Honeywell EC7830A, EC7850A, RM7830A, RM7850A Installation Instructions Manual

EC7830A, RM7830A, EC7850A, RM7850A

7800 SERIES Relay Modules

INSTALLATION INSTRUCTIONS

APPLICATION

The Honeywell EC/RM7830A and EC/RM7850A are
microprocessor-based integrated burner controls for
automatically fired gas, oil, or combination fuel single burner
full modulation (EC/RM7850A) or on/off (EC/RM7830A)
applications. The EC/RM7830A; EC/RM7850A system
consists of a relay module, subbase, amplifier, and purge
card. Options include keyboard display module (KDM),
Personal Computer Interface, Data ControlBus Module™,
remote display mounting and Combustion System Manager®
Software.

Functions provided by the EC/RM7830A and EC/RM7850A
include automatic burner sequencing, flame supervision,
system status indication, system or self-diagnostics and
troubleshooting. Text readout on the Keyboard Display Module
is available in English, Spanish, Portuguese, Katakana
(Japanese), French, Chinese, German, and Italian languages.

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.
65-0228: S7810B Multi-Drop Switch Module Product Data.
65-0095: S7820 Remote Reset Module Product Data.
65-0097: 221729C Dust Cover Packing Instructions.
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

Electrical Ratings (See Tables 3A, 3B, 3C and 3D):

Voltage and Frequency:

RM7830A and RM7850A:

120 Vac (+10/-15%), 50/60 Hz (±10%).

EC7830A and EC7850A:

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.

® U.S. Registered Trademark
Copyright © 1998 Honeywell Inc. • All Rights Reserved

Environmental Ratings:

Ambient T emperature:

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:

RM7830A and RM7850A:

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.

EC7830A and EC7850A: Factory Mutual Approved.
These products also comply with the following European

directives:
Gas Appliance Directive: 90/396/EEC.
Low Voltage Directive: 73/23/EEC.
EMC Directive: 89/336/EEC.
GASTEC: CE-63AP3070/1.
Lloyds Register Approval.

Oil appliances:

EC7830A: DIN-5F 106/96.
EC7850A: DIN-5F 107/96.

These products are approved according to EN298, “Automatic
gas burner systems for gas burners and gas burning
appliances with or without fans.”

Please note the following to comply with EN60730 for remote
mounting of the KDM and/or remote reset module. It is
necessary to provide electrical separation using insulation at
least equivalent to double or reinforced insulation. This can be
accomplished by either:

1. Optically isolating the communication and/or remote
reset lines from the control cabinet or

2. Providing physical separation from the communication
and/or remote reset lines using electrical conduit and a
204718a Remote Display Cover Assembly or other
suitable enclosure that meets ip40 class of protection.

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EC7830, RM7830A,EC7850A,RM7850A 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.

Carefully follow safety requirements when installing a
burner control.

CA UTION

Electrical Shock Hazard or Equipment/
Control Damage.
Can cause electrical shock or equipment damage.

Disconnect power supply before beginning
installation.

IMPORTANT

1. Wiring connections for the relay modules are unique;
refer to Fig. 3 and 4 or the appropriate Specifications
for individual 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 EC/RM7830A and
EC/RM7850A must not exceed those listed on the
relay module 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 C7015 Infrared Flame
Detectors.

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 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 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 relay
module, expanded annunciator, KDM, 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).

66-1092—2

2

EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

Wiring Subbase

CAUTION

Electrical Shock Hazard or Equipment Damage.
Can cause electrical shock or damage equipment.

Disconnect the power supply before beginning
installation.

The internal block diagram of the EC/RM7830A is shown in
Fig. 1 and the internal block diagram of the EC/RM7850A is
shown in Fig. 2.

1. For subbase wiring and sequence charts, refer to Fig. 3
and 4.

5

CONFIGURATION
JUMPERS

RUN/TEST
SWITCH

MICROCOMPUTER

RESET
PUSHBUTTON

RELAY
DRIVE
CIRCUIT

ES2

6K1

3K1

RS485

2

SAFETY RELAY
CIRCUIT

20 6

LD2

5

REMOTE
RESET

3

17

RTLOS

7

STATUS
LEDS

3K2

16

2

OPTIONAL KEYBOARD

DDL

DDL
COMMUNICATIONS

1

120 VAC, 50/60 Hz POWER SUPPLY, RM7830A; 220-240 VAC, 50/60 Hz POWER SUPPLY, EC7830A.
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

2

TO CONNECT L1 DIRECTLY TO LOS, AT LEAST ONE CONTROLLED SHUTDOWN MUST BE PROVIDED EVERY 24 HOURS.

DISPLAY MODULE

1

Fig. 1. Internal block diagram of EC/RM7830A (see Fig. 3 for detailed wiring instructions).

2. For remote wiring of the KDM, refer to the

Specifications for the KDM (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.

