Honeywell Thermostat RM7800 User Manual - Honeywell Thermostat Manual Download

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Sunday, April 5, 2020

Honeywell Thermostat RM7800 User Manual

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 burner (±10%). applications. The RM7800/RM7840 Relay Modules are used Power Dissipation: RM7800/RM7840: 10W maximum. for UL/CSA On/Off, UL/CSA Modulating, and FM/IRI Modulating burner applications. The RM7800/RM7840 system Maximum Total Connected Load: 2000 VA. consists of a Relay Module. Keyboard Display Modules (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 Environmental Ratings: MODULE™, Remote Display Mounting, First-Out Expanded Ambient Temperature: Annunciator and Combustion System Manager™ Software. Operating: -40°F to +140°F (-40°C to +60°C). Storage: -40°F to +150°F (-40°C to +66°C). Functions provided by the RM7800/RM7840 include Humidity: 85% relative humidity continuous, noncondensing. automatic burner sequencing, flame supervision, system Vibration: 0.5G environment. status indication, system or self-diagnostics and troubleshooting. The RM7800/RM7840 is a solid state Approvals: replacement for the electromechanical R4140 Automatic Underwriters Laboratories Inc. Listed: File No. MP268, Programming Control. Guide No. MCCZ. Canadian Standards Association Certified: LR9S329-3. This document provides installation and static checkout Factory Mutual Approved: Report No. J.I.1V9A0.AF. instructions. Other applicable publications are: IRI Acceptable. Federal Communications Commission, Part 15, 65-0084:Q7800A,B 22-Terminal Wiring Subbase Product Class B—Emissions. Data. 65-0089:ST7800A Plug-In Purge Timer Installation Instructions. 65-0090:S7800A Keyboard Display Module Product Data. INSTALLATION 65-0091:S7810A Data ControlBus Module™ Product Data. 65-0095:S7820 Remote Reset Module Product Data. 65-0097:221729C Dust Cover Packing Sheet. When Installing this Product... 65-0101:S7830 Expanded Annunciator Product Data. 1. Read these instructions carefully. Failure to follow 65-0109:R7824, R7847, R7848, R7849, R7851, R7861, them could damage the product or cause a hazardous R7886 Flame Amplifiers for the 7800 SERIES Product condition. Data. 2. Check the ratings given in the instructions and marked 65-0131:221818A Extension Cable Assembly Product on the product to make sure the product is suitable for Data. the application. 65-0228:7800 SERIES Multi-Drop Switch Module Product 3. Installer must be a trained, experienced, flame Data. safeguard service technician. 65-0229:7800 SERIES RELAY MODULES Checkout and 4. After installation is complete, check out the product Troubleshooting Product Data. operation as provided in these instructions. 65-0249:S7810M ModBus™ Module Product Data. ® U.S. Registered Trademark Copyright © 2002 Honeywell • All Rights Reserved 66- 1085- 3 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, verify reaches the saturation point. The relay module is designed to safety requirements each time a control is installed on operate in a maximum 85 percent relative humidity a burner. continuous, noncondensing, moisture environment. Condensing moisture may cause a safety shutdown. WARNING Vibration Do not install the relay module where it could be subjected to Electrical Shock Hazard. vibration in excess of 0.5G continuous maximum vibration. Can cause serious injury or death. Disconnect the power supply before beginning installation. More than one power supply disconnect Weather may be required. The relay module is not designed to be weather tight. When installed outdoors, protect the relay module using an IMPORTANT approved weather-tight enclosure. 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 Mounting Wiring Subbase sequence charts. 1. Mount the subbase in any position except horizontally 2. Wiring must comply with all applicable codes, with the bifurcated contacts pointing down. The ordinances and regulations. standard vertical position is recommended. Any other 3. Wiring must comply with NEC Class 1 (Line Voltage) position decreases the maximum ambient temperature wiring. rating. 