Grieve Corporation EC7895C Installation 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
self-diagnostics and troubleshooting. The RM7896 provides
a postpurge function.

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

Publication

No. Product

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, R7851,

R7861, R7886 Flame Amplifiers for the
7800 Series Product Data

Publication

No. Product

65-0131 221818A Extension Cable Assembly

Product Data

65-0229 7800 SERIES Relay Modules Checkout and

Troubleshooting Product Data.

65-0092 QS7800A ControlBus™ Module, Standard

65-0227 QS7800B ControlBus™ Module, Multidrop

SPECIFICATIONS

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: 15A Fast Blow, type SC 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:

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.

66-1090-06

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

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.

WARNING

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

Disconnect power supply before beginning installation.

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, ordi-

nances 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 component-rec-

ognized 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).

66-1090—06 2

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

Wiring Subbase

WARNING

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

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

PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.

2

LOCKOUT IF JUMPER JR2 REMOVED.

INDICATES FEEDBACK SENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLT INPUTS

FIELD WIRING

INTERNAL WIRING

OPTIONAL KEYBOARD
DISPLAY MODULE

DDL

DDL
COMMUNICATIONS

M23996

1

RS485

2

3

REMOTE
RESET

5

RUN/TEST
SWITCH

RESET
PUSHBUTTON

STATUS LEDs

LIMITS

CONFIGURATION
JUMPERS

SAFETY RELAY
CIRCUIT

CONTROLLER

6K1

3K1

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.

1

MICROCOMPUTER

RELAY
DRIVE
CIRCUIT

6

INTERLOCK
(INCLUDING
AIRFLOW SWITCH)

2

L1
(HOT)

1K

L2

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

7

4K1

2K2

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

CONTROL
POWER

10

8

9

4

3

TEST
JACK

F

G

22

IGNITION

PILOT

MAIN VALVE

BLOWER

ALARM

L2

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).

3 66-1090—06

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

Q7800

FOR DIRECT SPARK IGNITION

12

(OIL OR GAS)

13

14

15

16

17

18

19

20

21

22

10

8

2

MASTER
SWITCH

IGNITION
TRANSFORMER

MAIN VALVE

LINE VOLTAGE ALARM

BURNER MOTOR
(BLOWER)

BURNER
CONTROLLER/LIMITS

LOCKOUT INTERLOCK
(INCLUDING
AIRFLOW SWITCH)

INTERMITTENT
PILOT/IGNITION

MAIN FUEL VALVE(S)

IGNITION

FLAME DETECTOR

4

G

L2

3

4

(L1)

5

6

7

8

9

10

F

3

L1
(HOT)

L2

L2

1

LED
DISPLAY

BURNER
START

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

1

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.

2

3

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

6

00 00 00

STANDBY

POWERPOWER

START

POWER

LIMITS AND BURNER CONTROLLER CLOSED

SAFE START CHECK

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

10

IGN/ PILOT

SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.

4

FOR RM7895A1048 (ONLY), IGNITION TERMINAL 10

5

IS DE-ENERGIZED WHEN FLAME IS PROVEN.

6

AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895B,RM7896B.

RM7896A,B ONLY.

7

RUN

5

MAIN VALVE

6

FLAME
PROVING

POWER

PILOT

FLAME

MAIN

ALARM

4

8

L1

TO

POST PURGE

9

TO

6

7

15 SEC

7

7

STANDBY

POWER

AFSC

SSC

M23997

66-1090—06 4

LINE VOLTAGE
ALARM

BURNER MOTOR
(BLOWER)

BURNER
CONTROLLER/LIMITS

LOCKOUT INTERLOCK
(INCLUDING
AIRFLOW SWITCH).

