Honeywell Thermostat Ec7895A Users Manual 65 0205 7800 SERIES EC7895A, RM7895A Relay Module

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PRODUCT DATA

Copyright © 1996 Honeywell Inc. • All Rights Reserved X-XX UL

7800 SERIES EC7895A, RM7895A

Relay Module

GENERAL

The Yamatake Honeywell EC7895A and RM7895 is a microprocessor

based integrated burner control for automatically fired gas, oil, or

combination fuel single burner applications. The RM7895 consists of

the Relay Module. Subbase, Amplifier and Purge Card. Options

include Keyboard Display Module, Personal Computer Interface,

DATA CONTROLBUS MODULE™, Remote Display Module, and

COMBUSTION SYSTEM MANAGER™ Software.

The EC7895 and RM7895 are programmed to provide a level of

safety, functional capability and features beyond the capacity of

conventional controls.

Functions provided by the EC7895 and RM7895 include automatic

burner sequencing, flame supervision, system status indication,

system or self-diagnostics and troubleshooting.

FEATURES

•Safety features:

—Airflow switch check.

—Closed loop logic test.

—Dynamic AMPLI-CHECK®.

—Dynamic input check.

— Dynamic safety relay test.

—Dynamic self-check logic.

—Internal hardware status monitoring.

—Tamper resistant timing and logic.

•Access for external electrical voltage checks.

•Application flexibility.

•Communication interface capability.

•Dependable, long-term operation provided by microcomputer

technology.

•First-out annunciation and system diagnostics provided by a 2

row by 20 column Vacuum Fluorescent Display (VFD) located

on the optional Keyboard Display Module.

•Five (LEDs) for sequence information.

•Interchangeable plug-in flame amplifiers.

• Local or remote annunciation of EC7895 and RM7895

operation and fault information.

•Nonvolatile memory; EC7895 and RM7895 retain history files

and sequencing status after loss of power.

•Remote reset (optional).

•Report generation (optional).

•Selectable recycle or lockout on loss of airflow.

•Selectable recycle or lockout on loss of flame.

•Shutter drive output.

•Burner controller data (optional):

—Flame signal strength.

—Hold status.

—Lockout/alarm status.

—Sequence status.

—Sequence time.

—Total cycles of operation.

—Total hours of operation.

—Fault history providing for the six most recent faults:

•Cycles of operation at the time of the fault.

•Fault message and code.

•Hours of operation at the time of the fault.

•Sequence status at the time of the fault.

•Sequence time at the time of the fault.

—Diagnostic information:

•Device type.

•Flame amplifier type.

•Flame failure response time.

•Manufacturing code.

•On/Off status of all digital inputs and outputs.

•Selected prepurge time.

•Software revision and version of EC7895 and RM7895

and optional Keyboard Display Module.

•Status of configuration jumpers.

Contents

General ......................................................................................... 1

Features ........................................................................................ 1

Specifications ................................................................................ 2

Ordering Information ..................................................................... 2

Principal Technical Features ......................................................... 8

Safety Provisions .......................................................................... 8

Installation ..................................................................................... 9

Wiring ............................................................................................ 11

Assembly ...................................................................................... 14

Operation ...................................................................................... 17

Checkout ....................................................................................... 20

Troubleshooting ............................................................................ 26

65-0205

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 2

ORDERING INFORMATION

When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the

TRADELINE® Catalog or price sheets for complete ordering number.

If you have additional questions, need further information, or would like to comment on our products or services, please write or

phone:

1. Your local Home and Building Control Sales Office (check white pages of your phone directory).

2. Home and Building Control Customer Relations

Honeywell, 1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386

In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.

International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,

Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

SPECIFICATIONS

Model:

RM7895A

Electrical Ratings, see Table 1A:

Voltage and Frequency: 100 Vac (+10/-15%), 50 or 60 Hz

(+/- 10%). 1

Power Dissipation: RM7895: 10W maximum.

Maximum Total Connected Load: 2000 VA.

Fusing Total Connected Load: 20A maximum, type FRN or

equivalent.

Table 1A. RM7895A Terminal Ratings.

1Range of allowable operating frequency: 45 to 66 Hz.

2The 7895 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 20A fuse (or breaker) in event of an internal short

circuit. The 7895 needs a low impedance ground connection to the equipment frame which, in turn, needs a low impedance

connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be made with

minimum length conductors that have maximum surface areas. Wide straps or brackets rather than leadwires are preferred.

Be careful to verify that mechanically tightened joints along the ground path, such as pipe or conduit threads or surfaces held

together with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion.

32000 VA maximum connected load to 7895 Assembly.

4Can also be 100 Vac, 1A pilot duty.

5Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.

Terminal No. Description Ratings

G Flame Sensor Ground

Earth G Earth Ground2

L2(N) Line Voltage Common

3 Alarm 100 Vac, 1A pilot duty.

4 Burner Motor 100 Vac, 9.8 AFL, 58.8 ALR (inrush).

5 Line Voltage Supply (L1) 100 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).3,4

6 Burner Controller and Limits 100 Vac, 1 mA.

7 Airflow Interlock 100 Vac, 9A.

8 Pilot Valve/Ignition 100 Vac, 4.5A ignition and 50VA pilot duty.4

9 Main Fuel Valve 100 Vac, 2A pilot duty.5

10 Ignition 100 Vac, 4.5A ignition.4

F(11) Flame Sensor 60 to 220 Vac, current limited.

12 Unused

13 Unused

14 Unused

15 Unused

16 Unused

17 Unused

18 Unused

19 Unused

20 Unused

21 Unused

22 Shutter 100 Vac, 0.5A

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

3

Model:

EC7895 Electrical Ratings, see Table 1B:

Voltage and Frequency: 200 Vac (+10/-15%), 50 or 60 Hz

(+/- 10%). 1

Power Dissipation: EC7895: 10W maximum.

Maximum Total Connected Load: 2000 VA.

Fusing Total Connected Load: 20A maximum, type FRN or

equivalent.

Table 1B. EC7895A Terminal Ratings.

1Range of allowable operating frequency 45 through 66 Hz.

2The EC7895 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 20A fuse (or breaker) in event of an internal short

circuit. The RM7895 needs a low impedance ground connection to the equipment frame which, in turn, needs a low

impedance connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be

made with minimum length conductors that have maximum surface areas. Wide straps or brackets rather than leadwires are

preferred. Be careful to verify that mechanically tightened joints along the ground path, such as pipe or conduit threads or

surfaces held together with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion.

32000 VA maximum connected load to EC7895 Assembly.

4Total load current excluding burner/boiler motor and firing rate outputs cannot exceed 5A, 25A inrush.

Terminal No. Description Ratings

G Flame Sensor Ground

Earth G Earth Ground2

L2 (N) Line Voltage Common

3 Alarm 200 Vac, 1A pilot duty.

4 Burner Motor 200 Vac, 4A at pF = 0.5, 20A inrush4

5 Line Voltage Supply (L1) 200 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).3,4

6 Burner Controller and Limits 200 Vac, 1 mA.

7 Airflow Interlock 200 Vac, 9A.

8 Pilot Valve/Ignition 200 Vac, 4A at pF = 0.5, 20A inrush4

9 Main Fuel Valve 200 Vac, 4A at pF = 0.5, 20A inrush4

10 Ignition 200 Vac, 4A at pF = 0.5, 20A inrush4

F(11) Flame Sensor 60 to 220 Vac, current limited.

12 Unused

13 Unused

14 Unused

15 Unused

16 Unused

17 Unused

18 Unused

19 Unused

20 Unused

21 Unused

22 Shutter 200 Vac, 0.5A

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 4

Environmental Ratings:

Ambient Temperature:

Operating: -40° F to 140° F.

Storage: -60° F to 150° F.

Humidity: 85% RH continuous, noncondensing.

Vibration: 0.5G environment.

Dimensions:

Refer to Fig. 1 and 2.

Weight:

RM7895 with Dust Cover: 1 pound 15 ounces, unpacked.

IMPORTANT

Flame Detection System available for use with

EC7895 and RM7895. To select your Plug-in Flame

Signal Amplifier and applicable Flame Detector, see

Table 2 and Fig. 3 through 5.

Table 2. Flame detection systems (Figs. 3, 4, 5).

aOrder flame rod separately; see holder Instructions.

bUse

only

Honeywell Photocell, part no. 38316.

cThe C7012A,C, C7027, C7035 and C7044 Flame Detectors should be used only on burners that cycle on-off at least once

every twenty-four hours. Appliances with burners that remain on continuously for twenty-four hours or longer should use the

C7012E,F Flame Detector with the R7847C Amplifier or the C7076A,D Flame Detector with the R7886A Amplifier or the C7061

Flame detector with the R7861 Amplifier as the ultraviolet flame detection system.

dCircuitry tests the flame signal amplifier at least 12 times a minute during burner operation and shuts down the burner if the

amplifier fails.

eCircuitry tests all electronic components in the flame detection system (amplifier and detector) 12 times a minute during burner

operation and shuts down the burner if the detection system fails.

fWhen R7861 is used with EC7895, the application requires a step down transformer. See Fig. 14.

gUse with RM7895A only.

Plug-in Flame Signal Amplifiers Applicable Flame Detectors

Type Color Self-

Checking Model

Flame

Failure

Response

Time Fuel Type Models

Rectification Green No R7847A .8 or 3 sec Gas Rectifying Flame

Rod HoldersaC7004, C7007, C7011

Complete Assemblies:

C7008, C7009, Q179.

No R7847A .8 or 3 sec Oil Rectifying

Photocell C7003, C7010, C7013,

C7014b

No R7847A 3 sec Gas,

Oil, Coal Ultraviolet

(Purple Peeper) C7012A,C.c

Dynamic

AMPLI-

CHECK®

R7847Bd.8 or 3 sec Gas Rectifying Flame

Rod HoldersaC7004, C7007, C7011

Complete Assemblies:

C7008, C7009, Q179.

Dynamic

AMPLI-

CHECK®

R7847Bd.8 or 3 sec Oil Rectifying

Photocell C7003, C7010, C7013,

C7014b

Dynamic

AMPLI-

CHECK®

R7847Bd3 sec Gas,

Oil, Coal Ultraviolet

(Purple Peeper) C7012A,C.c

Dynamic

Self-Check R7847Ce3 sec Gas,

Oil, Coal Ultraviolet

(Purple Peeper) C7012E,F.