4. Loads connected to the RM7800/RM7840 must not 2. Select a location on a wall, burner or electrical panel. exceed those listed on the RM7800/RM7840 label or The Q7800 can be mounted directly in the control the Specifications, see Table 1. cabinet. Be sure to allow adequate clearance for 5. Limits and interlocks must be rated to simultaneously servicing, installation, access or removal of the carry and break current to the ignition transformer, RM7800/RM7840, Expanded Annunciator, Keyboard pilot valve, and main fuel valve(s). Display Module, flame amplifier, flame amplifier signal 6. All external timers must be listed or component voltage probes, Run/Test Switch, electrical signal recognized by authorities who have jurisdiction for voltage probes and electrical field connections. the specific purpose for which they are used. 3. For surface mounting, use the back of the subbase as a 7. For on-off gas-fired systems, some authorities who template to mark the four screw locations. Drill the pilot have jurisdiction prohibit the wiring of any limit or holes. operating contacts in series between the flame 4. Securely mount the subbase using four no. 6 screws. safeguard control and the main fuel valve(s). 8. Two Flame Detectors can be connected in parallel with the exception of Infrared Flame Detectors Wiring Subbase (C7015). 9. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause WARNING interference to radio communications. It has been Electrical Shock Hazard. tested and found to comply with the limits for a Can cause serious injury, death or equipment Class B computing device of Part 15 of FCC rules damage. which are designed to provide reasonable protection Disconnect the power supply before beginning against such interference when operated in a installation to prevent electrical shock, equipment commercial environment. Operation of this and control damage. More than one power supply equipment in a residential area may cause disconnect may be required. interference; in which case, the users at their own expense may be required to take whatever 1. For proper subbase wiring, refer to Figs. 2, 3, 4 or 5. measures are required to correct this interference. 2. For proper remote wiring of the Keyboard Display 10.This digital apparatus does not exceed the Class B Module, through a 203541 5-wire Connector, refer to limits for radio noise for digital apparatus set out in the Specifications for the Keyboard Display Module the Radio Interference Regulations of the Canadian (65-0090), Network Interface Unit Department of Communications. (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. 66-1085—3 2 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES 4. All wiring must comply with all applicable electrical NOTE: A 13 Vdc power supply must be used any time more codes, ordinances and regulations. Wiring, where than one Keyboard Display Module is used. required, must comply with NEC, Class 1 (Line Voltage) wiring. 9. Maximum wire lengths follow: 5. Recommended wire size and type: see Table 1. a. RM7800/RM7840 leadwires—The maximum length 6. Recommended grounding practices: see Table 2. of leadwire is 300 feet to terminal inputs (Control, The Keyboard Display Module, Data ControlBus Module™ Preignition Interlock, Running/Lockout Interlock, (for remote mounting or communications), through a 203541 High Fire Switch and Low Fire Switch). 5-wire Connector, or Communication Interface ControlBus b. Flame Detector leadwires—The maximum flame Module must be wired in a daisy chain configuration, sensor leadwire length is limited by the flame signal (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order of interconnection of strength. all the devices listed above is not important. Be aware that c. Remote Reset leadwires—The maximum length of modules on the closest and farthest end of the daisy chain wire is 1000 feet to a Remote Reset pushbutton. configuration string require a 120 ohm (1/4 watt minimum) d. Data Controlbus Module™—The maximum Data resistor termination across terminals 1 and 2 of the electrical Controlbus Module™ cable length depends on the connectors, for connections over number of system modules connected, the noise 100 feet. conditions and the cable used. The maximum length of all Data Controlbus Module™ interconnecting 7. Recommended wire routing of leadwires: wire is 1000 feet. a. Do not run high voltage ignition transformer wires in 10. Make sure loads do not exceed the terminal ratings. the same conduit with the flame detector, Data Refer to the label on the RM7800/RM7840 or to the Controlbus Module™, or Remote Reset Module ratings in Tables 3, 4 and 5. wiring. b. Do not route flame detector, Data Controlbus Module™, or Remote Reset Module leadwires in Final Wiring Check conduit with line voltage circuits. 1. Check the power supply circuit. The voltage and c. Enclose flame detector leadwires without armor frequency tolerance must match those of the cable in metal cable or conduit. RM7800/RM7840. A separate power supply circuit may d. Follow directions in flame detector, Data Controlbus be required for the RM7800/RM7840. Add the required Module™, or Remote Reset Module Instructions. disconnect means and overload protection. 