10 SEC. INTERRUPTED
PILOT/IGNITION

MAIN FUEL VALVE(S)

IGNITION

FLAME DETECTOR

4

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

Q7800

FOR DIRECT SPARK IGNITION
(OIL OR GAS)

IGNITION

10

TRANSFORMER

8

9

MAIN VALVE

2

DELAYED
(2ND STAGE)
MAIN VALVE

MASTER
SWITCH

L1
(HOT)

L2

L2

1

(L1)

12

13

14

15

16

17

18

19

20

21

22

G

L2

3

4

5

6

7

8

9

10

F

3

00 00 00

LED
DISPLAY

BURNER
START

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

1

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

2

DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

3

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

SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.

4

INITIATE

AIRFLOW SW. CHECK

5

STANDBY

POWERPOWER

START

POWER

LIMITS AND BURNER CONTROLLER CLOSED

SAFE START CHECK

TIMED
PURGE

POWER

PILOT

FLAME

MAIN

ALARM ALARM

BURNER/BLOWER MOTOR

LOCKOUT INTERLOCK CLOSED AFSC

7

PFEP

4 OR 10 SEC

IGN.

10 SEC. IGN./ PILOT

MFEP

POWER POWER

PILOT

FLAME

MAIN

POWER

PILOT

FLAME

MAIN

ALARM

10

8

2ND STAGE MAIN

FLAME PROVING

5

AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895D, RM7896D.

6

RM7896C,D ONLY.

7

RM7895C1020, RM7896C1036 PFEP 10 SECONDS ONLY;
RM7895C1053 PFEP 4 SECONDS ONLY, 3 SECONDS ONLY SOFTWARE
REVISION 4151.

8

RM7895C1020, RM7896C1036: DURING FIRST 8 SECONDS OF PFEP,
WHEN A FLAME SIGNAL IS DETECTED, TERMINAL 10 IS DE-ENERGIZED.
IF FLAME SIGNAL IS LOST, TERMINAL 10 WILL RE-ENERGIZE.

RUN

4

8

MAIN VALVE

L1

6

TO

TO

7

POST PURGE

POWER

PILOT

FLAME

MAIN

ALARM

9

21

6

15SEC

6

STANDBY

POWER

6

SSC

M23998

Fig. 3. Wiring subbase and sequence chart for RM7895C,D/EC7895C; RM7896C,D.

5 66-1090—06

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

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,

TTW60C, THW75C, THHN90C.

moisture-resistant wire.

Keyboard Display Module 22 AWG two-wire twisted pair with ground, or five-wire. Belden 8723 shielded cable or equivalent.

a

Data ControlBus™ Module

22 AWG two-wire twisted pair with ground, or five-wire. Belden 8723 shielded cable or equivalent.

Remote Reset Module 22 AWG two-wire twisted pair, insulated for low voltage. —

Communications Interface
ControlBus™ Module

a

13 Vdc full-wave rectified
transformer power input.

a

The KDM, Data ControlBus™ Module (for remote mounting or communications) or Communication Interface ControlBus™

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

18 AWG wire insulated for voltages and temperatures

TTW60C, THW75C, THHN90C.

for given application.

Module must be wired in daisy 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).

Table 2. Recommended Grounding Practices.

Ground Type Recommended Practice

Earth ground (subbase and relay
module).

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

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

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

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

Use the shield of the signal wire to ground the device to the signal ground terminal 3(c) of

each device. Connect the shield at both ends of the daisy chain to earth ground.
Communications Interface
ControlBus™ Module.

7. Recommended wire routing of leadwires:
a. Do not run high voltage ignition 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 flame detector leadwires without armor

cable in metal cable or conduit.

d. Follow directions in flame detector, Data

ControlBus™ Module, or Remote Reset Module

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 cable used. The maximum length
of all Data ControlBus™ Module interconnecting
wire is 4000 feet (1219 meters).

10. Be sure loads do not exceed the terminal ratings. Refer
to the label on the RM7895A,B,C,D/EC7895A,C;
RM7896A,B,C,D or to the terminal ratings in Table 3.

Instructions.

8. 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.

