Greenheck 7800 User Manual

RM7895A,B,C,D/EC7895A,C;

RM7896A,B,C,D

7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION

The RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D are microprocessor-based integrated burner controls for automatically fired gas, oil, or combination fuel single burner applications. They are intended to replace the R4795 and R7795 Primary Controls. The RM7895A,B,C,D/EC7895A; RM7896A,B,C,D systems consist of a relay module, subbase, amplifier, and purge card. Options include keyboard display module (KDM), Personal Computer Interface, Data ControlBus Module™, remote display mounting, expanded annunciator and Combustion System Manager® Software.

Functions provided by the RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D include automatic burner sequencing, flame supervision, system status indication, system or selfdiagnostics and troubleshooting. The RM7896 provides a postpurge function.

This document provides installation and static checkout instructions. Other applicable publications are: 63-2278: Q7700 Network Interface Unit Product Data. 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. 65-0102 ZM7850A Combustion System Manager“

Operating Instructions. 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 Product Data.

SPECIFICATIONS

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:

RM7895/RM7896:

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. IRI Acceptable. Federal Communications Commission: Part 15, Class B,

Emissions.

EC7895A,C: Factory Mutual Approved.

INSTALLATION

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 the 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.

WARNING

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

Follow applicable safety requirements when installing a control on a burner to prevent death or severe injury.

Electrical Ratings (See Table 3):

Voltage and Frequency:

RM7895/RM7896: 120 Vac (+10/-15%), 50/60 Hz (± 10%). EC7895A,C: 220/240 Vac (+10%/-15%), 50/60 Hz (±10%)

Power Dissipation: 10W maximum. Maximum Total Connected Load: 2000 VA. Fusing Total Connected Load: 20A maximum, type FRN or

equivalent.

CAUTION

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

Disconnect power supply before beginning installation.

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RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D 7800 SERIES RELAY MODULES

IMPORTANT

1. Wiring connections for the relay modules are unique; refer to Fig. 2 and 3 or the appropriate Specifications for proper subbase wiring.

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

3. Wiring must comply with NEC Class 1 (Line Voltage) wiring.

4. Loads connected to the RM7895A,B,C,D/ EC7895A,C; RM7896A,B,C,D must not exceed those listed on the RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D label or the Specifications; see Table 1.

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 installed and used in accordance with the instructions, can cause interference with radio communications. It has been tested and found to comply with the limits 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 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 Communications.

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

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 service, installation, access or removal of the RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D, expanded annunciator, keyboard display module, 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. Then drill the pilot holes.

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

Wiring Subbase

CAUTION

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

Disconnect the power supply before beginning installation.

The internal block diagram of the RM7895A,B,C,D/ EC7895A,C;RM7896A,B,C,D is shown in Fig. 1.

1. For proper subbase wiring and sequence chart, refer to Fig. 2 and 3.

2. For remote wiring of the Keyboard Display Module, refer to the Specifications for the Keyboard Display Module (65-0090), Network Interface Unit (63-2278), Data ControlBus Module™ (65-0091) or Extension Cable Assembly (65-0131).

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

4. All wiring must comply with all applicable electrical codes, ordinances and regulations. Wiring, where required, must comply with NEC, Class 1 (Line Voltage) wiring.

5. For recommended wire size and type, see Table 1.

6. For recommended grounding practices, see Table 2.

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RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D 7800 SERIES RELAY MODULES

RUN/TEST SWITCH

RESET PUSHBUTTON

STATUS LEDs

LIMITS

DDL

DDL COMMUNICATIONS

CONFIGURATION JUMPERS

SAFETY RELAY CIRCUIT

CONTROLLER

6K1 3K1

OPTIONAL KEYBOARD DISPLAY MODULE

RS485

REMOTE

RESET

L1 (HOT)

MICROCOMPUTER

RELAY DRIVE CIRCUIT

LOCKOUT INTERLOCK (INCLUDING AIRFLOW SWITCH)

RM7895, RM7896: 120 VAC, 50/60 HZ. EC7895A,C: 220-240 VAC, 50/60 HZ.

PLUG-IN PURGE TIMER CARD

FLAME SIGNAL

PLUG-IN

TEST

FLAME AMPLIFIER

2K 3K 4K 5K

6K 7K

POWER SUPPLY

1K1 2K1 5K1

INDICATES FEEDBACK SENSING TO RELAY STATUS FEEDBACK AND LINE VOLT INPUTS

FIELD WIRING INTERNAL WIRING

4K1

7K1

2K2

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

CONTROL POWER

9 4 3

TEST JACK

F G

IGNITION

PILOT

2ND STAGE VALVE

MAIN VALVE

BLOWER

ALARM

PROVIDE DISCONNECT MEANS AND

OVERLOAD PROTECTION AS REQUIRED.

FOR EC7895, MUST USE A 220 TO 240 VAC TO 120 VAC, 10 VA MINIMUM STEPDOWN TRANSFORMER (NOT PROVIDED) MUST BE USED TO DRIVE THE SHUTTER.

Fig. 1. Internal block diagram of RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D

(see Fig. 2 and 3 for detailed wiring instructions).

M5110F

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RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D 7800 SERIES RELAY MODULES

Q7800

FOR DIRECT SPARK IGNITION (OIL OR GAS)

IGNITION

TRANSFORMER

MAIN VALVE

MASTER SWITCH

L1 (HOT)

LINE VOLTAGE ALARM

BURNER MOTOR (BLOWER)

BURNER CONTROLLER/LIMITS

LOCKOUT INTERLOCK (INCLUDING AIRFLOW SWITCH)

INTERMITTENT PILOT/IGNITION

MAIN FUEL VALVE(S)

IGNITION

FLAME DETECTOR

(L1)

LED DISPLAY

BURNER START

OPERATING CONTROLS AND INTERLOCKS

FLAME SIGNAL

RM7895, RM7896: 120 VAC , 50/60 HZ; EC7895: 220-240 VAC, 50/60 HZ POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

FOR EC7895, A 220 TO 240 VAC TO 120 VAC, 10 VA MINIMUM STEPDOWN TRANSFORMER (NOT PROVIDED) MUST BE USED TO DRIVE THE SHUTTER.

INITIATE

AIRFLOW SW CHECK

STANDBY

00 00 00

START

POWERPOWER

SAFE START CHECK

POWER

LIMITS AND BURNER CONTROLLER CLOSED

TIMED PURGE

BURNER/BLOWER MOTOR

LOCKOUT INTERLOCK CLOSED

Fig. 2. Wiring subbase and sequence chart for RM7895A,B/EC7895A; RM7896A,B.

PFEP

4 OR 10 SEC

POWER PILOT FLAME MAIN

ALARM ALARM

POWER POWER PILOT

FLAME MAIN

IGN

IGN/ PILOT

SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING. FOR RM7895A1048 (ONLY), IGNITION TERMINAL 10

IS DE-ENERGIZED WHEN FLAME IS PROVEN. AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895B,RM7896B.

RM7896A,B ONLY.

RUN

MAIN VALVE

FLAME PROVING

POWER PILOT

FLAME MAIN ALARM

L1 TO 6

TO 7

POST PURGE

15 SEC

STANDBY

POWER

AFSC

SSC

M15123A

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