8. Keyboard Display Module (KDM): Because the KDM is 2. Check all wiring circuits and complete the Static powered from a low voltage, energy limited source, it Checkout, see Table 8, before installing the can be mounted outside of a control panel if it is RM7800/RM7840 on the subbase. protected from mechanical damage. 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) 22 AWG two-wire twisted pair with Belden 8723 shielded cable or equivalent. ground, or five wire. Data ControlBus Module™ 22 AWG two-wire twisted pair with Belden 8723 shielded cable or equivalent. ground, or five wire. Remote Reset Module 22 AWG two-wire twisted pair, insulated — for low voltage. Communications Interface ControlBus™ 22 AWG two-wire twisted pair with Belden 8723 shielded cable or equivalent. Module ground. 13 Vdc full-wave rectified transformer 18 AWG wire insulated for voltages and TTW60C, THW75C, THHN90C. power input. temperatures for given application. 3 66-1085—3 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 8K1 DDL DISPLAY MODULE COMMON 13 INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS RS485 8K2 MODULATE AND LINE VOLT INPUTS 1 15 9K1 DDL 2 9K2 FIELD WIRING COMMUNICATIONS 3 REMOTE LOW FIRE RESET 14 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). 66-1085—3 4 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™, Use the shield of the signal wire to ground the device to the Communications Interface ControlBus™ Module). 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 Grounda — 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,d 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 Valve 120 Vacc. 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. d RM7800G,M/RM7840G,M operating frequency determined by relay module selection. 5 66-1085—3 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES Table 4. Combinations for Terminals 8, 9, 10 and 21. Combination No. Pilot Fuel 8 Main 9 Ignition 10 Intermittent Pilot Valve 21 1 C F No Load No Load 2 B F No Load No Load 3 No Load F No Load B 4F F A No Load 5 No Load F A F 6D F A No Load 7 No Load D A D 8D D A No Load 9 No Load D A D Table 5. Explanation of Each Combination. AB CDF 4.5A ignition. 50 VA Pilot Duty plus 180 VA ignition plus 2A Pilot Duty. 64 VA Pilot Duty plus motor 4.5A ignition. motor valve with: 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 of the Relay Module (Fig. 5) subbase so it does not interfere with the knife blade 1. Mount the RM7800/RM7840 vertically on the Q7800 terminals or bifurcated contacts. Subbase, or mount horizontally with the knife blade terminals pointing downward. When mounted on the IMPORTANT Q7800A, the RM7800/RM7840 must be in an electrical The RM7800/RM7840 must be installed with a enclosure. plug-in motion rather than a hinge action. 2. When mounting in an electrical enclosure, provide adequate clearance for servicing, installation and 4. Mount the RM7800/RM7840 by aligning the four removal of the RM7800/RM7840, Keyboard Display L-shaped corner guides and knife blade terminals with Module, flame amplifier, flame amplifier signal voltage the bifurcated contacts on the wiring subbase and probes, electrical signal voltage probes, and electrical securely tighten the two screws without deforming the connections. 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. 66-1085—3 6 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 17 CONTROLLER/LIMITS 6 4 LOCKOUT INTERLOCKS 7 18 LOW FIRE (INC. AIR FLOW SWITCH) 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 5 SECOND IGNITION FOR CORRECT WIRING. 21 (EARLY SPARK 10 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 00TIMED 00DRIVE TO 00(4 SEC. IF 1020 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 14 13 TO 14 13 TO 12 TO 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. 7 66-1085—3 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 FOR DIRECT SPARK IGNITION BURNER MOTOR 3 (BLOWER) 5 16 (OIL OR GAS) IGNITION 10 TRANSFORMER BURNER 17 CONTROLLER/LIMITS 6 4 1ST STAGE 21 FUEL VALVE L2 RUNNING INTERLOCKS 7 18 LOW FIRE (INC. AIR FLOW SWITCH) 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 00TIMED 00DRIVE TO 00(4 SEC. IF 1020 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 SAFE START CHECK FLAME PROVING SSC SIGNAL RM7800/7840G SWITCHING 13 TO 15 13 14 13 TO 14 13 TO 12 TO FIRING RATE MOTOR ACTION MOTOR M12264A Fig. 3. Wiring subbase and sequence for RM7800G/RM7840G. 66-1085—3 8 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 5 16 (BLOWER) 9 2ND STAGE FUEL VALVE (OPTIONAL) BURNER 17 CONTROLLER/LIMITS 6 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 FLAME DETECTOR SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS FOR CORRECT WIRING. L1 4 (HOT) 1 L2 MASTER M12262A SWITCH RM7800M/RM7840M INITIATE PREPURGE