Infrared Red No R7848A 3 sec Gas,

Oil, Coal Infrared

(Lead Sulfide) C7015

Dynamic

AMPLI-

CHECK®

R7848Bd3 sec Gas,

Oil, Coal Infrared

(Lead Sulfide) C7015

Ultraviolet Purple No R7849A .8 or 3 sec Gas, Oil Ultraviolet

(MiniPeeper) C7027, C7035,

C7044.c

Dynamic

AMPLI-

CHECK®

R7849Bd.8 or 3 sec Gas, Oil Ultraviolet

(MiniPeeper) C7027, C7035,

C7044.c

Dynamic

Self-CheckfR7861A 3 sec Gas,

Oil, Coal Ultraviolet C7061

Blue Dynamic

Self-CheckgR7886Ae3 sec Gas,

Oil, Coal Ultraviolet

(Adjustable

Sensitivity)

C7076

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

5

Sequence Timing For Normal Operation:

Flame Establishing Period

Device Initiate Standby Purge Pilot Main

EC7895A/RM7895A 10 sec. * ** 4 or 10 sec. No

*STANDBY and RUN can be an infinite time period.

** PURGE is determined by the ST7800A Purge Card selected.

Approval Bodies:

RM7895A:

Underwriters Laboratories Inc. listed: File no. MP268,

Guide no. MCCZ.

Factory Mutual approved.

EC7895A:

Factory Mutual approved.

Mounting:

Q7800A for panel mount or Q7800B for wall or burner mount.

Required Components:

Plug-in Flame Signal Amplifier, see Table 2.

Plug-in Purge Timer Cards: Selectable ST7800A, two

seconds to 30 minutes.

Q7800A or Q7800B.

Fig. 1. Mounting dimensions of EC7895/RM7895 Relay Module and Q7800A Subbase in in. (mm).

POWER

PILOT

FLAME

MAIN

ALARM

RESET

5

(127)

5 (127)

M11135

(133)

BURNER

CONTROL

REMOVE ONLY FOR TERMINAL TEST ACCESS.

1

1

5-1/4

Accessories:

Optional:

Network Interface Unit,

Part No. Q7700A1014, 120V 50/60 Hz

Part No. Q7700B1004, 100V to 200V 50/60 Hz

Network Interface ControlBus Module,

Part No. QS7800A1001.

COMBUSTION SYSTEM MANAGER™,

Part No. ZM7850A1001.

ControlBus 5-Wire Electrical Connector,

Part No. 203541.

DATA CONTROLBUS MODULE™,

Part No. S7810A1009.

Dust Cover, Part No. 221729A.

Flame Simulators:

UV Flame Simulator, Part No. 203659.

Rectification Simulator, Part No. 123514A.

Keyboard Display Module, Part No. S7800A1001,

English.

Keyboard Display Module, Part No. S7800A1118,

Japanese.

Remote Display Mounting Bracket, Part No. 203765.

Remote Display Power Supply, Part No. 203968A Plug-in.

Remote Reset Module, Part No. 57820A1007.

Sixty-inch Extension Cable Assembly, Part No. 221818A.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 6

Fig. 2. Mounting dimensions of EC7895/RM7895 Relay Module and Q7800B Subbase in in. (mm).

POWER

PILOT

FLAME

MAIN

ALARM

RESET

5

(127)

5 (127)

M11134

REMOVE ONLY FOR TERMINAL TEST ACCESS.

1

1

6-3/32 (155)

BURNER

CONTROL

Fig. 3. Rectification detectors.

THREADED

MOUNTING

HOLES (2)–

10-32 UNF

1 (25)

FLAME ROD

TARGET

CERAMIC

INSULATORS

IGNITION

ELECTRODE

(Q179C ONLY)

BRACKET M1983

3-1/8

(79)

1-21/32

(42) 1-13/32

(36)

3/8 (10)

1/2 (13)

1-1/16

(27)

25/32

(20)

25/32

(20)

2-25/32

(62)

3/32 (2) 11/16

(18)

17/32

(14)

MOUNTING FLANGE

1/2–14 NPSM

LEADWIRES FACEPLATE

3/4–14 NPT

M1962A

3-3/4

(95)

7-7/32

(183)

5-1/8 (130)

3-7/16

(87)

5-1/4 (133)

2

(51)

C7013A C7014A M1847

13/16 (21) 1-1/4 (32) 1-3/8 (35)

1-3/4

(45)

1-1/4 (32) 1-5/16 (33) 5/16

(8)

Q179 C7012A,C,E,F

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

7

Fig. 4. Ultraviolet detectors in in. (mm).

COLLAR WITH 1/2-14 NPSM

INTERNAL THREADS

4 (102) 6 FOOT (1.83 METER)

LEADWIRES (2)

M1943A

MODEL AVAILABLE WITH 24 FOOT (7.32 METER) LEADWIRES.

MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL

THREADS) INSTEAD OF CLAMP TYPE CONNECTOR.

1

2

1

2

3-1/2 (89)

1-1/16

(27)

1/2-14 NPSM

INTERNAL THREADS

2

2 (51)

COLLAR WITH

1–11-1/2 NPSM

INTERNAL

THREADS 1

1DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL THREADS.

DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL THREADS.

MODEL AVAILABLE WITH 12 FOOT [3.66 METER] LEADWIRES.

2

3

INSERTION DEPTH

6 FOOT

[1.83 METER]

LEADWIRES (2) 3

M1945A

2-5/8 (67)

1-1/2

(38)

31/32

(25)

4-1/8 (105)

1-3/16

(30)

MOUNTING BRACKET

6 FOOT [1.83 METER]

LEADWIRES (2)

M1944A

3-5/8 (92)

1/2

(13)

9/16

(14)

7/8

(22)

3/8

(10)

1-27/64

(36)

C7027 C7035

C7044

4

(102)

4 (102)

3/8 INCH NPT

1 INCH NPT

7/8 (22) OPENING

FOR 1/2-INCH CONDUIT

ALLOW 9 INCHES (228 MILLIMETERS)

CLEARANCE TO SWING OUT THE DETECTOR

FOR LENS CLEANING OR SERVICING.

1

M5083A

1-1/16 (27)

2-1/4

(57)

2-1/4

(57)

4-27/32 (123)

1-13/32 (188)

10-9/32 (261)

2-5/16

(58)

29/32 (23)

3/4 (19)

1-19/32

(41)

2-11/16

(68) 7-5/8 (194)

C7076A

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 8

Fig. 4. Ultraviolet detectorsin in. (mm)

(Continued).

15/16 [24] DIA.

2 (51)

1 (25)

1 INCH NPT

15/16–18 UNC

(2 EACH)

M5084A

2-1/2

(64)

6-7/32

(158)

6-19/32

(168)

2-5/32

(55)

11-13/16 (300)

7-13/16 (198) 1-27/32

(47) 5-13/16 (147)

5-13/16

(147)

C7076D

Fig. 5. Infrared detector in in. (mm).

PRINCIPAL TECHNICAL FEATURES

The EC7895 or RM7895 provides all customary flame

safeguard functions while providing significant advancements

in the areas of safety, annunciation and system diagnostics.

Safety Shutdown (Lockout) Occurs If:

1. Initiate Period

a. Purge card is not installed or removed.

b. Purge card is bad.

c. Configuration jumpers have been changed (after

200 hours).

d. AC line power errors occurred, see Operation.

e. Four minute INITIATE period was exceeded.

2. Standby Period

a. Flame signal is present after 40 seconds.

b. Ignition/pilot valve/intermittent pilot valve terminal

is energized.

c. Main valve terminal is energized.

d. Internal system fault occurred.

e. Purge card is not installed or removed.

f. Purge card is bad.

3. Prepurge Period

a. Airflow lockout feature is enabled and the airflow

switch does not close after ten seconds or within

the specified purge card timing.

b. Flame signal is detected after 30 seconds.

c. Ignition/pilot valve/intermittent pilot valve terminal

is energized.

d. Main valve terminal is energized.

e. Internal system fault occurred.

f. Purge card is removed.

g. Purge card is bad.

4. Pilot Flame Establishing Period (PFEP)

a. Airflow lockout feature is enabled and the airflow

switch opens.

b. Ignition/pilot valve terminal is not energized.

c. No flame present at end of PFEP.

d. Main valve terminal is energized.

e. Internal system fault occurred.

f. Purge card is removed.

g. Purge card is bad.

5. Run Period

a. No flame present.

b. Airflow lockout feature is enabled and the airflow

switch opens.

c. Main valve terminal is not energized.

d. Internal system fault occurred.

e. Purge card is removed.

f. Purge card is bad.

SAFETY PROVISIONS

Internal Hardware Status Monitoring

The EC7895 or RM7895 checks the purge card for correct

parity to prevent purge timing shifts and circuitry failures. It

also analyzes the integrity of the configuration jumpers and

internal hardware. The POWER LED blinks every four

seconds, signifying an internal hardware check.

Closed Loop Logic Test

The test verifies the integrity of all safety critical loads,

terminals 8, 9, 10 and 21. If the loads are not energized

properly; i.e., the main valve terminal is powered during

PREPURGE, the EC7895 or RM7895 locks out on safety

shutdown. The EC7895 or RM7895 must react to input

changes but avoid the occurrence of

nuisance

shutdown

events. Signal conditioning is applied to line voltage inputs to

verify proper operation in the presence of

normal

electrical

line noise such as transient high voltage spikes or short

periods of line dropout. Signal conditioning is tolerant of

synchronous noise (line noise events that occur at the same

time during each line cycle).

APERTURE

BUSHING WITH

MAGNIFYING LENS COLLAR, 3/4-14 NPSM

INTERNAL THREADS

3/4-14

NPSM

3/4-14 NPSM

INTERNAL

THREADS

HEAT BLOCKCELL MOUNT

M1982A

2 LEADS IN A

48 INCH (1.2 METER)

FLEXIBLE CONDUIT

2-3/4

(70)

1-1/4

(32)

1-5/8 (41)

1-1/16 (27)

1-1/4

(32)

C7015

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

9

Dynamic Ampli-Check

®

Dynamic AMPLI-CHECK® circuitry tests the flame signal

amplifier during burner operation and shuts down the EC7895

or RM7895 if the flame amplifier fails.

Dynamic Flame Amplifier and Shutter Check

Self-checking circuitry tests all electronic components in the

flame detection system and amplifier 10 to 12 times per

minute and shuts down the EC7895 or RM7895 if the

detection system fails.

Dynamic Input Check

All system input circuits are examined to assure that the

EC7895 or RM7895 is capable of recognizing the true status

of external controls, limits and interlocks. If any input fails this

test, a safety shutdown occurs and the fault is annunciated.

Dynamic Safety Relay Test

Checks the ability of the dynamic safety relay contact to open

and close. Verifies that the safety critical loads, terminals 8, 9,

10 and 21, can be de-energized, as required, by the Dynamic

Self-Check logic.

