CaptiveAire EC7890A Installation Manual

RM7890A,B,C/EC7890A,B

7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION

The Honeywell RM78 90A,B,C/EC7890A ,B Relay Mod ules are microprocessor based integrated burner controls for semi-automatically fired gas, oil, or combination fuel single burner applications. The RM/EC7 890 Rel ay Mo dul e is intended to replace the RA890F,G, H Protectorelay® Primary Control. The RM/EC7890 System consists of a relay module, subbase, and amplifier. Options include Personal Computer Interface, keyboard display module (KDM), Data ControlBus Module™, remote display mounting, first-out expanded annunciator and Combustion System Manager¨ Software.

Functions the RM/EC7890 provides include automatic burner sequencing, flame supervision, system status indication, system or self-diagnostics and troubleshooting.

This document provides installation and static checkout instructions. Other applicable publications are:

63-2278: Q7700 Network Interface Unit. 65-0084: Q7800A,B 22-Terminal Wiring Subbase Product Data. 65-0090: S7800A Keyboard Display Module Product Data. 65-0091: S7810A Data ControlBus Module™ Product Data. 65-0095: S7820 Remote Reset Module Product Data. 65-0097: 221729C Dust Cover Packing Instructions. 65-0101: S7830 Expanded Annunciator Product Data. 65-0109: R7824, R7847, R7848, R7849, R7861, R7886 Flame Amplifiers for the 7800 SERIES Product Data. 65-0131: 221818A Extension Cable Assembly Product Data. 65-0229: 7800 SERIES Relay Modules Checkout and Troubleshooting.

SPECIFICATIONS

Electrical Ratings (See Table 3):

Volta ge and Frequency: RM7890: 120 Vac (+10/-15%), 50/60 Hz (±10%). EC7890: 220/ 240 Vac (+10%/-15%), 50/60 Hz (±10%).

Power Dissipation: 10W maximum. Maximum Total Connected Load: 2000 VA. Fusing Total Connected Load: 2 0A max imum , type FRN or

equivalent.

Environmental Ratings:

Ambient Temperature:

Operating: -40°F to +140°F (-40°C to +60°C).

Storage: -40°F to +150°F (-40°C to +66°C). Humidity: 85% relative humidity continuous, noncondensing. Vibration: 0.5G environment.

Approvals:

RM7890A,B:

Underwriters Laboratories Inc. Listed: File No. MP268,

Guide No. MCCZ. Canadian Standards Association Certified: LR9S329-3. Factory Mutual Approved: Report No. J.I.1V9A0.AF. Industrial Risk Insurers: Acceptable. Federal Communications Commission: Part 15, Class B,

Emissions.

RM7890C:

Underwriters Laboratories Inc.: Component Recognized.

EC7890:

Factory Mutual: Approved.

66- 1089-3

RM7890A,B,C/EC7890A,B 7800 SERIES RELAY MODULES

INSTALLATION

WARNING

Fire or Explosion Hazard. Can cause property damage, serious injury, or death.

T o preven t possible hazardous bur ner operation, verif y safety requirements eac h tim e a co ntro l is installed on a burner.

WARNING

Electrical Shock Hazard. Can cause personal injury, death or equipment damage.

Disconnect the power supply before beginning installation.

When Installing this Product...

Read these instructio ns c aref ull y. Failure to follow them could damage the product or cause a hazardous condition.

Check the ratings given in the instructions and marked on the product to make sure the product is suitable for the application.

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

After installation is complete, check out the product operation as provided in these instructions.

IMPORTANT

1. Wiring connecti ons for the relay m odules are unique; refer to Fig. 2 or the appropriate Specifications for individual subbase wiring.

2. Wiring must comply with all applicable codes, ordinances and regulations.

3. Wiring must comp ly with N EC Clas s 1 (Line Voltage) wiring.

4. Loads connected to the RM/EC7890 must not exceed those listed on the RM/EC7890 label or the Specifications; see Tables 3, 4, and 5.

5. Limits and interlocks must be rated to simultaneously carry and break current to the ignition transformer, pilot valve, and main fuel valve(s).

6. All external timers must be listed or componentrecognized by authorities who have proper jurisdiction.

7. 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).