PFEP (INITIAL HOLD 10 SEC. POWERUP 00TIMED 00DRIVE TO 00(4 SEC. IF 1020 25 00 15 ONLY) STANDBY PREPURGE LOW FIRE JR1 CLIPPED MFEP RUN POSTPURGE STANDBY POWER POWER POWER POWER POWER POWER POWER POWER POWER ED PILOT PILOT PILOT PILOT PILOT ISPLAY FLAME FLAME FLAME FLAME FLAME MAIN MAIN MAIN MAIN MAIN ALARM ALARM ALARM ALARM ALARM URNER BURNER/BLOWER MOTOR 5 10 IGN. 5 SEC. 10 SEC. IGN./PILOT 8 INTERMITTENT PILOT VALVE 21 MAIN VALVE 9 PERATING LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6 ONTROLS ND NTERLOCKS INTERLOCK. CHECK RUNNING INTERLOCKS CLOSED 6 TO 7 IC PREIGNITION INTERLOCK CLOSED 4 TO 20 PII LOW FIRE SW. 5 TO 18 LAME SAFE START CHECK FLAME PROVING SSC IGNAL RM7800M/7840M SWITCHING 13 TO 15 13 TO 15 MOTOR ACTION AMPER OTOR M12265A Fig. 4. Wiring subbase and sequence for RM7800M/RM7840M. 9 66-1085—3 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 RESET POWER BUTTON PILOT FLAME MAIN ALARM KEYBOARD CAPTIVE DISPLAY RESET MOUNTING MODULE SCREW (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 SAFETY SHUTDOWN energized. e. Main valve terminal is energized. f. Internal system fault occurred. Safety Shutdown (Lockout) occurs if any of g. Purge card is not installed or is removed. the following occur during the indicated h. Purge card is bad. 3. PREPURGE Period: period: a. Preignition Interlock opens anytime during 1. INITIATE Period: PREPURGE period (RM7840E,L). a. Purge card is not installed or is removed. b. Flame signal is detected after first ten seconds b. Purge card is bad. during PREPURGE (RM7840E,L). c. Configuration jumpers are changed (after 200 hours c. High Fire Switch fails to close within four minutes of operation). and fifteen seconds after the firing rate motor is d. Ac line power errors occurred, see Operation commanded to drive to the high fire position at the section. start of PREPURGE (RM7840E,L). e. Four minute INITIATE period has been exceeded. d. Low Fire Switch fails to close within four minutes 2. STANDBY Period: and fifteen seconds after the firing rate motor is a. Flame signal is present after 40 seconds. commanded to drive to the low fire position at the b. Preignition Interlock is open an accumulative time end of PREPURGE. of 30 seconds. e. Running Interlock does not close within 30 seconds c. Interlock check feature is enabled and the (RM7840G,M). Interlock String (including airflow switch) is closed f. Lockout Interlock does not close within 10 seconds for 120 seconds with controller closed. (RM7840E,L). 66-1085—3 10 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES g. Lockout Interlock opens during PREPURGE fluctuations of +/-10 percent during any part of the operating (RM7840E,L). sequence. The INITIATE sequence lasts for ten seconds h. Ignition/pilot valve/intermittent pilot valve terminal is unless the voltage or frequency tolerances are not met. When energized. the tolerances are not met, a hold condition is initiated and i. Main valve terminal is energized. displayed on the VFD for at least five seconds. When the j. Internal system fault occurred. tolerances are met, the INITIATE sequence restarts. If the k. Purge card is removed. condition is not corrected and the hold condition exists for four l. Purge card is bad. minutes, the RM7800/RM7840 locks out. Causes for hold 4. PILOT FLAME ESTABLISHING Period (PFEP): conditions in the INITIATE sequence: a. Low Fire Switch opens. b. Lockout Interlock opens (RM7840E,L). a. AC line dropout is detected. c. Ignition/pilot valve/intermittent pilot valve terminal is b. AC line frequency error occurs caused by using a not energized. 60 Hz device on a 50 Hz line, or vice versa. d. Early spark termination terminal is energized after c. AC line noise prevents a sufficient reading of the five seconds. line voltage inputs. e. No flame is present at the end of PFEP. d. Low line voltage brownouts occur. f. Main valve terminal is energized (RM7800G,M). The INITIATE sequence also delays the burner motor starter g. Internal system fault occurred. from being energized and de-energized from an intermittent h. Purge card is removed. AC line input or control input. i. Purge card is bad. 5. MAIN FLAME ESTABLISHING Period (MFEP): Standby a. Low Fire Switch Opens. b. Lockout Interlock opens (RM7840E,L). The RM7800/RM7840 is ready to start an operating sequence c. Ignition/pilot valve/intermittent pilot valve terminal is when the operating control determines a call for heat is not energized. present. The burner switch, limits, operating control and all d. Main valve terminal is not energized. microcomputer monitored circuits must be in the correct state e. No flame is present at the end of MFEP. for the RM7800/RM7840 to continue into the PREPURGE f. Internal