Honeywell EC7850A1072, EC7850A1080, EC7850A1122, RM7830A1029, RM7830A1003 Instruction 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, 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.

65-0095: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.

65-0228:S7810B Multi-Drop Switch Module Product Data.

65-0229:7800 SERIES Relay Modules Checkout and

Troubleshooting Product Data.

65-0249:S7810M ModBus Network Protocol.

®

®

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: 15A maximum, 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.

SIL 3 Capable:

SIL 3 Capable in a properly designed Safety Instrumented

System. See form 65-0312 for Certificate Agreement

Approvals:

RM7830A and RM7850A:

Factory Mutual Approved: Report No. J.I.1V9A0.AF.

Swiss Re (formerly 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

SIL

Capable

3

66-1092-06

EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES

WARNING

WARNING

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.

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.

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

Carefully follow safety requirements when installing a
burner control.

Electrical Shock Hazard or Equipment Damage
Hazard.
Can cause severe injury, death or equipment
damage.

Disconnect power supply before beginning installation.
More than one disconnect may be involved.

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.

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
component-recognized 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.

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—06 2

EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES

WARNING

Wiring Subbase

Electrical Shock Hazard or Equipment Damage
Hazard.
Can cause sever injury, death or equipment
damage.

Disconnect the power supply before beginning
installation. More than one disconnect may be
involved.

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.

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),
S7810M ModBus Module (65-0249) 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. 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 Control-

Bus™ Module, or Remote Reset Module Instruc­tions.

7. For recommended grounding practices, see Table 2.

8. The KDM is powered from a low voltage, energy limited

source. Mount the KDM outside of a control panel when
it is protected from mechanical damage.

IMPORTANT

A 13 Vdc power supply must be used any time more
than one KDM is used. A maximum of two KDM,
Data ControlBus™ Modules or S7810B Multi-Drop
Switch Modules are allowed in any combination.

9. Maximum wire lengths:
a. EC/RM7830A and EC/RM7850A leadwires: The

maximum leadwire length is 300 feet (91 meters) to
terminal inputs (Control, Running/Lockout Interlock).

b. Flame Detector leadwires: The maximum flame

sensor leadwire length is limited by the flame signal
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 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 relay module or to the terminal
ratings in Tables 3A, 3B, 3C and 3D.

3 66-1092—06

EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES

L1
HOT

N

1

5

2

CONFIGURATION
JUMPERS

PLUG-IN PURGE
TIMER CARD

F

G

22

PLUG-IN
FLAME
AMPLIFIER

MICROCOMPUTER

RUN/TEST
SWITCH

RESET
PUSHBUTTON

FLAME SIGNAL

TEST
JACK

RELAY
DRIVE
CIRCUIT

1K

2K

3K
4K

5K

6K
7K

CONTROL
POWER

POWER SUPPLY

17

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

10

8

21

9

4

3

OPTIONAL KEYBOARD
DISPLAY MODULE

RS485

16

1K1

2K2 5K1

4K1

7K1

2K1

PV1

PV2

MV

3K1

6K1

7

ES2

3K2

SAFETY RELAY
CIRCUIT

20 6

FAN

AL

IGN

AL

DDL

REMOTE
RESET

INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLTAGE INPUTS

RELAY CONTACT OPEN

INTERNAL WIRING

FIELD WIRING

RELAY COIL

RELAY CONTACT CLOSED

DDL
COMMUNICATIONS

1

2

3

5

USER TERMINALS

1

2

2

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.

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

M15183B

STATUS
LEDS

RTLOS

LD2

SHUTTER

SAFETY RELAY
CIRCUIT

F

G

...

22

66-1092—06 4

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

L1
HOT

N

1

4

2

19

CONFIGURATION
JUMPERS

PLUG-IN PURGE
TIMER CARD

F

G

22

PLUG-IN
FLAME
AMPLIFIER

MICROCOMPUTER

RUN/TEST
SWITCH

RESET
PUSHBUTTON

FLAME SIGNAL

TEST
JACK

RELAY
DRIVE
CIRCUIT

1K

2K

3K

4K

5K

6K

7K

8K

9K

CONTROL
POWER

POWER SUPPLY

18

17

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

10

8

21

9

5

3

OPTIONAL KEYBOARD
DISPLAY MODULE

RS485

16

1K1

2K2 5K1

4K1

7K1

2K1

PV1

PV2

MV

3K1

6K1

7

ES1

ES3

ES2

3K2

SAFETY RELAY
CIRCUIT

20 6

FAN

AL

IGN

AL

DDL

13

15

14

12

HIGH FIRE

COMMON

LOW FIRE

MODULATE

REMOTE
RESET

8K1

8K2

9K2

9K1

INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
AND LINE VOLTAGE INPUTS

RELAY CONTACT OPEN

INTERNAL WIRING

FIELD WIRING

RELAY COIL

RELAY CONTACT CLOSED

DDL
COMMUNICATIONS

1

2

3

5

USER TERMINALS

1

2

2

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.

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

M15184B

STATUS
LEDS

RTLOS

LD2

SHUTTER

FG

...

22

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

EC7830A, RM7830A, EC7850A, RM7850A 7800 SERIES RELAY MODULES

5 66-1092—06