Dynamic Self-Check Safety Circuit

The microcomputer tests itself and related hardware, and at

the same time, the safety relay system tests the

microcomputer operation. If a microcomputer or safety relay

failure occurs and does not allow proper execution of the self-

check routine, safety shutdown occurs and all safety critical

loads are de-energized.

Expanded Safe-Start Check

The conventional safe-start check, which prevents burner

start-up if flame is indicated at start-up, is expanded to

include a flame signal check during STANDBY, an airflow

switch check and a safety critical load check.

Off Cycle (Standby or Prepurge) Flame

Signal Check

The flame detection subsystem (flame detector and amplifier)

is monitored during STANDBY. If a flame simulating condition

or an actual flame exists, a system hold occurs and start-up is

prevented. If the flame signal exists at any time after the first

40 seconds of STANDBY, a safety shutdown occurs and is

annunciated. A shutter-check amplifier and self-checking

detector are energized for the first 40 seconds during

STANDBY and the last two seconds before exiting STANDBY.

If a flame exists, a safety shutdown occurs. An AMPLI-

CHECK® Amplifier is energized continually through

STANDBY and PREPURGE to detect any possibility of a

runaway detector or a flame. If a flame exists, a safety

shutdown occurs. A standard amplifier is energized

continually through STANDBY and PREPURGE; if a flame

exists, a safety shutdown occurs.

Tamper Resistant Timing and Logic

Safety and logic timings are inaccessible and cannot be

altered or defeated.

Verified Spark Termination

The ignition terminal is monitored to assure early spark

termination (ten seconds ignition and pilot and ten seconds

pilot and main only

).

First-Out Annunciation AND Self-Diagnostics

Sequence Status Lights (LEDs)

provide positive visual

indication of the program sequence: POWER, PILOT,

FLAME, MAIN and ALARM. The green POWER LED blinks

every four seconds, signifying that the RM7895 hardware is

running correctly.

Optional multi-function Keyboard Display Module

shows

elapsed time during PREPURGE, PILOT IGN and MAIN IGN.

As an additional troubleshooting aid, it provides sequence

timing, diagnostic information and historical information when

a safety shutdown or hold or normal operation occurs.

First-out Annunciation

reports the cause of a safety shutdown

or identifies the cause of a failure to start or continue the

burner control sequence with text and numbered code via the

optional Keyboard Display Module. It monitors all field input

circuits, including the flame signal amplifier. The system

distinguishes 43 modes of failure and detects and

annunciates difficult-to-find intermittent failures.

Self-Diagnostics

add to the First-out Annunciation by allowing

the EC7895 or RM7895 to distinguish between field (external

device) and internal (system related) problems. Faults

associated within the flame detection subsystem, EC7895 or

RM7895 or Plug-in Purge Card are isolated and reported by

the optional Keyboard Display Module. See the 7800 SERIES

System Annunciation Diagnostics and Troubleshooting,

form 65-0118.

Airflow Switch Interlock

This interlock is typically connected to an airflow switch. The

Airflow Interlock (ILK) input must close ten seconds into

PREPURGE or within the specified purge card timing;

otherwise, a recycle to the beginning of PRE-PURGE or

lockout will occur, depending on how the airflow switch

selectable jumper is configured (see Table 3 in Operation

section).

INSTALLATION

WARNING

FIRE OR EXPLOSION HAZARD

CAN CAUSE PROPERTY DAMAGE,

SEVERE INJURY, OR DEATH

To prevent possible hazardous burner operation,

verification of safety requirements must be performed

each time

a control is installed on a burner.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 10

When Installing this Product…

1. Read these instructions carefully. Failure to follow them

could damage the product or cause a hazardous

condition.

2. Check the ratings given in the instructions and marked

on the product to make sure the product is suitable for

your application.

3. Installer must be a trained, experienced, flame

safeguard service technician.

4. After installation is complete, check out the product

operation as provided in these instructions.

CAUTION

1. Disconnect the power supply before beginning

installation to prevent electrical shock and

equipment damage. More than one power supply

disconnect may be involved.

2. Wiring connections for the EC7895 or RM7895

are unique; therefore, refer to Fig. 7 or 8 for the

correct Specifications for proper subbase wiring.

3. Wiring must comply with all applicable codes,

ordinances and regulations.

4. Wiring, where required, must comply with NEC

Class 1 (Line Voltage) wiring.

5. Loads connected to the EC7895 or RM7895 must

not exceed those listed on the EC7895 or RM7895

label or the Specifications, see Table 1A or 1B.

6. Limits and interlocks must be rated to carry and

break current simultaneously to the ignition

transformer, pilot valve, and main fuel valve(s).

7. All external timers must be listed or components

recognized by authorities who have jurisdiction

for specific purpose for which they are used.

IMPORTANT

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

have jurisdiction prohibit the wiring of any limit or

operating contacts in series between the flame

safeguard control and the main fuel valve(s).

2. Two Detectors can be connected in parallel with

the exception of Infrared Detectors (C7015).

3. This equipment generates, uses and can radiate

radio frequency energy and, if not installed and

used in accordance with the instructions, may

cause interference to radio communications. It is

designed to meet the requirements for a Class B

computing device of part 15 of FCC rules, which

are designed to provide reasonable protection

against such interference when operated in a

commercial environment. Operation of this

equipment in a residential area may cause

interference; in which case, the user at their own

expense may be required to take whatever

measures are required to correct this interference.

Humidity

Install the EC7895 or RM7895 where the relative humidity

never reaches the saturation point. The EC7895 or RM7895

is designed to operate in a maximum 85% RH continuous,

noncondensing, moisture environment. Condensing moisture

can cause a safety shutdown.

Vibration

Do not install the EC7895 or RM7895 where it could be

subjected to vibration in excess of 0.5G continuous maximum

vibration.

Weather

The EC7895 or RM7895 is not designed to be weather tight.

If installed outdoors, the EC7895 or RM7895 must be

protected by an approved weather-tight enclosure.

Mounting Wiring Subbase

NOTE: For installation dimensions, see Fig. 1 or 2.

1. Mount the subbase in any position except horizontally

with the bifurcated contacts pointing down. The standard

vertical position is recommended. Any other position

decreases the maximum ambient temperature rating.

2. Select a location on a wall, burner or electrical panel. The

Q7800 can be mounted directly in the control cabinet. Be

sure to allow adequate clearance for servicing, instal-

lation, access and removal of the EC7895 or RM7895,

Dust Cover, flame amplifier, flame amplifier signal voltage

probes, Run/Test Switch, electrical signal voltage probes

and electrical field connections.

3. For surface mounting, use the back of the subbase as a

template to mark the four screw locations. Drill the pilot

holes.

4. Securely mount the subbase using four no. 6 screws.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

11

CONFIGURATION

JUMPERS

MICROCOMPUTER

RESET

PUSHBUTTON

RUN/TEST

SWITCH

STATUS LEDs

PLUG-IN PURGE

TIMER CARD

SAFETY RELAY

CIRCUIT

POWER SUPPLY

OPTIONAL KEYBOARD

DISPLAY MODULE

PLUG-IN

FLAME

AMPLIFIER

RELAY

DRIVE

CIRCUIT

CONTROL

POWER

TEST

JACK

REMOTE

RESET

DDL

DDL

COMMUNICATIONS

INDICATES FEEDBACK SENSING

OF RELAY CONTACT STATUS

AND LINE VOLTAGE INPUTS

FIELD WIRING

INTERNAL WIRING

IGNITION

PILOT

PILOT/V2

MAIN VALVE

1K

RELAY

STATUS

FEEDBACK

AND LINE

VOLTAGE

INPUTS

LIMITS CONTROLLER

LOCKOUT

INTERLOCK 1K1 2K1 5K1

FLAME SIGNAL

TEST

PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

RM7895:,100VAC; EC7895: 200VAC.

RS485

1

23

5

L1

(HOT) L2

5

67

4K1

7K1

2K2

10

8

21

9

7K

6K

5K

4K

3K

2K

F

G

22

1

BLOWER

6K1

4

ALARM

3K1

3

L2

M11128

2

2

1

Fig. 6. Internal block diagram of the EC7895 or RM7895 (see Fig. 7 and 8 for detailed wiring instructions).

WIRING

1. a. For proper wiring, refer to Fig. 7 or 8.

b. For proper remote wiring of the Keyboard Display

Module, refer to the Specifications for the Keyboard

Display Module (65-0090), Communication Interface

Base Unit (63-2278), DATA CONTROLBUS

MODULE™ (65-0091) or Extension Cable Assembly

(65-0131).

2. Disconnect the power supply from the main disconnect

before beginning installation to prevent electrical shock

and equipment damage. More than one disconnect may

be involved.

3. All wiring must comply with all appropriate electrical codes,

ordinances and regulations. Wiring, where required, must

comply with NEC Class 1 (Line Voltage) wiring.

4. Recommended wire size and type: use no. 14, 16, or 18

copper conductor (TTW60C or THW75C or THHN90C)

600 volt insulation wire for all Line Voltage terminals. For

high temperature installations, use wire selected for a

temperature rating above the maximum operating

temperature. All leadwires must be moisture resistant.

5. Recommended grounding practices:

a. Use the earth ground to provide 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 20A fuse (or

breaker) in event of an internal short circuit. The

EC7895 or RM7895 needs a low impedance

ground connection to the equipment frame which,

in turn, needs a low impedance connection to earth

ground. For a ground path to be low impedance at

RF frequencies, the connection must be made with

minimum length conductors that have a maximum

surface area. Wide straps or brackets are preferred

rather than leadwires. Be careful to verify that

mechanically tightened joints along the ground

path, such as pipe or conduit threads or surfaces

held together with fasteners, are free of noncon-

ductive coatings and are protected against mating

surface corrosion.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 12

b. For EC7895 or RM7895, each device has an

earth ground terminal that must be grounded to

the metal control panel with wire as short as

practical. Each ground wire must be capable of

carrying a fault current equal to the rating of the

protective fuse (20A). A number 14 copper

conductor is adequate but wide straps or

brackets are preferred rather than leadwires.

6. Recommended wire routing for flame detector

leadwires:

1. Do not run high voltage ignition transformer wires

in the same conduit with the flame detection wiring.

2. Do not route scanner wires in a conduit with line

voltage circuits.

3. Enclose scanner wires without armor cable in

metal cable or conduit.

4. Follow directions given in the flame detector

Instructions.

7. Maximum wire lengths:

a. For the EC7895 or RM7895, the maximum length

of leadwire to the terminal inputs is 300 feet

(Control and Airflow Interlock).

b. For the flame detector leadwires, the maximum

flame sensor leadwire length is limited by the

flame signal strength.

