION
Equipment Damage Hazard. 11.
as required.
Make sure normal operation is obtained for each
Improper testing can damage equipment. required test before continuing the checkout.
Internal surge protectors can break down and 12. After completing each test, be sure to remove the
conduct a current, causing the RM7800/RM7840 test jumper(s).
to fail the dielectric test or possibly destroy the
internal lightning and high current protection. Do
not perform a dielectric test with the
RM7800/RM7840 installed.
WARNING
Explosion Hazard.
Can cause serious injury or death.
Equipment Recommended Make sure all manual fuel shutoff valves are closed
before performing static checkout.
1. Voltmeter (1M ohm/volt minimum sensitivity) set on
the 0-300 Vac scale.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
(304.8 mm) long with insulated alligator clips at
both ends. An ammeter may be used in place of a

32-00143—01 16
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 8. Static Checkout.

Test RM7800/RM Test If Operation is Abnormal,
No. 7840 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below
1 All None 4-L2 Line voltage at Terminal 4. 1. Master Switch.
2. Power connected to the Master Switch.
3. Overload protection (fuse, circuit
breaker, etc.) has not opened the power
line.
2 6-L2 Line voltage at Terminal 6. 1. Limits.
2. Burner Controller.
3 20-L2 Line voltage at Terminal 20. 1. Preignition interlocks.
4 4-5 7-L2 1. Burner motor (fan or 1. Burner motor circuit.
blower) starts. a. Manual switch of burner motor.
2. Line voltage at Terminal b. Burner motor power supply,
7 within 10 seconds. overload protection, and starter.
c. Burner motor.
2. Running or Lockout Interlocks
(including Airflow Switch).
5 4-10 — Ignition spark (if ignition 1. Watch for spark or listen for buzz.
transformer is connected to a. Ignition electrodes are clean.
Terminal 10) b. Ignition transformer is okay.
6 All 4-8 — 1. Ignition spark (if ignition 1. Watch for spark or listen for buzz.
transformer is connected to a. Ignition electrodes are clean.
Terminal 8). b. Ignition transformer is okay.
2. Automatic pilot valve opens (if 2. Listen for click or feel head of valve for
connected to Terminal 8). activation.
a. Actuator if used.
NOTE: Refer to wiring diagram b. Pilot valve.
of system being tested.
7 4-21 — Same as test no. 6 for Same as test no. 6. If using direct spark
connections to Terminal 8. If ignition, check the first stage fuel
using direct spark ignition, check valve(s) instead of the pilot valve.
the first stage fuel valve(s)
instead of the pilot valve.
8 4-9 — Automatic main fuel valve(s) 1. Listen for and observe operation of the
open. main fuel valve(s) and actuator(s).
If using direct spark ignition on a 2. Valve(s) and actuator(s).
model with intermittent pilot on
Terminal 21, check the optional
second stage fuel valve, if used.
9 4-3 — Alarm (if used) turns on. 1. Alarm.
10 RM7800E,G,L; 4-5 18-L2 Firing rate motor drives open; 1. Low Fire Start Switch.
RM7840E,G,L and zero volts at Terminal 18 after 2. Firing rate motor and transformer.
12-13 motor starts driving open.
11 RM7800E,G,L; 4-5 18-L2 Firing rate motor drives closed; 1. Low Fire Start Switch.
RM7840E,G,L and line voltage at Terminal 18 after 2. Firing rate motor and transformer.
14-13 motor is in Low Fire position.
12 RM7800E,L; 4-5 19-L2 Firing rate motor drives open; 1. High Fire Purge Switch.
RM7840E,L and line voltage at Terminal 19 after 2. Firing rate motor and transformer.
12-13 motor is in High Fire position.
13 RM7800E,L; 4-5 19-L2 Firing rate motor drives closed; 1. Low Fire Start Switch.
RM7840E,L and zero volts at Terminal 19 after 2. Firing rate motor and transformer.
14-13 motor starts driving closed.
14 RM7800E,G,L; 15-13 — 1. Raise setpoint of Series 90 1. Series 90 Controller.
RM7840E,G,L controller—firing rate motor 2. Firing rate motor and transformer.
should drive toward open.
2. Lower setpoint of Series 90
controller—firing rate motor
should drive toward closed.

17 32-00143—01
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 8. Static Checkout. (Continued)

Test RM7800/RM Test If Operation is Abnormal,
No. 7840 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below
15 RM7800M; 14-13 — If damper motor is used, motor Damper motor.
RM7840M drives damper open.
with open
damper
contacts..
16 RM7800M; 4-5 18-L2 If damper motor is used, motor 1. Low Fire Start Switch.
RM7840M drives open; line voltage at 2. Damper motor.
with open Terminal 18 after motor is in Low
damper Fire position.
contacts..
17 RM7800M; 4-5 18-L2 If damper motor is used, motor 1. Low Fire Start Switch.
RM7840M and drives open; zero volts at 2. Damper motor.
with open 4-13 Terminal 18.
damper
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.

32-00143—01 18
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

SAFETY AND SECURITY Modbus & DDL Interface security

Any conducts critical to device functionality (DDL,
Physical device protection Modbus lines etc.) shall be physically protected (installed
outside public access) since they could be damaged or
Device shall be accessible to authorized personnel tampered-with by unauthorized people, either
only – Installation on publicly accessible places is accidentally or for purpose.
not recommended as this could lead to unwanted
and potentially unsafe changes to device (wiring, Modbus RS-485 & DDL protocols do not support security
configuration, etc). features. For DDL interface - only DDL devices shall be
connected to the Burner Controller DDL line.
It is recommended to lock the device in an enclosed
cabinet with access allowed only to approved and trained
personnel. Also, it is strongly advised to keep all the wiring
License agreement
of device physically secure. Copying and reverse engineering is prohibited by the law.
Physical protection of the device is applied via Run/Test
switch label/seal. It is intended to prevent and detect
unauthorized access.

19 32-00143—01
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

For More Information

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