Final Wiring Check

1. Check the power supply circuit. The voltage and
frequency tolerance must match those of the

NOTE: A 13 Vdc power supply must be used any time more

than one KDM is used.

RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D. A
separate power supply circuit can be required for the
RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D. Add

9. Maximum wire lengths:
a. RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D

leadwires: The maximum leadwire length is 300 feet
to terminal inputs (Control, Running/Lockout
Interlock).

b. Flame Detector leadwires: The maximum flame

the required disconnect means and overload protection.

2. Check all wiring circuits and complete Static Checkout
in Table 6 before installing the RM7895A,B,C,D/
EC7895A,C; RM7896A,B,C,D on the subbase.

3. Install all electrical connectors.

4. Restore power to the panel.

sensor leadwire length is limited by the flame signal
strength.

66-1090—06 6

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

Table 3. Terminal Ratings.

Terminal

Number Description

RM7895/RM7896 EC7895

Ratings

G Flame Sensor Ground — —

Earth G

Earth Ground

a

——

L2(N) Line Voltage Common — —

3 Alarm 120 Vac, 1A pilot duty. 220-240 Vac, 1A pilot duty.

4 Burner Motor 120 Vac, 9.8A AFL, 58.8 ALR (inrush). 220-240 Vac, 4A at PF = 0.5, 20A inrush.

5 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz

(±10%).

b

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

6 Burner Controller and Limits 120 Vac, 1 mA. 220-240 Vac, 1 mA.

7 Lockout Interlock 120 Vac, 8A run, 43A inrush. 8A at PF = 0.5, 40A inrush, 2A at PF = 0.2.

8 Pilot Valve/Ignition

9 Main Fuel Valve

10 Ignition

120 Vac

120 Vac

120 Vac

c

c

c

220-240 Vac, 4A at PF = 0.5, 20A inrush.

220-240 Vac, 4A at PF = 0.5, 20A inrush.

220-240 Vac, 2A at PF = 0.2

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

12 to 20 Unused — —

21 2nd Stage Main Valve (EC7895C,

RM7895C,D; RM7896C,D)

120 Vac

22 Shutter 120 Vac, 0.5A

a

See Table 2.

b

2000 VA maximum load connected to RM7895A,B,C,D/EC7895A,C/RM7896A,B,C,D Assembly.

c

See Tables 4 and 5.

d

Requires 220-240 Vac, 10 VA minimum, stepdown transformer to operate the shutter.

c

220-240 Vac, 4A at PF = 0.5, 20A inrush.

220-240 Vac

d

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

Combination Number Pilot Fuel 8 Main 9 Ignition 10 Delayed Main Valve 21

1 C F No Load No Load

2 B F No Load No Load

3

a

F

No Load A No Load

4FFANo Load

5

a

F

No Load A F

6 D F A No Load

7

a

D

No Load A D

8 DDANo Load

9

a

RM7895C,D: EC7895C, RM7896C,D only, jumper terminals 8 to 9.

a

D

No Load A D

Table 5. Composition of each Combination.

ABCDF

4.5A ignition

50 VA Pilot Duty

4.5A ignition.

a

Pilot Duty refers to solenoid-type valves.

a

plus

180 VA Ignition plus
motor valves with:
660 VA inrush,
360 VA open,
240 VA hold.

2A Pilot Duty.

a

65 VA Pilot Dutya plus
motor valves with:
3850 VA inrush,
700 VA open,
250 VA hold.

7 66-1090—06

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

STATIC CHECKOUT

After checking all wiring, perform this checkout before
installing the EC7895A,C/RM7895A,B,C,D/RM7896A,B,C,D
on the subbase. These tests verify the Q7800 Wiring
Subbase is wired correctly, and the external controllers, limits,
interlocks, actuators, valves, transformers, motors and other
devices are operating properly.

WARNING

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

Close all manual fuel shutoff valve(s) before starting
these tests.

Use extreme care while testing the system. Line
voltage is present on most terminal connections when
power is on.