8. Make sure loads do not exceed the terminal ratings.

Refer to the label on the EC7895 or RM7895 or to the

ratings in the Specifications, see Table 1A or 1B.

9. Check the power supply circuit. The voltage and

frequency tolerance must match those of the EC7895

or RM7895. A separate power supply circuit may be

required for the EC7895 or RM7895 with the required

disconnect means and overload protection added.

10. Check all wiring circuits and complete the Static

Checkout, see Table 4, before installing the EC7895 or

RM7895 on the subbase.

11. Install all electrical connectors.

12. Restore power to the panel.

Fig. 7. Wiring the RM7895A.

M5111A

G

L2

3

5

6

7

8

9

10

F

(L1)

13

14

15

16

17

18

19

20

21

22

12

MASTER

SWITCH

IGNITION

MAIN FUEL

VALVE(S)

BURNER

CONTROLLER/LIMITS

BURNER MOTOR

(BLOWER)

INTERMITTENT

PILOT/IGNITION

RECTIFYING FLAME

ROD, RECTIFYING

PHOTOCELL, OR INFRA-

RED (LEAD SULFIDE)

FLAME DETECTOR

120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

FOR DIRECT SPARK IGNITION

(OIL OR GAS)

100V ALARM

L1

(HOT)

L2 1

L2

WHITE

WHITE

WHITE

BLACK

BLACK L1

L2

9

8

10 IGNITION

TRANSFORMER

MAIN VALVE

1

Q7800

2

2

L2

4

AIRFLOW

INTERLOCK

OR

OR

YELLOW

BLUE

BLUE

C7027A, C7035A, OR

C7044A ULTRAVIOLET

FLAME DETECTOR

C7012A,C,E,F OR

C7076A,D ULTRAVIOLET

FLAME DETECTOR

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

13

Fig. 8. Wiring the EC7895.

M11074

G

L2

3

5

6

7

8

9

10

F

(L1)

13

14

15

16

17

18

19

20

21

22

12

MASTER

SWITCH

IGNITION

MAIN FUEL

VALVE(S)

BURNER

CONTROLLER/LIMITS

BURNER MOTOR

(BLOWER)

INTERMITTENT

PILOT/IGNITION

RECTIFYING FLAME

ROD, RECTIFYING

PHOTOCELL, OR INFRA-

RED (LEAD SULFIDE)

FLAME DETECTOR

C7027A, C7035A, OR

C7044A ULTRAVIOLET

FLAME DETECTOR

C7012F OR

C7076A ULTRAVIOLET

FLAME DETECTOR

200V, 50/60 HZ EC7895 POWER SUPPLY. PROVIDE DISCONNECT

MEANS AND OVERLOAD PROTECTION AS REQUIRED.

DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

USE 2:1 STEP DOWN POWER TRANSFORMER, 300 VA MINIMUM

(STANCOR P8620 OR EQUIVALENT).

VERIFY THAT THE OPERATING VOLOTAE OF THE FLAME

DETECTOR IS THE SAME AS THE LINE VOLTAGE.

FOR DIRECT SPARK IGNITION (OIL

OR GAS)

AIRFLOW INTERLOCK

200 VAC ALARM

L1

(HOT)

L2 1

OR

OR

OR

OR

BLUE

BLUE

BLUE

WHITE

YELLOW

YELLOW

YELLOW

WHITE

WHITE

WHITE

WHITE

BLACK

BLACK

BLACK

BLACK 9

8

10 IGNITION

TRANSFORMER

MAIN VALVE

1

Q7800

2

2

3

3

4

4

L2

4

4

C7012A,C ULTRAVIOLET

FLAME DETECTOR

BLUE

C7061A 1:2

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 14

ASSEMBLY

Mounting RM7895

NOTE: For installation dimensions, see Fig. 1 or 2.

Relay Module Mounting

1. Mount the EC7895 or RM7895 vertically, see Fig. 9 or

10, or mount horizontally with the knife blade terminals

pointing downward. When mounted on the Q7800A, the

EC7895 or RM7895 must be in an electrical enclosure,

see Fig. 9.

2. Select the location in the electrical enclosure. Be sure

to allow adequate clearance for servicing, installation

and removal of the EC7895 or RM7895, Dust Cover,

flame amplifier, flame amplifier signal voltage probes,

electrical signal voltage probes and electrical

connections.

a. Allow an additional two inches below the EC7895

or RM7895 for the flame amplifier mounting.

b. Allow an optional three-inch minimum to both

sides of the EC7895 or RM7895 for electrical

signal voltage probes.

3. Make sure no subbase wiring is projecting beyond the

terminal blocks. Tuck wiring in against the back of the

subbase so it does not interfere with the knife blade

terminals or bifurcated contacts.

4. Mount the EC7895 or RM7895 by aligning the four L

shaped corner guides and knife blade terminals with

the bifurcated contacts on the wiring subbase and

securley tightening the two screws without deforming

the plastic.

IMPORTANT

Install the EC7895 or RM7895 with a plug-in motion

rather than a hinge action.

Installing ST7800 Purge Card

1. Remove the Dust Cover, Keyboard Display Module,

DATA CONTROLBUS MODULE™or Extension Cable

Assembly.

2. Remove the current ST7800 from the EC7895 or

RM7895 by pulling upward on the plastic support cover,

see Fig. 12.

3. Make sure that the ST7800 selected has the desired

timing.

4. Insert the Purge Card into the opening of the RM7895

compartment, see Fig. 11.

5. Reinstall the Dust Cover, Keyboard Display Module,

DATA CONTROLBUS MODULE™ or Extension Cable

Assembly onto the EC7895 or RM7895 and restore

power to the device.

Run the burner system through at least one complete cycle to

verify the system is operating as desired.

Mounting Dust Cover

1. Align the two interlocking ears of the Dust Cover with

the two mating slots on the EC7895 or RM7895, see

Fig. 12.

2. Insert the two interlocking ears into the two mating slots,

and with a hinge action, push on the upper corners of the

Dust Cover to secure it to the EC7895 or RM7895.

3. Be sure the Dust Cover is firmly in place.

Installing Plug-In Flame Signal Amplifier

1. Disconnect the power supply before beginning

installation to prevent electrical shock and equipment

damage. More than one disconnect may be involved.

2. Align the amplifier circuit board edge connector with the

keyed receptacle on the EC7895 or RM7895. Ensure

the amplifier nameplate faces away from the Relay

Module, see Fig. 13.

3. Push in the amplifier until the circuit board is fully

inserted into the receptacle and then push the amplifier

toward the EC7895 or RM7895 retaining clasp.

4. Verify the amplifier is firmly in place.

5. Perform all required checkout tests.

Installing the Flame Detector

NOTE: Table 2 lists the flame detection systems available

for use with the EC7895 or RM7895. Make sure the

correct combination of amplifier and flame

detector(s) is used.

Proper flame detector installation is the basis of a safe and

reliable flame safeguard installation. Refer to the Instructions

packed with the flame detector and the equipment

manufacturer instructions.

Keep the flame signal leadwires as short as possible from the

flame detector to the wiring subbase. Capacitance increases

with leadwire length, reducing the signal strength. The

maximum permissible leadwire length depends on the type of

flame detector, leadwire and conduit. The ultimate limiting factor

in the flame detector leadwire is the flame signal; see Table 5.

Fig. 9. Electrical panel installation.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

15

Fig. 10. Wall or burner installation.

Fig. 11. ST7800 Purge Card installation.

Fig. 12. Dust Cover mounting.

Fig. 13. Flame signal amplifier mounting.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 16

Fig. 14. Flame detector wiring.

BLUE

YELLOW

WHITE

WHITE

WHITE

WHITE

BLACK

BLACK

F

G

22

L2

L1

L2

M11131

BLUE

WHITE

F

G

WHITE

BROWN

F

G

INFRARED (C7015)

ULTRAVIOLET (C7027/C7035/C7044)

SOLID STATE SELF-CHECKING

ULTRAVIOLET (C7012E,F)

BLUE

YELLOW

BLACK

BLACK

F

G

L1

L2

SOLID STATE

ULTRAVIOLET (C7012A,C)

1

22

BLUE

YELLOW

F

G

SOLID STATE SELF-CHECKING

ULTRAVIOLET (C7061A)

2

F G

4

5

3

L2

C7076A,D ULTRAVIOLET DETECTOR

522

6

SHUTTER

G

SHUTTER

F

1

8

2

7

7800 SERIES

L1

L2

3a 3b

REMOTE

SENSOR

2b

2a

EARTH

GROUND

C7076A

OR

C7076D

TERMINAL

BLOCK

L2 (COMMON)

L1 (HOT)

G

F

X

X

FLAME ROD

G

F

X

X

PHOTOCELL

1FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE

MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN

MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.

FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW

MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN

MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.

WHEN USING A C7061A OR 200V VERSIONS OF THE C7012E,F, OR C7076A, A 2:1 STEP DOWN TRANSFORMER IS

REQUIRED. SEE FIGURE 8.

2

3

3

3

3

22

N

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

17

OPERATION

Sequence of Operation

The EC7895 or RM7895 has the following operating

sequences, see Fig. 15.

Initiate

The EC7895 or RM7895 enters the INITIATE sequence when

the Relay Module is powered. The EC7895 or RM7895 can

also enter the INITIATE sequence if the Relay Module verifies

voltage fluctuations of +10/-15% or frequency fluctuations of

+/- 10% during any part of the operating sequence. The

INITIATE sequence lasts for ten seconds unless the voltage

or frequency tolerances are not met. When the tolerances are

not met, a hold condition is initiated and is displayed on the

optional VFD for at least five seconds. When the tolerances

are met, the INITIATE sequence restarts. If the condition is

not corrected and the hold condition exists for four minutes,

the RM7895 locks out. Causes for hold conditions in the

INITIATE sequence are:

•AC line dropout is detected.

•AC line noise that can prevent a sufficient reading of the

line voltage inputs.

•Brownouts caused by a low line voltage.

The INITIATE sequence also delays the burner motor starter

from being energized and de-energized from an intermittent

AC line input or control input.

Standby

The EC7895 or RM7895 is ready to start an operating

sequence when the operating control input determines a

call

for heat

is present. The burner switch, limits, operating limit

control and all microcomputer monitored circuits must be in

the correct state for the EC7895 or RM7895 to continue into

the PRE-PURGE sequence.