system fault occurred. sequence. g. Purge card is removed. h. Purge card is bad. Normal Start-Up Prepurge 6. RUN Period: The RM7800/RM7840 provides a prepurge timing selectable a. No flame is present. from two seconds to 30 minutes with power applied and the b. Lockout Interlock opens (RM7840E,L). RM7800 operating control indicating a call for heat: c. Interrupted pilot valve terminal is energized (RM7840G,M). a. Running Interlocks, Preignition Interlocks, Burner d. Main valve terminal is not energized. Switch, Run/Test Switch, Lockout Interlocks and all e. Internal system fault occurred. microcomputer monitored circuits must be in the f. Purge card is removed. correct operating state. g. Purge card is bad. b. The blower motor output, terminal 5, is powered to 7. POSTPURGE Period: start the PREPURGE sequence, except for the a. Preignition Interlock does not close in five seconds RM7800E/RM7840. The firing rate motor is driven to and opens after five-second time period. the high fire position. The PREPURGE timing for the b. Ignition/pilot valve/intermittent pilot valve terminal is RM7800/RM7840E,L does not begin until the energized. Lockout Interlock String and High Fire Switch are c. Main valve terminal is energized. both closed. The blower motor output for the d. Internal system fault occurred. RM7800E is not energized until the High Fire Switch e. Purge card is removed. is closed. 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 OPERATION the RM7800/RM7840G,M or safety shutdown for the RM7800/RM7840E,L occurs. d. The Lockout Interlock or Running Interlock inputs Sequence of Operation (interlock circuit including Airflow Switch) must close The RM7800/RM7840 has the following operating sequences, by ten seconds into PREPURGE; otherwise, a see Fig. 2, 3, 4, and Table 6. The RM7800/RM7840 LED recycle to the beginning of PREPURGE for the provide positive visual indication of the program sequence: RM7800/RM7840G,M will happen or a safety POWER, PILOT, FLAME, MAIN and ALARM. shutdown for the RM7800/RM7840E,L occurs. e. When PREPURGE timing is complete, the firing rate motor drives to the low fire position, Initiate RM7800/RM7840E,G,L. The RM7800/RM7840 enters the INITIATE sequence when f. When the firing rate motor reaches low fire position, the Relay Module is powered. The RM7800/RM7840 can also the Low Fire Switch, terminal 18, input must be enter the INITIATE sequence if the Relay Module verifies energized before entering the Ignition Trial state. voltage fluctuations of +10/-15 percent or frequency 11 66-1085—3 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES Ignition Trials (a) Not turned off, or 1. Pilot Flame Establishing Period (PFEP): (b)15 seconds after Terminal 9 is energized and a. With the firing rate motor at the low fire position: JR2 is clipped, or (1) The pilot valve and ignition transformer, (c)30 seconds after Terminal 9 is energized and terminals 8, 10 and 21, are energized. The Terminals 5 and 19 are jumpered and jumper RM7800M has an intermittent pilot valve, JR2 is clipped. terminal 21. The RM7800/RM7840G has an (3) RM7800L1053, RM7840L1026, interrupted or intermittent pilot valve, terminal RM7800M/RM7840M: Remain energized as 21, depending on the selection of configuration long as call for heat is present. jumper 2. The RM7800/RM7840E,L has a fifteen-second interrupted pilot valve, terminal Run 21. All of the RM7800/RM7840s have a 1. A ten-second stabilization period occurs at the ten-second interrupted pilot valve/ignition, beginning of the RUN period. terminal 8. 2. The firing rate motor releases to modulation (2) During PFEP, the Low Fire Switch must remain (RM7800/RM7840E,G,L). Damper motor is energized closed. If it opens, a safety shutdown occurs. (RM7800/RM7840M). (3) The Preignition Interlock input is ignored 3. The RM7800/RM7840 is now in RUN and remains in throughout the Ignition Trial state. RUN until the controller input, terminal 6, opens, b. Flame must be proven by the end of the ten-second indicating that the demand is satisfied or a limit opened. 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. Postpurge c. After five seconds, the ignition, terminal 10, is The RM7800/RM7840 provides a fifteen-second de-energized for early spark termination. POSTPURGE following the completion of the RUN period. 2. Main Flame Establishing Period (MFEP): The blower motor output is powered to drive all products of a. Terminal 9 is energized when the presence of flame combustion and any unburned fuel from the combustion is verified at the end of a 10-second Pilot Flame chamber. It also supplies combustion air to burn fuel being Establishing Period (PFEP) (four seconds if JR1 is purged from the fuel line downstream of the fuel shutoff valve. clipped). b. Terminal 8 is turned off 10 seconds after Terminal 9 1. The main fuel valve and intermittent pilot valve, is energized. Terminals 9 and 21, are de-energized and the firing rate c. Terminal 21 action: motor is commanded to the low fire position to begin the (1) RM7800E,L/RM7840E,L: De-energized POSTPURGE period. 