Ensure proper selection of configuration jumpers before
starting the burner operation.

CAUTION

Electrical Hazard.
Can cause equipment damage or failure.

Do not perform a dielectric test with the relay module
installed. Internal surge protectors can break down,
allowing relay module to fail the dielectric test and
destroy the internal lightning and high current
protection.

1. Open the master switch before installing or removing a
jumper on the subbase.

2. Before continuing to the next test, be sure to remove the
test jumper(s) used in the previous test.

3. Replace all limits and interlocks that are not operating
properly. Do not bypass limits and interlocks.

Equipment Recommended

1. Voltmeter (1M ohm/volt minimum sensitivity) set on the
0 to 300 Vac scale.

2. Two jumper wires, no. 14 wire, insulated, 12 in.
(304.8 mm) long with insulated alligator clips at both
ends.

General Instructions

1. Perform all applicable tests listed in Static Checkout,
Table 6, in the order listed.

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

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

jumper wire(s) between the subbase wiring terminals
listed in the Test Jumpers column.

4. Close the master switch before observing operation.

5. Read the voltage between the subbase wiring terminals

listed in the Voltmeter column.

6. If there is no voltage or the operation is abnormal, check
the circuits and external devices as described in the last
column.

7. Check all wiring for correct connections, tight terminal
screws, correct wire, and proper wiring techniques.
Replace all damaged or incorrectly sized wires.

8. Replace faulty controllers, limits, interlocks, actuators,
valves, transformers, motors and other devices, as
required.

9. Make sure normal operation is obtained for each
required test before continuing the checkout.

10. After completing each test, be sure to open the master
power switch and remove the test jumper(s) before pro­ceeding to the next test.

WARNING

Explosion hazard.
Can cause serious injury or death.

Be sure all manual fuel shutoff valves are closed.

Table 6. Static Checkout .

Test

Number

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

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

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

4 All 5-10 — 1. Ignition spark (if ignition

66-1090—06 8

Relay Module

Model

Test

Jumpers Voltmeter Normal Operation

starts.

2. Line voltage at terminal 7
within 10 seconds.

transformer is connected to
terminal 10).

If Operation is Abnormal,

Check Items Listed Below

2. Power connected to master switch.

3. Overload protection (fuse, circuit breaker,
etc.) has not opened power line.

2. Burner controller.

1. Burner motor circuit.
a. Manual switch of burner motor.
b. Burner motor power supply, overload
protection and starter.
c. Burner motor.

1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.

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

Table 6. Static Checkout (Continued).

Test

Number

5 All 5-8 — 1. Ignition spark (if ignition

Relay Module

Model

Test

Jumpers Voltmeter Normal Operation

transformer is connected to
terminal 8).

2. Automatic pilot valve opens
(if connected to terminal 8).

If Operation is Abnormal,

Check Items Listed Below

1. Watch for spark or listen for buzz.

2. Listen for click or feel head of valve for
activation.
a. Actuator if used.
b. Pilot valve.

NOTE: Refer to wiring diagram

6 All 5-9 — Automatic fuel valve(s) open(s). If

7 EC7895C;

RM7895C,D;
RM7896C,D

8 All 5-3 — Alarm (if used) turns on. 1. Alarm.

Final All

5-21 — Automatic second stage main fuel

using direct spark ignition, check
first stage fuel valve(s) instead of
pilot valve.

valve(s) open(s).

of system being tested.

Same as test 5. If using direct spark
ignition, check first stage fuel valve(s)
instead of pilot valve.

1. Listen for and observe operation of
second stage main fuel valve(s) and
actuator(s).

2. Valve(s) and actuator(s).

CAUTION

Equipment Damage Hazard.
Can cause equipment damage.

After completing these tests, open master switch and remove all test jumpers from subbase
terminals. Also remove bypass jumpers, if used, from low fuel pressure limits.