Normal Start-Up Prepurge

The EC7895 or RM7895 provides a selectable PREPURGE

timing from two seconds to 30 minutes with power applied

and the EC7895 or RM7895 operating control indicating a

call

for heat

.

a. Airflow Interlock, burner switch, and all microcomputer

monitored circuits must be in the correct operating state.

b. The blower motor output, terminal 4, is powered to start

the PREPURGE sequence.

c. The Airflow Interlock input must close ten seconds into

PREPURGE or within the specified purge card timing;

otherwise, a recycle to the beginning of PRE-PURGE

or lockout occurs depending on how the airflow switch

selectable jumper is configured.

Ignition Trials

a. Pilot Flame Establishing Period (PFEP):

1. The pilot valve and ignition transformer, terminals 8

and 10, are energized. The EC7895 or RM7895A

has an intermittent pilot valve, terminal 8.

2. Flame must be proven by the end of the 4 or 10

sec-ond PFEP to allow the sequence to continue.

If flame is not proven by the end of PFEP, a

safety shutdown occurs.

3. At the end of PFEP, the ignition, terminal 10, is

de-energized.

b. Main Flame Establishing Period (MFEP):

1. After the Ignition Trials, and with the presence of

flame, the main fuel valve, terminal 9, is powered.

If a flameout occurs, the EC7895A or RM7895A

will lock out or recycle within .8 or 3 seconds,

depending on the Flame Failure Response Time

(FFRT) of the amplifier.

Run

1. The EC7895A or RM7895 is now in RUN and remains

in RUN until the controller input, terminal 6, opens,

indicating that the demand is satisfied or a limit opened.

See Table 6 for further details of Hold conditions.

Selectable Site-Configurable Jumpers

The EC7895 or RM7895 has three site-configurable jumper

options, see Fig. 17 and Table 3. The site-configurable

jumpers should be clipped with side cutters and the resistors

removed from the Relay Module.

SERVICE NOTE: Clipping and removing a site-configurable

jumper enhances the level of safety.

Static Checkout

CAUTION

1. Use extreme care while testing the system. Line

voltage is present on most terminal connections

when power is on.

2. Open the master switch before installing or

removing a jumper on the subbase.

3. Before continuing to the next test, be sure to re-

move test jumper(s) used in the previous tests.

4. Replace all limits and interlocks not operating

properly. Do not bypass limits and interlocks.

5. Close all manual fuel shutoff valve(s) before

starting these tests.

After checking all wiring, perform this checkout before

installing the EC7895 or RM7895 on the subbase. These

tests verify the Q7800 Wiring Subbase is wired correctly, and

that the exter-nal controllers, limits, interlocks, actuators,

valves, transformers, motors and other devices are operating

properly.

NOTE: Do not perform a dielectric test with the EC7895 or

RM7895 installed. Internal surge protectors will

break down and conduct a current. This could cause

the EC7895 or RM7895 to fail the dielectric test or

possibly destroy the internal lightning and high

current transient protection components.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 18

Equipment Recommended

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.

General Instructions

1. Perform all applicable tests listed in, Table 4, in the

order listed.

2.

MAKE SURE THAT ALL MANUAL FUEL SHUT-OFF

VALVE(S) ARE CLOSED.

3. Perform only those tests designated for the specific

RM7895 model being tested.

4. Raise the set point of the operating controller to

simulate a

call for heat.

Fig. 15. 7895 sequence.

5. For each test, open the master switch and install the

jumper wire(s) between the subbase wiring terminals

listed in the Test Jumpers column of Table 4.

6. Close the master switch before observing operation.

7. Read the voltage between the subbase wiring terminals

listed in the Voltmeter column of Table 4.

8. If there is no voltage or the operation is abnormal,

check the circuits and external devices as described in

the last column.

9. Check all wiring for correct connections, tight terminal

screws, correct wire, and proper wiring techniques.

Replace all damaged or incorrectly sized wires.

10. Replace faulty controllers, limits, interlocks, actuators,

valves, transformers, motors and other devices as

required.

11. Obtain normal operation for each required test before

continuing the checkout.

12. After completing each test, be sure to remove the test

jumper(s).

SEQUENCE

STATUS

LEDs

RESET

PUSHBUTTON

FLAME

SIMULATOR INPUT FLAME CURRENT

TEST JACKS

CAPTIVE

MOUNTING

SCREW

PLUG-IN

PURGE

CARD

DUST

COVER

RELAY

MODULE

FLAME

AMPLIFIER

M11127

Fig. 16. Sequence status LEDs.

IGN.

OPERATING

CONTROLS

AND

INTERLOCKS

INITIATE

ALARM ALARM

STANDBY

POWER POWER

PILOT

FLAME

MAIN

TIMED

PURGE

ALARM

POWER

PILOT

FLAME

MAIN

RUN STANDBY

BURNER

START

MAIN VALVE

LIMITS AND BURNER CONTROLLER CLOSED

IGN./ PILOT

SAFE START CHECK FLAME

PROVING SSC

LED

DISPLAY

POWER

PILOT

FLAME

MAIN

PFEP

4 OR 10 SEC

POWER

START

POWERPOWER

FLAME

SIGNAL

M11130

00 00 00

10

L1 TO 6

9

8

4

BURNER/BLOWER MOTOR

AIRFLOW INTERLOCK CLOSED TO 76

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

19

Table 3. Site Configurable Jumper Options.

Jumper

Number Description Intact Clipped

JR1 Pilot Flame

Establishing

Period

10 seconds 4 seconds

JR2 Flame Failure

Action Recycle Lockout

JR3 Airflow Switch

(ILK) Failure Recycle Lockout

Fig. 17. Selectable site-configurable jumpers.

SELECTABLE CONFIGURATION JUMPERS

M11126

Table 4. Static Checkout.

Test

No. Test

Jumpers Volt-

meter Normal Operation If Operation Is Abnormal,

Check The Items Listed Below

WARNING

Make sure all manual fuel shutoff valves are closed.

IMPORTANT

Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if

required).

1 None 5-L2 Line voltage at terminal 5. 1. Master switch.

2. Power connected to the master switch.

3. Overload protection (fuse, circuit breaker) has not

opened the power line.

2 None 6-L2 Line voltage at terminal 6. 1. Limits.

2. Burner controller.

3 4-5 7-L2 1. Burner motor (fan or blower) starts.

2. Line voltage at terminal 7 within 10

seconds.

1. Burner motor circuit.

a. Manual switch of burner motor.

b. Burner motor power supply, overload

protection and starter.

c. Burner motor.

4 5-10 — Ignition spark (if ignition transformer is

connected to terminal 10). 1. Watch for spark or listen for buzz.

a. Ignition electrodes are clean.

b. Ignition transformer is okay.

5 5-8 — 1. Ignition spark (if ignition transformer is

connected to terminal 8).

2. Automatic pilot valve opens

(if connected to terminal 8).

NOTE: Refer to wiring diagram of system

being tested.

1. Watch for spark or listen for buzz.

a. Ignition electrodes are clean.

b. Ignition transformer is okay.

2. Listen for click or feel head of valve for activation.

a. Actuator if used.

b. Pilot valve.

6 5-9 — Automatic fuel valve(s) opens. If using

direct spark ignition, check the first stage

fuel valve(s) instead of the pilot valve.

Same as test no. 6. If using direct spark ignition,

check the first stage fuel valve(s) instead of the pilot

valve.

75 -3 — Alarm (if used) turns on. 1. Alarm

Final CAUTION

After completing these tests, open the master switch and remove all test jumpers from the subbase terminals.

Also remove bypass jumpers from the low fuel pressure limits (if used).

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 20

CHECKOUT

WARNING

Do not allow fuel to accumulate in the combustion

chamber. If fuel is allowed to enter the chamber for

longer than a few seconds without igniting, an

explosive mixture could result. It is recommended that

you limit the trial for pilot to ten seconds, and limit the

attempt to light the main burner two seconds from the

time the fuel has reached the burner nozzle. In any

case, do not exceed the nominal lightoff time specified

by the equipment manufacturer. Close the manual fuel

shutoff valve(s) if the flame is not burning at the end of

the specified time.

CAUTION

1. Use extreme care while testing the system. Line

voltage is present on most terminal connections

when power is on.

2. Open the master switch before removing or

installing the EC7895 or RM7895.

3. Make sure all manual fuel shutoff valve(s) are

closed before starting the initial lightoff check and

the Pilot Turndown tests.

4. Do not put the system in service until you have

satisfactorily completed all applicable tests in this

section and any others required by the equipment

manufacturer.

CAUTION

If an EC7895 or RM7895 is replaced with a lower

or higher functioning 7800 SERIES Relay Module,

the burner will not sequence unless wiring changes

are made.

IMPORTANT

1. If the system fails to perform properly, refer to

7800 SERIES System Annunciation Diagnostics

and Troubleshooting, form 65-0118.

2. Repeat ALL required Checkout tests after all

adjustments are made. ALL tests must be satisfied

with the flame detector(s) in its FINAL position.

Equipment Recommended

Volt-ohmmeter (1M ohm/volt minimum sensitivity):

•0-300 Vac capability.

•0-6000 ohm capability.

•0-10 Vdc capability.

Checkout Summary

•Preliminary inspection—all installations.

•Flame signal measurement—all installations.

•Initial lightoff check for proved pilot—all installations using

a pilot.

•Initial lightoff check for direct spark ignition of oil—all

burners using DSI.

•Pilot turndown test—all installations using a pilot.

•Hot refractory saturation test—all installations using

Infrared (lead sulfide) Flame Detectors.

•Hot refractory hold-in test—all installations.

•Ignition interference test—all installations using flame

rods.

•Ignition spark pickup—all installations using Ultraviolet

Flame Detectors.

•Response to other ultraviolet sources—all installations

using Ultraviolet Flame Detectors.

•Flame signal with hot combustion chamber—all

installations.

•Safety shutdown tests—all installations.

See Fig. 1 and 2 for location of component parts and see Fig.

7 or Q7800 Specifications for terminal locations.

Preliminary Inspection

Perform the following inspections to avoid common problems.

Be sure:

1. Wiring connections are correct and all terminal screws

are tight.

2. Flame detector(s) is clean, installed and positioned

properly. Consult the applicable Instructions.

3. Correct combination of amplifier and flame detector is

used (see Table 2).

4. Plug-in amplifier and purge card are securely in place.

5. Burner is completely installed and ready to fire; consult

equipment manufacturer instructions. Fuel lines are

purged of air.

6. Combustion chamber and flues are clear of fuel and

fuel vapor.

7. Power is connected to the system disconnect switch

(master switch).

8. Lockout switch is reset (push in reset pushbutton) only

if the 7895 is powered, see Fig. 1 and 2.

9. System is in the STANDBY condition. POWER LED is

energized.