8. Two flame detectors can be connected in parallel with the exception of Infrared Flame Detectors (C7015).

9. This equipment generates, uses and can radiate radio frequency energy and, if not in stall ed and us ed in accordance with the instructi ons, can caus e interference with radio communications. It has been tested and found to com ply with th e lim its 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 can cause interference, in which case, the users, at their own expense, may be required to take whatever measures are required to correct this interference.

10.This digital apparatus does not exceed the Class B limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communica tio ns .

Location

Humidity

Install the relay module where the relative humidity never reaches the saturation point. The relay module is designed to operate in a maximum 85% relative humidity continuous, noncondensing, moisture environment. Condensing moisture can cause a safety shutdown.

Vibration

Do not install the relay module where it can be subjected to vibration in excess of 0.5G continuous maximum vibration.

Weather

The relay module is not designed to be weather tight. When installed outdoors, protect the relay module in an approved weather-tight enclosure.

Mounting Wiring Subbase

See Fig. 1 for the intern al blo ck dia gram o f RM/EC78 90 Rel ay Module.

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.

Select a location on a w all, burner or electrical panel. The Q7800 can be mounted directly in the control cabinet. Be sure to allow adequate clearance for servicing, installation, access or removal of the RM/EC7890, expanded annunciator, KDM, flame amplifier, flame amplifier signal voltage probes, run/test switch, electrical signal voltage probes and electrical field connections.

For surface mounting, u se the back of t he sub base a s a template to mark the four screw locations. Drill the pilot holes.

Securely mount the subbase using four no. 6 screws (not provided).

66-1089—3 2

RM7890A,B,C/EC7890A,B 7800 SERIES RELAY MODULES

Wiring

WARNING

Electrical Shock Hazard. Can cause personal injury or equipment damage.

Disconnect the power supply before beginning installation.

For proper subbase wiring and sequence chart, refer to Fig. 2.

For proper remote wiring of the KDM, refer to the Specifications for the KDM (65-009 0), Network Interface Unit (63-2278), Data ControlBus Module™ (65-0091) or Extension Cable Assembly (65-0 13 1).

Disconnect the power supply from the main disconnect before beginning installation to prevent electrical shock and equipment damage . More than one disconnec t can be required.

All wiring must comply with all applicable electrical codes, ordinances and regulations. Wiring, where required, must com ply wi th NEC, Clas s 1 (Li ne Voltage) wiring.

Use recommended wire routing of leadwires: a. Do not run high vol tag e ig ni tion transformer wires in

the same conduit with the flame detector, Data ControlBus Module™, or Remote Reset Module wiring.

b. Do not route flame detector, Data ControlBus

Module™, or Remote Reset Module leadwires in conduit with line voltage circuits.

c. Enclose fla me detector leadwires without arm or

cable in metal cable or conduit.

d. Follow directions in flam e detector, Data ControlBus

Module™, or Remote Reset Module Instructions. For KDM (KDM), because the KDM is powered from a low voltage, energy limited source, it can be mounted outside of a control panel if it is protected from mechanical damage.

NOTE: Use 13 Vdc power supply any time more than one

10.

11.

KDM is used. A maximum of two KDM, Data ControlBus Modules™ or S7810B Multi-Drop Switch Modules are allowed in any combination.

Use maximum wire lengths: a. RM/EC7890 leadwires: The maximum leadwire

length is 300 feet (91 meters) to terminal inputs (Control, Running/Lock out Interlo ck ).

b. Flame Detector leadwires: The maximum flame

sensor leadwire len gth i s li mi ted by the flam e s ign al strength.

c. Remote Reset leadwires: The maximum length of

wire is 1000 feet (305 meters) to a Remote Reset pushbutton.

d. Data ControlBus Module™: The maximum Data

ControlBus Module™ cable length depends on the number of system modules connected, the noise conditions and the c able used. The maximum l ength of all Data ControlBus Module™ interconnecting

wire is 4000 feet (1219 meters). For recommended wire size and type, see Table 1. The KDM, Data ControlBus Module™ (for remote mounting or communications) or Communication Interface ControlBus™ Modu le m ust b e wired in a dais y chain configuration, 1(a)-1(a), 2(b)-2(b), 3(c)-3(c). The order of interconnection of all the devices listed above is not important. Be aware that modules on the closest and farthest end of the daisy chain configuration string require a 120 ohm (1/4 watt minimum) resistor termination across terminals 1 and 2 of the electrical connectors for connections over 100 feet (31 meters). For recommended grounding practices, see Table 2. Be sure loads do not exceed the te rmi nal ratin gs . Refer to the label on the RM/EC7890 or to the terminal ratings in Table 3.

Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Numbers

Line voltage terminals 14, 16, or 18 AWG copper conductor, 600

volt insulation wire.

Keyboard Display Module 22 AWG two-wire twisted pair with ground,

Data ControlBus Module™ 22 AWG two-wire twisted pair with ground,

Remote Reset Module 22 AWG two-wire twisted pair, insulated for

Communications Interf ace C ontro lBus™ Module

13 Vdc full-wave rectified transformer power input.

or five-wire.

low voltage. 22 AWG two-wire twisted pair with ground. Belden 8723 shielded cable or

18 AWG wire insulated for voltages and temperatures for given application.

3 66-1089—3

TTW60C, THW75C, THHN90C.

Belden 8723 shielded cable or equivalent.

—

equivalent. TTW60C, THW75C, THHN90C.

RM7890A,B,C/EC7890A,B 7800 SERIES RELAY MODULES

Table 2. Recommended Grounding Practices.

Ground Type Recommended Practice

Earth ground (subbase and relay module).

Use to provide a connection between the subbase and the control panel of the equipment. Earth grou nd mu st b e c ap abl e of conducting enough current to blow the 20A fuse (or breaker) in the event of an internal short circuit.

Use wide straps or brackets to provide minimum length, maximum surface area ground conductors. If a leadwire is required, use 14 AWG copper wire.

Make sure that mechanically tightened joints along the ground path are free of nonconductive coatings and protected against corrosion on mating surfaces.

Signal ground (Keyboard Display Module, Data ControlBus Module™, Communications Interface

Use the shield of the signal wire to ground the device to the signal ground terminals— 3(c)—of each device. Connect the shield at both ends of the daisy chain to earth ground.

ControlBus™ Module).

Table 3. Terminal Ratings.

Terminal Number Description Ratings (RM7890A,B,C) Ratings (EC7890A,B)

G Flame Sensor Ground — — Earth G

Earth Ground

——

L2(N) Line Voltage Common — — 3 Line Voltage Supply (L1) 120 Vac (+10%/-15%), 50 or

60 Hz (±10%).

220-240 Vac (=10%/-15%), 50 or 60 Hz (±10%).

4 Alarm 120 Vac, 1A pilot duty. 220-240 VAc, 1A pilot duty. 5Unused — — 6 Burner Controller and Limits 120 Vac, 8A run, 43A inrush. 220-240 Vac, 5A (maximum). 7Unused — — 8 Pilot Valve/Ignition.

9 Main Fuel Valve. 10 Ignition

120 Vac. 120 Vac.

c c

120 Vac, 4.5A ignition.

220-240 Vac, 4A at P.F. = 0.5, 20A inrush. 220-240 Vac, 4A at P.F. = 0.5, 20A inrush. 220-240 Vac, 4A at P.F. = 0.2.

F(1 1) Flame Sensor 60 to 220 Vac, current limited. 60 to 220 Vac, current limited. 12 to 21 Unused. — — 22 Shutter 120 Vac, 0.5A (RM7890B).

The RM7890 must have an earth ground providing a connection between the subbase and the control panel or the equipment.

220-240 Va c (EC7890B only).

The earth ground wire must be ca pa ble of con ductin g the current to blow the 20A fuse (or breaker) in even t of an in tern al s hort circuit. The RM78 90 nee ds a l ow i mp eda nc e g roun d c on nec ti on to the equipment fra me w hi ch, in tur n, needs a low impe da nce connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be made with minimum length conductors having 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.

2000 VA maximum connected load to the RM7890 Assembly.

See Tables 4 and 5 for device load combinations.

Requires 220-240 to 120 Vac, 10 Va minimum stepdown transformer to drive the shutter.

66-1089—3 4

+ 8 hidden pages