Mounting RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D Relay Module

1. Mount the RM7895A,B,C,D/EC7895A,C;
RM7896A,B,C,D vertically on the Q7800 Subbase or
mount horizontally with the knife blade terminals
pointing down. When mounted on the Q7800A, the
RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D must be
in an electrical enclosure.

2. When mounting in an electrical enclosure, provide ade­quate clearance for servicing, installation and removal
of the RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D,
KDM, flame amplifier, flame amplifier signal voltage
probes, electrical signal voltage probes and electrical
connections.
a. Allow an additional two inches (51 mm) below the

RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D for
the flame amplifier mounting.

b. Allow an optional three-inch (76 mm) minimum on

both sides of the RM7895A,B,C,D/EC7895A,C;
RM7896A,B,C,D for electrical signal voltage probes.

3. Make sure no subbase wiring is projecting beyond the
terminal blocks. Tuck in wiring against the back of the
subbase so it does not interfere with the knife blade ter­minals or bifurcated contacts.

IMPORTANT

The RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D
must be installed with a plug-in motion rather than a
hinge action.

4. Mount the RM7895A,B,C,D/EC7895A,C;
RM7896A,B,C,D by aligning the four L-shaped corner
guides and knife blade terminals with the bifurcated
contacts on the wiring subbase and securely tightening
the two screws without deforming the plastic.

Mounting Other System Components (Fig. 4)

Refer to the applicable specifications for mounting other
system components.

PRINCIPAL TECHNICAL FEATURES

The RM7895 provides all customary flame safeguard
functions as well as significant advancements in 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)—Fault Code 110.
d. AC line power errors occurred, see Operation.
e. Four minute INITIATE period has been exceeded.

9 66-1090—06

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

WIRING
SUBBASE

RUN/TEST (C,D ONLY)
SWITCH

RELAY
MODULE

CONFIGURATION
JUMPERS

PURGE
TIMER

SEQUENCE
STATUS
LED PANEL

P

OWER

PI

F

LAM

MAIN

A

L

RES

LOT

ARM

E

E

T

DUST
COVER

RESET
BUTTON

HONEYWELL

CAPTIVE
MOUNTING
SCREW

B

URNE

R

CONTROL

Fig. 4. RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D Relay Module, exploded view.

2. STANDBY 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. Delayed main valve terminal is energized

(RM7895C,D).
f. Internal system fault occurred.
g. Purge card is removed.
h. Purge card is bad.

3. PREPURGE PERIOD
a. Airflow lockout feature is enabled and the airflow

switch opens.
b. Ignition/pilot valve terminal is energized.
c. Main valve terminal is energized.
d. Delayed main valve terminal is energized

(RM7895C,D).
e. Internal system fault occurred.

FLAME
AMPLIFIER

M15122

f. Purge card is removed.
g. Purge card is bad.
h. Flame signal is detected.

4. PILOT FLAME ESTABLISHING PERIOD (PFEP)
a. Airflow lockout feature is enabled and the airflow

switch opens.
b. No flame signal at end of PFEP.
c. Ignition/pilot valve/intermittent pilot valve terminal is

not energized.

NOTE: For the RM7895C1020 and RM7896C1036, during

the first 8 seconds of PFEP, when a flame signal is
detected, terminal 10 is de-energized. If the flame
signal is lost, terminal 10 will re-energize.

d. Main valve terminal is energized.
e. Delayed (second stage) main valve terminal is

energized (RM7895C,D/EC7895C; RM7896C,D).
f. Internal system fault occurred.
g. Purge card is removed.
h. Purge card is bad.

66-1090—06 10

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

5. MAIN FLAME ESTABLISHING PERIOD (MFEP)
(RM7895C, RM7896C,D; EC7895C)
a. Airflow lockout feature is enabled and the airflow

switch opens.
b. Ignition terminal is energized.
c. Ignition/pilot valve terminal is not energized.
d. Main valve terminal is not energized.
e. Delayed main valve terminal is energized.
f. No flame signal at end of Flame Failure Response

Time.
g. Internal system fault occurred.
h. Purge card is removed.
i. Purge card is bad.