10. All limits and interlocks are reset.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

21

Flame Detector Acceptable Flame

Signal Amplifier Minimum Maximum

Steady DC Voltage

a

Expected DC Voltage

Flame Rod Photocell

C7012A,C R7847A,B

b

1.25 Vdc 5.0 Vdc at the Keyboard Display Module

C7012E,F R7847C

c

C7015A R7848A,B

b

OR

C7027A

C7035A

C7044A

R7849A,B

b

C7061 R7861A

d

C7076A,D R7886A

e

5.0 Vdc at a 1M ohm/volt meter

Flame Signal Measurement (Fig. 18 and Table 5)

Table 5. Flame Signal.

aThis minimum or a stronger signal should easily be obtained if the detector is correctly installed and positioned to properly

sense the flame. This voltage must be obtained before completing checkout.

bThe flame amplifiers are AMPLI-CHECK® type.

cThe flame signal amplifier circuitry is tested one-half second every five seconds during burner operation and shuts down the

burner if the amplifier fails (all installations).

dRequires seperate stepdown power transformer. See Fig. 14.

eUse with RM7895A Only.

NEGATIVE (-)

METER LEAD

POSITIVE (+)

METER LEAD

ONE

MEGOHM/VOLT

METER

M7382

Fig. 18. Flame signal measurement.

Measure the flame signal at the appropriate times defined in

the following checkout tests. Read the flame signal volts dc at

the flame amplifier test jacks + and - (Com).

1. Use a 1M ohm/voltmeter with a 0 to 10 Vdc capability.

2. Set the 1M ohm/voltmeter to the 0 to 10 Vdc range.

3. Insert the positive (red) probe into the + jack of the

flame amplifier. Insert the negative (black) probe into

the - (Com) jack of the flame amplifier, see Fig. 19.

4. Allow a few seconds for the meter reading to stabilize.

5. If using AMPLI-CHECK® or shutter check amplifiers,

read the average stable voltage, disregarding the peaks

caused by the self-checking operation.

6. The meter reading must be as specified in Table 5 after

all tests are completed and all adjustments are made.

As an option, the flame signal can be checked by using the

optional Keyboard Display Module.

If the signal is unstable or less than the minimum ac-ceptable

voltage, check the flame detector installation and circuitry.

1. Check the supply voltages at terminals 5 (L1) and L2

(N). Make sure the master switch is closed,

connections are correct, and the power supply is of the

correct voltage and frequency and is sinusoidal.

2. Check the detector wiring for defects including:

•Incorrect connections.

•Wrong type of wire.

•Deteriorated wire.

•Open circuits.

•Short circuits.

•Leakage paths caused by moisture, soot or

accumulated dirt.

3. For a flame rod, make sure:

•Ground area is large enough.

•Flame rod is properly located in the flame.

•Temperature at the flame rod insulator is no

greater than 500° F (260° C).

4. For all optical detectors, clean the detector viewing

window and inside of the sight pipe as applicable.

5. With the burner running, check the temperature at the

detector. If it exceeds the detector maximum rated

temperature:

•Add a heat block to stop conducted heat traveling

up the sight pipe.

•Add a shield or screen to reflect radiated heat.

•Add cooling (refer to sight pipe ventilation in the

detector Instructions).

6. Make sure that the flame adjustment is not too lean.

7. Make sure that the detector is properly sighting the

flame.

8. If necessary, resight or reposition the detector.

Initial Lightoff Check for Proved Pilot

Perform this check on all installations that use a pilot. It

should immediately follow the preliminary inspection.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 22

NOTE: Low fuel pressure limits, if used, could be open. If

so, bypass them with jumpers during this check.

1. Open the master switch.

2. Make sure that the manual main fuel shutoff valve(s) is

closed. Open the manual pilot shutoff valve. If the pilot

takeoff is downstream from the manual main fuel

shutoff valve(s), very slightly open the manual main

valve to supply pilot gas flow. Make sure the main fuel

is shutoff just upstream from the burner inlet, or

disconnect power from the automatic main fuel

valve(s).

3. Close the master switch and start the system with a

call

for heat

by raising the set point of the operating

controller, see Fig. 15. The primary sequence should

start the ten-second INITIATE sequence.

4. Let the sequence advance through PREPURGE.

Ignition spark should occur and the pilot should light. If

the pilot ignites, the FLAME LED is energized. Proceed

to step 7.

5. If the pilot flame is not established in four or ten

seconds, safety shutdown occurs. Let the sequence

complete its cycle. Consult the equipment operating

manual for further information.

6. Push the reset pushbutton, and let the system recycle

once. If the pilot still does not ignite, make the following

ignition/pilot adjustments:

a. Open the master switch and remove the EC7895

or RM7895 from the subbase.

b. On the subbase, jumper terminal 5 to ignition

terminals 8 or 10; refer to the appropriate wiring

diagram to determine the proper terminal.

Disconnect the leadwire to the pilot valve if it is

connected to the same terminal.

c. Close the master switch to energize only the

ignition transformer.

d. If the ignition spark is not strong and continuous,

open the master switch and adjust the ignition

electrode spark gap setting to the manufacturer

recommendations.

e. Make sure the ignition electrodes are clean.

f. Close the master switch and observe the spark.

g. After a continuous spark is obtained, open the

master switch and add a jumper on the subbase

from terminal 5 (L1) to the pilot terminal 8.

Reconnect the leadwire from the pilot valve if it

was disconnected in step b.

h. Close the master switch to energize both the

ignition transformer and the pilot valve.

i. If the pilot does not ignite and if the ignition spark

is still continuous, adjust the pressure regulator

until a pilot is established.

j. When the pilot ignites properly and stays ignited,

open the master switch and remove the jumper(s)

from terminals 5 through 8 or 5 through 10 of the

subbase.

k. Check for adequate bleeding of the fuel line.

l. Reinstall the EC7895 or RM7895 on the subbase

and close the master switch, then return to step 4.

7. When pilot ignites, measure the flame signal. If the pilot

flame signal is unsteady or approaching the 1.25 Vdc

minimum value, adjust the pilot flame size or detector

sighting to provide a maximum and steady flame signal.

8. Recycle the system to recheck lightoff and pilot flame

signal.

9. When the MAIN IGN period is displayed by the MAIN

LED, make sure the automatic main fuel valve is open;

then smoothly open the manual main fuel shutoff

valve(s) and watch for main burner flame ignition.

When the main burner flame is established, proceed to

step 16.

10. If the main burner flame is not established within five

seconds or the normal lightoff time specified by the

equipment manufacturer, close the manual main fuel

shut-off valve(s).

11. Recycle the system to recheck the lightoff and pilot

flame signal.

12. Smoothly open the manual fuel shutoff valve(s) and try

lightoff again. (The first reattempt may have been

required to purge the lines and bring sufficient fuel to

the burner.)

13. If the main burner flame is not established within five

seconds or the normal lightoff time specified by the

equipment manufacturer, close the manual main fuel

shut-off valves(s). Check all burner adjustments.

14. If the main burner flame is not established after two

attempts:

a. Check for improper pilot size.

b. Check for excess combustion air.

c. Check for adequate fuel flow.

d. Check for proper gas supply pressure.

e. Check for proper valve operation.

f. Check for proper pilot flame positioning.

15. Repeat steps 8 through 14 to establish the main burner

flame; then proceed to step 16.

16. With the sequence in RUN, make burner adjustments

for flame stability and BTU input rating.

17. Shut down the system by opening the burner switch or

by lowering the set point of the operating controller.

Make sure the main flame goes out. There may be a

delay due to gas trapped between the valve(s) and the

burner. Make sure all automatic fuel valve(s) close.

18. Restart the system by closing the burner switch and/or

raising the set point of the operating controller. Observe

that the pilot is established during PILOT IGN and the

main burner flame is established during MAIN IGN

within the normal lightoff time.

19. Measure the flame signal. Continue to check for the

proper signal, see Table 5, through the RUN period.

20. Run the burner through another sequence, observing

the flame signal for:

a. Pilot flame alone (unless using direct spark

ignition).

b. Pilot and main flame together.

c. Main flame alone (unless monitoring an

intermittent pilot).

Also observe the time it takes to light the main flame. Ignition

of main flame should be smooth.

21. Return the system to normal operation.

22. Make sure all readings are in the required ranges be-

fore proceeding.

NOTE: Upon completing these tests, open the master

switch and remove all test jumpers from the subbase

terminals, limits/controls or switches.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

23

Initial Lightoff Check for Direct Spark Ignition

This check applies for gas and oil burners that do not use a

pilot. It should immediately follow the preliminary in-spection.

Refer to the appropriate sample block diagram of field wiring

for the ignition transformer and fuel valve(s) hookup.

NOTE: Low fuel pressure limits, if used, could be open. If

so, bypass them with jumpers during this check.

1. Open the master switch.

2. Complete the normal checkout of the fuel supply and

equipment as recommended by the equipment

manufacturer.

3. Close all manual main fuel shutoff valve(s). Check that

the automatic fuel valve(s) are closed. Make sure fuel is

not entering the combustion chamber.

4. Close the master switch and start the system with a

call

for heat

by raising the set point of the operating

controller, see Fig. 15. The primary sequence should

start the ten-second INITIATE sequence.

5. Let the sequence advance through PREPURGE.

Ignition spark should occur after the PREPURGE

period. Listen for the click of the first stage fuel solenoid

valve(s).

6. Let the program sequence complete its cycle.

7. Open the manual fuel shutoff valve(s).

8. Reset the Lockout Switch and recycle the primary

sequence through PREPURGE.

9. Watch for the FLAME LED to help determine when the

first stage burner flame is established. If it is

established, proceed to step 15.

10. If the first stage burner flame is not established within

four seconds, or within the normal lightoff time specified

by the equipment manufacturer, close the manual fuel

shutoff valve(s), and open the master switch.

11. Check all burner adjustments.

12. Wait about three minutes. Close the master switch,

open the manual fuel shutoff valve(s), and try again to

lightoff the burner. The first attempt may have been

required to purge the lines and bring sufficient fuel to

the burner.

13. If the first stage burner flame is not established with-in

four seconds, or within the normal lightoff time specified

by the equipment manufacturer, close the manual fuel

shutoff valve(s) and open the master switch.

14. If necessary, repeat steps 8 through 13 to establish the

first stage burner flame. Then proceed to step 15.

15. When the first stage burner flame is established, the

sequence will advance to RUN. Make burner

adjustments for flame stability and input rating. If a

second stage is used, proceed to step 18.

16. Shut down the system by opening the burner switch or

by lowering the set point of the operating controller.

Make sure the burner flame goes out and make sure all

automatic fuel valve(s) close.

17. If used, remove the bypass jumpers from the low fuel

pressure limit and subbase.