15 seconds after Terminal 9 is energized. 2. The Preignition Interlock closes within the first five (2) RM7840G: seconds of POSTPURGE. Table 6. Sequence Timing for Normal Operation. Flame Establishing Period Post- Firing Energy Approval Purge Interlock Rate Saving Code Device Initiate Standby Purge Pilot Maina Run Timing Circuits Circuit Prepurge Bodies RM7800E/ 10 sec.. * ** 4 or 10 10 or 15 * 15 sec. Preignition, 4-wire Yes FM/IRI RM7840E sec. sec. Lockout, modulating Modulating High and Low Fire RM7800G/ 10, 15 sec. Preignition, No UL/CSA RM7840G or Running, Modulating intermittent Low Fire RM7800L/ 10 or 15 Preignition, FM/IRI RM7840L sec.b Lockout, Modulating High and Low Fire RM7800M/ 10 sec. or Preignition, 2-wire UL/CSA RM7840M intermittent Running, isolated 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. 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. 66-1085—3 12 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 3. In Prepurge Drive to Low Fire position, the Run/Test RM7800 Relay Module (but is not required for operation) and Switch, when placed in the TEST position, holds the is an option for the RM7840 Relay Module. The first line of the burner sequence in PREPURGE with the firing rate Vacuum Fluorescent Display (VFD) provides: motor in the Low Fire position. 4. In PFEP, the Run/Test Switch, when placed in the TEST • Current status of the burner sequence (STANDBY, position, stops the timer during the first eight seconds PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE). when a ten second PFEP is selected or during the first • Timing information (PURGE, PILOT IGN, MAIN IGN and three seconds when a four second PFEP is selected, POSTPURGE) in minutes and seconds. allowing pilot-turn-down test and other burner • Hold information (PURGE HOLD: T19). adjustments to be made. This activates a fifteen second • Lockout information (Lockout, Fault Code, Message and flameout timer that permits pilot flame adjustment Sequence). without nuisance safety shutdowns. The Run/Test The extreme right side of the first line is either blank or shows Switch is ignored during PFEP for the RM7800/ a small arrow pointing to the second line followed by a RM7840E,L if Terminals 8 and 9 or 9 and 21 are two-letter code (DI-Diagnostic Information, Hn-Fault History jumpered. Information, and EA-Expanded Annunciator). When the arrow 5. During Run, the Run/Test Switch, when placed in the and two-letter code are displayed, it indicates the second line TEST position, drives the firing rate motor to the Low is showing a selectable message submenu. The second line Fire position. displays selectable or preemptive messages. NOTE: When RM7800/RM7840 is switched to the Test A selectable message supplies information for flame strength, mode, it stops and holds at the next Run/Test Switch system status indication, system or self-diagnostics and point in the operating sequence. Make sure that the troubleshooting. Run/Test Switch is in the RUN position before leaving the installation. 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 SETTINGS AND ADJUSTMENTS lockout message. A preemptive message replaces a selectable message to support the sequence status information. It also replaces a selectable message after 60 Selectable Site-Configurable Jumpers seconds if it or a lockout message is available. The RM7800/RM7840 has three site-configurable jumper options, see Fig. 6 and Table 7. If necessary, clip the Run/Test Switch site-configurable jumpers with side cutters and remove the resistors from the Relay Module. WARNING SELECTABLE CONFIGURATION JUMPERS Explosion Hazard. Can cause serious injury or death. RUN/TEST SWITCH 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. 2. 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. NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G. M12301 Fig. 6. Selectable site-configurable jumpers. 13 66-1085—3 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES Table 7. Site Configurable Jumper Options. Jumper Number Description Intact Clipped RM7800/RM7840 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. 