L1
HOT

N

1

PLUG-IN PURGE
TIMER CARD

FLAME SIGNAL

2K
3K

4K
5K

6K
7K

1K

POWER SUPPLY

2K2 5K1

1K1

RELAY CONTACT OPEN
RELAY CONTACT CLOSED

RELAY COIL
FIELD WIRING
INTERNAL WIRING

4K1

7K1

2K1

PLUG-IN
FLAME
AMPLIFIER

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

CONTROL
POWER

AL

10

8

21

9

4

3

F G ... 22

INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLTAGE INPUTS

USER TERMINALS

TEST
JACK

F

G

22

2

SHUTTER

IGN

PV1

PV2

MV

FAN

AL

M15183B

3

66-1092—2

EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

L1

N

HOT

RELAY
DRIVE
CIRCUIT

RTLOS

7

8K1

8K2

9K2

1

2K
3K

4K
5K

6K
7K
8K
9K

1K

POWER SUPPLY

1K1

HIGH FIRE

COMMON
LOW FIRE

9K1

MODULATE

PLUG-IN PURGE
TIMER CARD

FLAME SIGNAL

2K2 5K1

4K1

7K1

2K1

12

13

15

14

PLUG-IN
FLAME
AMPLIFIER

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

CONTROL
POWER

F G ... 22

4

CONFIGURATION
JUMPERS

RUN/TEST
SWITCH

MICROCOMPUTER

RESET
PUSHBUTTON

ES1

ES3

ES2

6K1

3K1

RS485

2

SAFETY RELAY
CIRCUIT

20 6

LD2

5

REMOTE
RESET

3

18

19

17

STATUS
LEDS

3K2

16

2

OPTIONAL KEYBOARD
DISPLAY MODULE

DDL

DDL
COMMUNICATIONS

1

120 VAC, 50/60 Hz POWER SUPPLY, RM7850A; 220-240 VAC,
50/60 Hz POWER SUPPLY, EC7850A. PROVIDE DISCONNECT
MEANS AND OVERLOAD PROTECTION AS REQUIRED.

2

TO CONNECT L1 DIRECTLY TO LOS, AT LEAST ONE CONTROLLED
SHUTDOWN MUST BE PROVIDED EVERY 24 HOURS.

1

Fig. 2. Internal block diagram of EC/RM7850A (see Fig. 4 for detailed wiring instructions).

TEST
JACK

F

G

SHUTTER

22

AL

10

8

21

9

5

3

INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLTAGE INPUTS

USER TERMINALS
RELAY CONTACT OPEN
RELAY CONTACT CLOSED
RELAY COIL
FIELD WIRING

INTERNAL WIRING

IGN

PV1

PV2

MV

FAN

AL

M15184B

2

66-1092—2

4

EC7830, RM7830A,EC7850A,RM7850A 7800 SERIES RELAY MODULES

L1
N

1

G 12
N 13
3 14
4 15
5 16
6 17
7 18
8 19

(L1)

9 20

10 21

F 22

AL

FAN

RT

LD2
PV1

MV

IGN

ES2

LOS
PV2

FLAME
DETECTOR

1

12O VAC, 50/60 Hz POWER SUPPLY (RM7830A). 220-240 VAC, 50/60 Hz POWER SUPPLY
(EC7830A). PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

SEE FLAME DETECTOR INSTRUCTIONS FOR CORRECT WIRING.

LEGEND

ALARM
(NORMALLY OPEN)

PREIGNITION
INTERLOCK INPUT

BURNER/BLOWER
MOTOR

IGNITION
LINE VOLTAGE SUPPLY
LOCKOUT INPUT
AIRFLOW SWITCH INPUT
MAIN FUEL VALVE
PILOT VALVE 1

(INTERRUPTED)
PILOT VALVE 2

(INTERMITTENT)
LIMITS AND BURNER

CONTROL

AL
ES2
FAN
IGN

L1
LOS
LD2
MV
PV1

Q7800

2

2

INITIATE

POWER
PILOT
FLAME
MAIN
ALARM

STANDBY

RUN

STANDBY

PRE
IGNITION

PILOT
STABIL.

MAIN
STABIL.

IGNITION

BURNER

POSTPURGE

MAIN VALVE

LIMITS AND BURNER CONTROL CLOSED

LOCKOUT INPUT

10 sec

AIRFLOW SWITCH CHECK

PILOT VALVE

V2

PREIGNITION INTERLOCK

OPTIONS

SAFE START CHECK

FLAME PROVING

3 sec

5 sec

5 sec

1 IF ON AT CALL FOR HEAT, HOLD (120 sec). LOCK OUT IF STILL ON.

3 or 5 sec

3 or 5 sec

SAFE START CHECK

IF OFF AFTER 10 SEC OF FAN, LOCK OUT.

2

2, 15 or 30 sec

3

4

5

TAKE LOCKOUT ACTION, CONTINUE POSTPURGE TIMING.

SELECT VIA ST7800A PURGE TIMER CARD.

4

5

6

SELECT VIA CONFIGURATION JUMPERS OR MODEL NUMBERS.

AFS CHK

1

2 sec

AFS CHK

AFS CHK

DUE TO ONE EXTRA SECOND FOR SAFETY RELAY TEST, TIMING CAN VARY FROM 3 TO 4 SECONDS.

6

LED
DISPLAY

"PREPURGE"

WAITING

FIRST SAFETY

TIME

MAIN TRIAL

TIME

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

EC/RM7830A Power Burner ON/OFF, GAS or OIL Sequence

2

3

6

6

M15185B

PV2

RT

8

21

9

6

20

7

10

17

BURNER/BLOWER MOTOR

4

Fig. 3. Wiring subbase and sequence chart for EC/RM7830A.

5

66-1092—2