18. If a second stage is used, make sure the automatic

second stage fuel valve(s) has opened and check the

light-off as follows. Otherwise proceed to step 19:

a. Open the manual second stage fuel valve(s).

b. Restart the system by raising the set point of the

operating controller.

c. When the first stage burner flame is established,

watch for the automatic second stage fuel

valve(s) to open. Observe that the second stage

lights off properly.

d. Make burner adjustments for flame stability and

input rating.

e. Shut down the system by lowering the set point of

the operating controller. Make sure the burner

flame goes out and all automatic fuel valve(s)

close.

19. Restart the system by closing the burner switch and/or

raising the set point of the operating controller. Observe

that the burner flame is established during PILOT IGN,

within the normal lightoff time specified by the

equipment manufacturer.

20. Measure the flame signal. Continue to check for the

proper signal, see Table 5, through the RUN period.

Any pulsating or unsteady readings require further

attention.

21. Make sure all readings are in the required ranges be-

fore proceeding.

NOTE: Upon completing these tests, open the master

switch and remove all test jumpers from the subbase

terminals, limits/control or switches.

22. Return the system to normal operation.

Pilot Turndown Test

(All Installations using a Pilot)

Perform this check on all installations that use a pilot. The

purpose of this test is to verify that the main burner can be lit

by the smallest pilot flame that will hold in the flame amplifier

and energize the FLAME LED. Clean the flame detector(s) to

make sure that it detects the smallest acceptable pilot flame.

If using AMPLI-CHECK® or Self-Checking Amplifier and 20K

ohm/voltmeter, the flame signal will fluctuate every time the

amplifier does a self-check or a shutter check.

NOTE: Low fuel pressure limits, if used, could be open. If

so, bypass them with jumpers during this test.

1. Open the master switch.

2. Close the manual main fuel shutoff valve(s).

3. Connect a manometer (or pressure gauge) to measure

pilot gas pressure during the turndown test.

4. Open the manual pilot shutoff valve(s).

5. Close the master switch and start the system with a

call

for heat

. Raise the set point of the operating controller.

The primary sequence should start and PREPURGE

should begin.

6. INTERMITTENT PILOT MODELS—After the sequence

has entered the normal burner run period, turn down

pilot gas pressure very slowly, reading the manometer

(or gauge) as the pressure drops. Stop immediately

when the FLAME LED goes out. Note the pressure at

this point.

a. If the Flame Failure Action jumper

is not clipped

,

allow the EC7895 or RM7895A to recycle through

PREPURGE. If the Flame Failure Action jumper

is clipped

, push the reset pushbutton and allow

the EC7895 or RM7895A to recycle through

PREPURGE.

b. As the control attempts to relight the pilot, turn

the pilot gas pressure back up slowly until the

FLAME LED comes on. This step must be

completed within 4 or 10 seconds, depending on

the selected PFEP, or lockout will occur.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 24

c. Turn the pilot back down slightly but not enough

to cause the FLAME LED to go out. (Keep the

pilot gas pressure just above the reading noted in

step 6 above.)

NOTE: Step d requires two people, one to open the manual

main fuel valve(s) and one to watch for ignition.

d. With the sequence in the normal burner run

mode, make sure the automatic main fuel

valve(s) is open. Smoothly open the manual main

fuel shutoff valve(s) and watch for main burner

lightoff.

e. If the main flame is not established within five

seconds or the normal lightoff period specified by

the burner manufacturer, close the manual main

fuel shutoff valve(s) and open the master switch.

Return to step 6. If the burner flame is

established in the normal lightoff period, proceed

to step 16.

7. When the main burner lights reliably with the pilot at

turndown, disconnect the manometer (or pressure

gauge) and turn the pilot gas flow up to that

recommended by the equipment manufacturer.

8. If used, remove the bypass jumpers from the subbase

terminals, limits/controls or switches.

9. Run the system through another cycle to check for

normal operation.

10. Return the system to normal operation.

Ignition Interference Test (All Flame Rods)

Test to be sure that a false signal from a spark ignition system

is not superimposed on the flame signal.

Ignition interference can subtract from (decrease) or add to

(increase) the flame signal. If it decreases the flame signal

enough, it causes a safety shutdown. If it increases the flame

signal, it could cause the FLAME LED to come on when the

true flame signal is below the minimum accep-table value.

Start the burner and measure the flame signal with both

ignition and pilot (or main burner) on, and then with only the

pilot (or main burner) on. Any significant difference (greater

than .5 Vdc) indicates ignition interference.

To Eliminate Ignition Interference

1. Be sure there is enough ground area.

2. Be sure the ignition electrode and the flame rod are on

opposite sides of the ground area.

3. Check for correct spacing on the ignition electrode:

a. 6,000V systems - 1/16 to 3/32 in. (1.6 to 2.4 mm).

b. 10,000V systems - 1/8 in. (3.2 mm).

4. Make sure the leadwires from the flame rod and ignition

electrode are not too close together.

5. Replace any deteriorated leadwires.

6. If the problem cannot be eliminated, the system may

have to be changed to an ultraviolet or infrared flame

detection system.

Hot Refractory Saturation Test

(All Infrared Detectors)

Test to be sure that radiation from hot refractory does not

mask the flickering radiation of the flame itself.

Start the burner and monitor the flame signal during the

warmup period. A decrease in signal strength as the

refractory heats up indicates hot refractory saturation. If

saturation is extreme, the flame signal will drop below 1.25

Vdc and the system will shut down as though a flame failure

has occurred.

If hot refractory saturation occurs, the condition must be

corrected. Add an orifice plate in front of the cell to restrict the

viewing area, try to lengthen the sight pipe or decrease the

pipe size (diameter). Continue adjustments until hot refractory

saturation is eliminated.

Hot Refractory Hold-In Test (Rectifying

Photocell or All Infrared Detectors)

Test to be sure hot refractory is not delaying the flame

detection system response to a flameout. This condition can

delay response to flame failure and also can prevent a

system restart as long as hot refractory is detected.

To check rectifying photocells for hot refractory hold-in,

operate the burner until the refractory reaches its maximum

temperature. Then terminate the firing cycle by lowering the

set point of the operating controller or setting the Fuel

Selector Switch to OFF. Do not open the master switch.

Visually observe when the burner flame or FLAME LED goes

out. If this takes longer than .8 or 3 seconds (depending on

the FFRT of the amplifier), the photocell is sensing hot

refractory. This condition must be corrected as described in

the last paragraph of this test.

Infrared (lead sulfide) detectors can respond to infrared rays

emitted by a hot refractory, even when the refractory has visibly

stopped glowing. Infrared radiation from a hot refractory is

steady, but radiation from a flame has a flickering characteristic.

The infrared detection system responds only to flickering

infrared radiation; it can reject a steady signal from hot

refractory. The refractory steady signal can be made to

fluctuate if it is reflected, bent or blocked by smoke or fuel mist

within the combustion chamber. Be careful when applying an

infrared system to verify its response to flame only.

To check infrared (lead sulfide) detectors for hot refractory

hold-in, operate the burner until the refractory reaches its

maximum temperature. If the installation has a multi-fuel

burner, burn the heaviest fuel that is most likely to reflect,

bend or obscure the hot refractory steady infrared radiation.

When the maximum refractory temperature is reached, close

all manual fuel shutoff valve(s) or open the electrical circuits

of all automatic fuel valve(s). Visually observe when the

burner flame or FLAME LED goes out. If this takes more than

three seconds, the infrared detector is sensing hot refractory.

Immediately terminate the firing cycle. Lower the set point to

the operating controller, or set the Fuel Selector Switch to

OFF. Do not open the master switch.

NOTE: Some burners continue to purge oil lines between

the valve(s) and nozzle(s) even though the fuel

valve(s) is closed. Terminating the firing cycle

(instead of opening the master switch) allows

purging of the combustion chamber. This reduces

fuel vapor buildup in the combustion chamber

caused by oil line purging.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

25

If the detector is sensing hot refractory, the condition must be

corrected. Add an orifice plate in front of the cell to restrict the

viewing area of the detector. If this does not correct the

problem, resight the detector at a cooler, more distant part of

the combustion chamber. While resighting the detector, be

aware that it must also properly sight the flame. When using

infrared detector, try lengthening the sight pipe or decreasing

the pipe size (diameter). For details, refer to the detector

Instructions and the equipment Operating Manual. Continue

adjustments until hot refractory hold-in is eliminated.

Ultraviolet Sensor, Ignition Spark Response

Test (All Ultraviolet Detectors)

Test to be sure that the ignition spark is not actuating the

FLAME LED:

1. Close the pilot and main burner manual fuel shutoff

valve(s).

2. Start the burner and run through the PILOT IGN period.

Ignition spark should occur, but the flame signal should

not be more than 0.5 Vdc and the FLAME LED should

not turn on.

3. If the flame signal is higher than 0.5 Vdc and the

FLAME LED does come on, consult the equipment

Operating Manual and resight the detector further out

from the spark, or away from possible reflection. It may

be necessary to construct a barrier to block the ignition

spark from the detector view. Continue adjustments

until the flame signal due to ignition spark is less than

0.5 Vdc.

NOTE: The Honeywell Q624A Solid State Spark Generator

prevents detection of ignition spark when properly

applied with the C7027, C7035 or C7044 Minipeeper

Ultraviolet Flame Detectors. The Q624A is only for

use with gas pilots.

Response To Other Ultraviolet Sources

Under certain conditions, an ultraviolet detector responds to

other ultraviolet sources as if it is sensing a flame. These

ultraviolet sources include artificial light, such as

incandescent or fluorescent bulbs, mercury and sodium vapor

lamps or daylight. To check for proper detector operation,

check the Flame Failure Response Time (FFRT) and conduct

Safety Shutdown tests under all operating conditions.

Flame Signal With Hot Combustion Chamber

(All Installations)

After all initial start-up tests and burner adjustments are

completed, operate the burner until the combustion chamber

is at the maximum expected temperature. Observe the

equipment manufacturer warmup instructions. Recycle the

burner under these hot conditions and measure the flame

signal. Check the pilot alone, the main burner flame alone,

and both together (unless monitoring only the pilot flame

when using an intermittent pilot, or only the main burner flame

when using DSI).

Check the FFRT of the Flame Amplifier. Lower the set point of

the operating controller and observe the time it takes for the

burner flame to go out. This should be within .8 or 3 seconds

maximum depending on the amplifier selected.

If the flame signal is too low or unsteady, check the flame

detector temperature. Relocate the detector if the

temperature is too high. If necessary, realign the sighting to

obtain the proper signal and response time. If the response

time is still too slow, replace the Plug-in Flame Signal

Amplifier. If the detector is relocated or resighted, or the

amplifier is replaced, repeat all required Checkout tests.