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 After checking all wiring, perform this checkout before 0-300 Vac scale. installing the RM7800/RM7840 on the subbase. These tests 2. Two jumper wires; no. 14 wire, insulated, 12 inches verify the Q7800 Wiring Subbase is wired correctly, and the (304.8 mm) long with insulated alligator clips at both external controllers, limits, interlocks, actuators, valves, ends. transformers, motors and other devices are operating properly. General Instructions 1. Perform all applicable tests listed in Static Checkout, Table 8, in the order listed. WARNING 2. Make sure all manual fuel shutoff valve(s) are closed. Explosion and Electrical Shock Hazard. 3. Perform only those tests designated for the specific Can cause serious injury, death or equipment RM7800/RM7840 model being tested. damage. 4. Raise the setpoint of the operating controller to simulate 1. Close all manual fuel shutoff valve(s) before starting a call for heat. these tests. 5. For each test, open the master switch and install the 2. Use extreme care while testing the system. Line jumper wire(s) between the subbase wiring terminals voltage is present on most terminal connections listed in the Test Jumpers column. when power is on. 6. Close the master switch before observing operation. 3. Open the master switch before installing or 7. Read the voltage between the subbase wiring terminals removing a jumper on the subbase. listed in the Voltmeter column. 4. Before continuing to the next test, be sure to 8. If there is no voltage or the operation is abnormal, check remove test jumper(s) used in the previous test. the circuits and external devices as described in the last 5. Replace all limits and interlocks that are not column. operating properly. Do not bypass limits and 9. Check all wiring for correct connections, tight terminal interlocks. screws, correct wire, and proper wiring techniques. Replace all damaged or incorrectly sized wires. 10. Replace faulty controllers, limits, interlocks, actuators, valves, transformers, motors and other devices as CAUTION required. Equipment Damage Hazard. 11. 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 conduct 12. After completing each test, be sure to remove the test a current, causing the RM7800/RM7840 to fail the jumper(s). 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. Make sure all manual fuel shutoff valves are closed before performing static checkout. 66-1085—3 14 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES Table 8. Static Checkout. RM7800/ Test RM7840 Test If Operation is Abnormal, No. 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, overload 7 within 10 seconds. 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. Te r m i n a l 1 0 ) 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 of b. Pilot valve. system being tested. 7 4-21 — 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 instead of the pilot valve. valve(s) instead of the pilot valve. 8 4-9 — Automatic main fuel valve(s) open. 1. Listen for and observe operation of the If using direct spark ignition on a main model with intermittent pilot on fuel valve(s) and actuator(s). Terminal 21, check the optional 2. Valve(s) and actuator(s). 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; zero 1. Low Fire Start Switch. RM7840E,G,L and volts at Terminal 18 after motor 2. Firing rate motor and transformer. 12-13 starts driving open. 11 RM7800E,G,L; 4-5 18-L2 Firing rate motor drives closed; line 1. Low Fire Start Switch. RM7840E,G,L and voltage at Terminal 18 after motor 2. Firing rate motor and transformer. 14-13 is in Low Fire position. 12 RM7800E,L; 4-5 19-L2 Firing rate motor drives open; line 1. High Fire Purge Switch. RM7840E,L and voltage at Terminal 19 after motor 2. Firing rate motor and transformer. 12-13 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. 15 66-1085—3 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES Table 8. Static Checkout. (Continued) RM7800/ Test RM7840 Test If Operation is Abnormal, No. Models Jumpers Voltmeter Normal Operation Check the Items Listed Below 15 RM7800M; 14-13 — If damper motor is used, motor Damper motor. RM7840M with drives damper open. open damper contacts.. 16 RM7800M; 4-5 18-L2 If damper motor is used, motor 1. Low Fire Start Switch. RM7840M with drives open; line voltage at 2. Damper motor. open damper Terminal 18 after motor is in Low contacts.. Fire position. 17 RM7800M; 4-5 18-L2 If damper motor is used, motor 1. Low Fire Start Switch. RM7840M with and drives open; zero volts at 2. Damper motor. open damper 4-13 Te r m i n a l 1 8 . 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 Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Scarborough, Ontario M1V 4Z9 Printed in U.S.A. on recycled 66-1085—3 G.R. Rev. 02-02 paper containing at least 10% www.honeywell.com post-consumer paper fibers.

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