6. RUN PERIOD
a. No flame present.
b. Airflow lockout feature is enabled and the airflow

switch opens.

c. Interrupted pilot valve terminal is energized

(RM7895C, RM7896C,D; EC7895C).
d. Main valve terminal is not energized.
e. Delayed main valve terminal is not energized

(RM7895C, RM7896C,D; EC7895C).
f. Internal system fault occurred.
g. Purge card is removed.
h. Purge card is bad.
i. Ignition terminal is energized.

OPERATION

Sequence of Operation

The RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D has the
operating sequences listed below; see Fig. 2 and 3. The
RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D LED provide
positive visual indication of the program sequence: POWER,
PILOT, FLAME, MAIN and ALARM.

Initiate

The EC7895A,C/RM7895A,B,C,D;RM7896A,B,C,D Relay
Module enters the INITIATE sequence when the relay module
is powered. The EC7895A,C/RM7895A,B,C,D;
RM7896A,B,C,D 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 not met, a hold condition is initiated and displayed
on the optional KDM for at least five seconds; when met, the
INITIATE sequence restarts. If the condition is not corrected
and the hold condition exists for four minutes, the
EC7895A,C/RM7895A,B,C,D; RM7896A,B,C,D locks out.
Causes for hold conditions in the INITIATE sequence:

1. AC line dropout detection.

2. AC line noise that can prevent a sufficient reading of the

line voltage inputs.

3. Low line voltage brownouts.
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 EC7895A,C/RM7895A,B,C,D;RM7896A,B,C,D 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 relay module to
continue into the PREPURGE sequence.

Normal Start-Up Prepurge

The EC7895A,C/RM7895A,B,C,D/RM7896A,B,C,D Relay
Module provides PREPURGE timing selectable from two
seconds to thirty minutes with power applied and the
operating control indicating a call for heat.

1. The Airflow Interlock, burner switch, Run/Test switch
and all microcomputer-monitored circuits must also be
in the correct operating state.

2. The motor output, terminal 4, is powered to start the
PREPURGE sequence.

3. The Airflow Interlock input closes ten seconds into
PREPURGE or within the specified purge card timing;
otherwise, a recycle to the beginning of PREPURGE or
lockout occurs, depending on how the Airflow Switch
selectable jumper (JR3) is configured.

Ignition Trials

1. Pilot Flame Establishing Period (PFEP):
a. When the PFEP begins:

(1) The pilot valve and ignition transformer,

terminals 8 and 10, are energized. The
EC7895A, RM7895A,B, and RM7896A,B have
an intermittent pilot valve, terminal 8. The
EC7895C, RM7895C,D, and RM7896C,D have
an interrupted pilot valve, terminal 8.

(2) Flame must be proven by the end of the ten

second PFEP (four seconds if Configuration
Jumper JR1 is clipped) to allow the sequence to
continue. If a flame is not proven by the end of
PFEP, a safety shutdown occurs.

b. With flame proven, the ignition, terminal 10, is

de-energized.

NOTE: For the RM7895C1020 and RM7896C1036, during

the first 8 seconds of PFEP, when a flame signal is
detected, terminal 10 is de-energized. If the flame
signal is lost, terminal 10 will re-energize.

2. Main Flame Establishing Period (MFEP):
a. After PFEP, and with the presence of flame,

the main fuel valve, terminal 9, is powered. If a
flameout occurs, the relay module locks out or
recycles (depending on status of jumper JR2) within

0.8 or 3 seconds, depending on the Flame Failure
Response Time (FFRT) of the amplifier.

b. The EC7895C, RM7895C,D and RM7896C,D

have a ten second MFEP. After the Ignition Trials,
the pilot valve, terminal 8, is de-energized. If a
flameout occurs, the relay module locks out or
recycles (depending on status of jumper JR2) within

0.8 or 3 seconds, depending on the Flame Failure
Response Time (FFRT) of the amplifier.