Safety Shutdown Tests (All Installations)

Perform these tests at the end of Checkout after all other

tests are complete. If used, the external alarm should turn on.

Press the RM7895 reset pushbutton to restart the system.

1. Close the Airflow Interlock during PREPURGE, PILOT

IGN, MAIN IGN or RUN period.

a. Safety shutdown occurs if the Airflow ILK Switch

Failure configuration jumper (JR3) is clipped.

2. Detect flame 40 seconds after entry to STANDBY. Detect

flame 30 seconds during measured PREPURGE time.

a. Simulate a flame to cause the flame signal voltage

level to be at least 1.25 Vdc for 40 seconds after

entry to STANDBY and also simulate a flame

signal for 30 seconds during PREPURGE.

b. Safety shutdown occurs.

3. Failure to ignite pilot.

a. Close the pilot and main fuel manual shutoff

valve(s).

b. Depress the reset push button.

c. Start the system.

d. Automatic pilot valve(s) should be energized but

the pilot cannot ignite.

e. Safety shutdown occurs.

4. Failure to ignite main.

a. Open the manual pilot valve(s); leave the main

fuel manual shutoff valve(s) closed.

b. Depress the reset pushbutton.

c. Start the system.

d. Pilot should ignite and the flame signal should be

at least 1.25 Vdc but the main burner cannot light.

e. Close the manual pilot valve(s).

f. Flame signal should drop below 1.25 Vdc within

.8 or 3 seconds (depending on the FFRT of the

amplifier) after the pilot goes out.

g. Safety shutdown occurs.

5. Loss of flame during RUN.

a. Open the main fuel manual shutoff valve(s). The

manual pilot shutoff valve(s) must also be opened.

b. Depress the reset push button.

c. Start the system. Startup should be normal and

the main burner should light normally.

d. After the sequence is in the normal RUN period

for at least ten seconds with the main burner

firing, close the manual main and pilot fuel shutoff

valve(s) to extinguish the main burner flame.

e. The flame signal should drop below 1.25 Vdc

within .8 or 3 seconds (depending on the FFRT of

the amplifier) after the main flame goes out.

f. Safety shutdown occurs.

IMPORTANT

1. If the EC7895 or RM7895 fails to shut down on

any of these tests, take corrective action (refer to

Troubleshooting, EC7895 or RM7895 diagnostics

and return to the beginning of all Checkout tests).

2. When all Checkout tests are complete, reset all

switches to original states.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 26

TROUBLESHOOTING

EC7895 or RM7895 System Diagnostics

Troubleshooting control system equipment failures is easier

with the 7895 self-diagnostics and first-out annunciation. In

addition to an isolated spst alarm relay (audible annunciation),

the 7895 provides visual annunciation by displaying the

ALARM LED.

Self-diagnostics of the 7895 enable it to detect and annunciate

both external and internal system problems. Ex-ternal faults

such as interlock failures, flame failures and false flame signals

are annunciated by the 7895, which energizes the ALARM LED

or by using the optional Keyboard Display Module. The 7800

SERIES provides a System Annunciation Diagnostics and

Troubleshooting manual, form 65-0118.

The 7895 provides diagnostic information to aid the service

mechanic to obtain information when troubleshooting the

system, see Table 6.

The optional Keyboard Display Module displays sequence

status messages indicating: STANDBY, PRE-PURGE, PILOT

IGN, MAIN IGN and RUN. The selectable messages also

provide visual indication, current status and historical status

of the equipment such as: Flame Signal, Total Cycles, Total

Hours, Fault History, and Diagnostic Information. With this

information most problems can be diagnosed without

extensive trial and error testing. Information available in the

Diagnostic Information file includes: Device Type, Device

Suffix, Software Revision, Manufacturing Code, Flame

Amplifier Type, Flame Failure Response Time, Selectable

Jumper Configuration Status, and Terminal Status.

Diagnostic Information Index

The EC7895 or RM7895 with the optional Keyboard Display

Module can monitor input/output terminals and can display

the status of the terminal at the VFD (example; Pilot Valve T8

ON<), see S7800A Keyboard Display Module Specifications.

A complete terminal description and number are provided.

The display will show the actual status of the terminal. If

voltage is detected at the terminal, ON is displayed; but if no

voltage is detected at the terminal, OFF is displayed.

Historical Information Index

The EC7895 or RM7895 has nonvolatile memory that allows

the Relay Module to retain Historical Information for the six

most recent lockouts. Each of the six lockout files retains the

cycle when the fault occurred, the hour of operation when the

fault occurred, and the fault message and burner status when

the fault occurred. The Historical Information can be viewed

by the optional S7800A Keyboard Display Module

Specifications.

SERVICE NOTE: A Lockout condition or restart of a EC7895

or RM7895 can be accomplished by

pressing the reset push-button on the

EC7895 or RM7895, or by pressing a

remote reset pushbutton wired through an

optional Keyboard Display Module, DATA

CONTROLBUS MODULE™, Extension

Cable Assembly or Remote Reset Module.

A power-up reset causes an electrical reset

of the EC7895 or RM7895 but does not

reset a lockout condition.

SERVICE NOTE: Remove the access slot covers on the

sides of the Q7800A,B to check voltages.

CAUTION

Reinstall access slot covers on the Q7800A,B

Subbase after performing voltage checks.

SERVICE NOTE: Maximum ambient operating temperature

of a C7012E,F Series 1 through 6 is

reduced to 125° F because of the duty

cycle operation of the 7895 Relay Module.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205

27

Table 6. Sequence And Status Hold Information.

NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type.

Sequence Status

INITIATE The LED indicates the burner status, POWER, which is a stabilization period

for the RM7895 to check for any fluctuations in AC line voltage inputs or

control input on power-up or during normal operation. The timing of the

INITIATE period is ten seconds before entering STANDBY.

If the EC7895 or RM7895 is in a HOLD status, the following conditions could exist:

INITIATE HOLD: (AC Frequency/Noise) The LED indicates the burner status, POWER, and that it is waiting for

excess line noise to clear up. The burner sequence does not advance into

STANDBY until the excess line noise, which prevents sufficient reading of

the line voltage inputs, ceases or a line frequency error is corrected.

INITIATE HOLD: (AC Line Dropout) The LED indicates the burner status, POWER, and that AC Line power has

momentarily dropped out. The burner sequence does not advance into

STANDBY until the AC line voltage stabilizes throughout the INITIATE

sequence.

INITIATE HOLD: (AC Frequency) The LED indicates the burner status, POWER, and that line frequency is

faster than the expected value. The burner sequence does not advance into

STANDBY until the line frequency returns to the proper value.

INITIATE HOLD: (Low Line Voltage) The LED indicates the burner status, POWER, and that low line voltage has

occurred. The burner sequence does not advance into STANDBY until the

line voltage is at a sufficient level for proper operating parameters.

STANDBY The LED indicates the burner status, POWER. The burner can be placed in

STANDBY by opening the burner switch or if the operating controller

indicates its set point is satisfied. If a demand is present for burner

operation, the burner sequence does not advance from STANDBY to

PURGE until the recycle limits close.

If the EC7895 or RM7895 is in a HOLD status, the following conditions could exist:

STANDBY HOLD: F/G (Flame Detected) The LEDs indicate the burner status, POWER and FLAME, and that a flame

is detected. A demand is present for burner operation. The burner sequence

does not advance to PREPURGE because a flame is detected as being

present. The sequence does not advance to PREPURGE until the flame

signal clears. If the flame signal does not clear within 40 seconds, the

RM7895 locks out.

STANDBY HOLD: T7 (Airflow Interlock) The LED indicates the burner status, POWER, and that the Air-flow Interlock

is closed. A demand is present for burner operation and the burner

sequence does not advance to PREPURGE until the Airflow Interlock

proves open.

PURGE The LED indicates the burner status, POWER, and that it is the period of

time before ignition during which time the blower motor is running. The

timing of the PURGE period is selectable.

7800 SERIES EC7895A, RM7895A RELAY MODULE

65-0205 28

Honeywell Europe S.A.

3 Avenue du Bourget

B-1140 Brussels Belgium

Honeywell Asia Pacific Inc.

Room 3213-3225

Sun Hung Kai Centre

No. 30 Harbour Road

Wanchai

Hong Kong

Home and Building Control

Honeywell Limited-Honeywell Limitée

155 Gordon Baker Road

North York, Ontario

M2H 2C9

Honeywell Latin American Division

Miami Lakes Headquarters

14505 Commerce Way Suite 500

Miami Lakes FL 33016

Helping You Control Your World®

65-0205 G.R. 1-97 Printed in U.S.A.

Home and Building Control

Honeywell Inc.

Honeywell Plaza

P.O. Box 524

Minneapolis MN 55408-0524

Table 6. Sequence And Status Hold Information.

(Continued)

NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type.

Sequence Status

If the EC7895 or RM7895 is in a HOLD condition, the following conditions could exist:

PURGE HOLD: F/G (Flame Detected) The LEDs indicate the burner status, POWER and FLAME, and that a flame

is detected. The burner sequence does not advance through PREPURGE

because a flame is detected as being present. The sequence holds, waiting

for the flame signal to clear. If the time exceeds 30 seconds, the EC7895 or

RM7895 locks out.

PURGE HOLD: T7 (Airflow Interlock) The LED indicates the burner status, POWER, and that the Air-flow Interlock

is not closed. The sequence does not advance to ignition until the Airflow

Interlock proves closed. If this time exceeds a 30 second HOLD, the

EC7895 or RM7895 locks out.

PILOT IGN The LEDs indicate the burner status, POWER, PILOT and FLAME, which is

the period of time the EC7895 or RM7895 permits the pilot valve to be open

and the pilot flame to be established.

If the EC7895 or RM7895 is in a HOLD status, the following condition could exist:

MAIN IGN The LEDs indicate the burner status, POWER, PILOT, FLAME and MAIN,

which is the period of time the EC7895 or RM7895 permits the main valve to

be open and the main flame to be established.

RUN The LEDs indicate the burner status, POWER, PILOT, FLAME and MAIN,

which is the period of time after the Ignition Trials and before the operating

controller set point is reached. During this time, the burner is firing under the

control of the operating controller (EC7895 or RM7895A).

RUN The LEDs indicate the burner status, POWER, FLAME and MAIN, which is

the period of time after the Ignition Trials and before the operating controller

set point is reached.

RESET/ALARM TEST The LED indicates the burner status, POWER and ALARM. This condition

indicates the reset push button is pressed. If it is held for more than four

seconds, the alarm output is energized. The alarm output will be de-

energized after the reset pushbutton is released.

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