11 66-1090—06

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

Run

1. The EC7895C, RM7895C,D, RM7896C,D has a
delayed main valve that is energized once the RUN
period is entered.

2. The relay module is now in RUN and remains in RUN
until the controller input, terminal 6, opens, indicating
that the demand is satisfied or a limit has opened.

Post Purge (RM7896A,B,C,D Only)

After demand is satisfied or a limit opens, de-energizing
terminal 6, the Ignition/Pilot valve, main valve and delayed
main valve, terminals 8, 9 and 21, are de-energized. The
blower motor, terminal 4, remains powered for 15 seconds.

Run/Test Switch (RM/EC7895C,D; RM7896C,D only)

The Run/Test Switch is located on the top side of the relay
module, see Fig. 5. The Run/Test Switch allows the burner
sequence to be altered as follows:

1. In the measured PREPURGE sequence, the Run/Test
Switch, placed in the TEST position, causes the
PREPURGE timing to stop.

2. In the Pilot Flame Establishing Period, the Run/Test
Switch, placed in the TEST position, stops the timer dur­ing the first eight seconds of a ten-second PFEP selec­tion or during the first three seconds of a four-second
PFEP selection. It also allows for pilot turn-down test
and other burner adjustments. This activates a fifteen­second flameout timer that permits pilot flame adjust­ment without nuisance safety shutdowns. The Run/Test
Switch is ignored during PFEP for the C and D relay
modules if terminals 8 and 9 or 9 and 21 are jumpered.

IMPORTANT

When the relay module is switched to the TEST
mode, it stops and holds at the next Run/Test Switch
point in the operating sequence. Make sure that the
Run/Test Switch is in the RUN position before
leaving the installation.

RUN/TEST SWITCH

SEQUENCE
STATUS
LEDs

RESET
PUSHBUTTON

FLAME
SIMULATOR INPUT

Fig. 5. Sequence Status LEDs.

FLAME CURRENT
TEST JACKS

CAPTIVE

MOUNTING

SCREW

PLUG-IN

PURGE

CARD

DUST

COVER

RELAY

MODULE

FLAME

AMPLIFIER

M7552A

SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers

The relay module has three site-configurable jumper options,
see Fig. 6 and Table 6. If necessary, clip the site-configurable
jumpers with side cutters and remove the resistors from the
relay module.

SERVICE NOTE: Clipping and removing a site-configurable
jumper enhances the level of safety.

SELECTABLE CONFIGURATION JUMPERS

RUN/TEST SWITCH
(EC7895C; RM7895C,D; RM7896C,D)

M7553A

Fig. 6. Selectable site-configurable jumpers.

Table 7. Site-configurable jumper options.

Jumper
Number Description Intact Clipped

a, b

JR1

c

JR2

JR3 Airflow Switch (ILK)

a

The RM7895C1020 and RM7896C1036 have fixed PFEP
of ten seconds and do not have jumper JR1 (3 seconds
software revision 4151 or greater).

b

The RM7895C1053 has fixed PFEP of four seconds and
does not have jumper JR1.

c

The RM7895C1053 locks out on Flame Failure Action and
does not have jumper JR2.

IMPORTANT

Pilot Flame Establishing
Period (PFEP)

10
seconds

4 seconds

Flame Failure Action Recycle Lockout

Recycle Lockout

Failure

Clipping and removing a jumper after 200 hours of
operation causes a nonresettable Fault 110. The
relay module must then be replaced.

Automation and Control Solutions

Honeywell International Inc. Honeywell Limited-Honeywell Limitée

1985 Douglas Drive North 35 Dynamic Drive

Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9

customer.honeywell.com

® U.S. Registered Trademark
© 2007 Honeywell International Inc.
66-1090—06 M.S. Rev. 06-07