Honeywell RM7895A2014, RM7895A1048, RM7895B2013, RM7896A2012, RM7895C1020 Installation Instructions Manual

32-00156-01

RM7895A,B,C,D/EC7895A,C;
RM7896A,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,C; RM7896A,B,C,D systems
consist of a relay module, subbase, amplifier, and purge
card. Options include: 2-line VFD (see document 65­0090-6) or 4-line LCD (see document 32-00110-01)
Keyboard Display Module, 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 covers the following 7800 Series Relay
Modules:

• RM7895A1014

• RM7895A1048

• RM7895B1013

• RM7896A1012

• RM7895A2014

• RM7895A2048

• RM7895B2013

• RM7896A2012

• RM7895C1020

• RM7895C1012

• RM7895D1011

• RM7896C1010

• RM7896D1019

• RM7895C2020

• RM7895C2012

• RM7895D2011

• RM7896C2010

• RM7896D2019

• EC7895A1010

• EC7895A2010

• EC7895C1000

• EC7895C2000

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

Publication

No. Product

32-00110 S7800A2142 4-line LCD Keyboard

Display Module Product Data

63-2278 Q7700 Network Interface Unit Product

Data

65-0084 Q7800A,B 22-Terminal Wiring Subbase

Product Data

65-0090 S7800A1142 2-line VF 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

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.

SIL

3

Capable

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

WARNING

WARNING

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, noncon-

densing.

Vibration: 0.5G environment.

SIL 3 Capable

SIL 3 Capable in a properly designed Safety Instrumented

System. See form number 65-0312 for Certificate
Agreement.

Approvals:

RM7895/RM7896:

Underwriters Laboratories Inc. Listed: File No. MP268,

Guide No. MCCZ.
Factory Mutual Approved: Report No. 1V9A0.AF.
Swiss RE (formerly 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 condi-

tion.

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 safe-

guard service technician.

4. After installation is complete, check out the product

operation as provided in these instructions.

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

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 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.

32-00156—01 2

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.

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

WARNING

Mounting Wiring Subbase

1. Mount the subbase in any position except horizon-

tally 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 ser­vicing, installation, access or removal of the relay
module, 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. Drill
the pilot holes.

4. Securely mount the subbase using four no. 6 screws.

Wiring Subbase

NOTE: There are several different subbase models that

can be purchased. It is important to note which
subbase is compatible with the relay module
when purchasing repair or replacement parts.

Series 1000 Subbase

All relay product codes that start with a 1 (example:
RM7840G1
Q7800A1005/U. These relays can also be used on the
Series 2000 subbase noted below.

Series 2000 Subbase

All relay product codes that start with a 2 (example:
RM7840G2
Q7800A2005/U.

Subbase Compatibility

Any relay module in the 1000 series is fully backward
compatible with any subbase already installed in the field
(Q7800A1005/U, Q7800B1003/U, Q7800A2005/U,
Q7800B2003/U).

014/U) can be used with existing subbase

014/U) can be used with subbase

Any relay module in the new 2000 series will only be able
to be installed on subbase Q7800A2005/U, and will not be
backward compatible with any Q7800A1005/U legacy
subbases already installed in the field.

IMPORTANT

Make sure to check the relay model number and
check the subbase compatibly prior to ordering or
attempting a new installation or field upgrade.

If you attempt to place a 2000 series relay on a
non-compatible 1000 series subbase, you will
receive an error code of 101. This indicates that
you must a) change out the subbase to a
Q7800A2005/U or b) choose a compatible 1000
series relay module.

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. 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 2-line VFD KDM
(65-0090), the 4-line LCD KDM (32-00110), Net­work Interface Unit (63-2278), Data ControlBus™
Module (65-0091) or Extension Cable Assembly (65-

0131).

3. Disconnect the power supply from the main discon-

nect 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.

3 32-00156—01

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

CONFIGURATION
JUMPERS

MICROCOMPUTER

RESET
PUSHBUTTON

RUN/TEST
SWITCH

STATUS LEDs

PLUG-IN PURGE
TIMER CARD

SAFETY RELAY
CIRCUIT

POWER SUPPLY

OPTIONAL KEYBOARD
DISPLAY MODULE

PLUG-IN
FLAME
AMPLIFIER

RELAY
DRIVE
CIRCUIT

CONTROL
POWER

TEST
JACK

REMOTE
RESET

DDL

DDL
COMMUNICATIONS

INDICATES FEEDBACK SENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLT INPUTS

FIELD WIRING

INTERNAL WIRING

IGNITION

PILOT

MAIN VALVE

1K

RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS

LIMITS

CONTROLLER

INTERLOCK
(INCLUDING
AIRFLOW SWITCH)

1K1 2K1 5K1

FLAME SIGNAL

TEST

PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.

LOCKOUT IF JUMPER JR2 REMOVED.

RS485

1

2

3

L1
(HOT)

L2

5

6

7

4K1

2K2

10

8

9

7K

6K

5K

4K

3K

2K

F

G

22

1

BLOWER

6K1

4

ALARM

3K1

3

L2

M23996

1

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

2

2

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).

32-00156—01 4

M23997

G

L2

3

5

6

7

8

9

10

F

(L1)

13

14

15

16

17

18

19

20

21

22

12

MASTER
SWITCH

IGNITION

MAIN FUEL VALVE(S)

BURNER
CONTROLLER/LIMITS

BURNER MOTOR
(BLOWER)

INTERMITTENT
PILOT/IGNITION

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.

FOR DIRECT SPARK IGNITION
(OIL OR GAS)

LINE VOLTAGE ALARM

L1
(HOT)

L2

1

8

10

IGNITION
TRANSFORMER

MAIN VALVE

1

Q7800

2

2

L2

4

LOCKOUT INTERLOCK
(INCLUDING
AIRFLOW SWITCH)

FLAME DETECTOR

IGN

OPERATING
CONTROLS
AND
INTERLOCKS

INITIATE

ALARM ALARM

STANDBY

POWER POWER

PILOT

FLAME

MAIN

TIMED
PURGE

ALARM

POWER

PILOT

FLAME

MAIN

RUN

STANDBY

BURNER
START

MAIN VALVE

LIMITS AND BURNER CONTROLLER CLOSED

IGN/ PILOT

SAFE START CHECK

FLAME
PROVING

SSC

LED
DISPLAY

POWER

PILOT

FLAME

MAIN

PFEP

4 OR 10 SEC

POWER

START

POWERPOWER

FLAME
SIGNAL

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.

00 00 00

10

L1

TO

6

9

8

BURNER/BLOWER MOTOR

LOCKOUT INTERLOCK CLOSED

AFSC

TO

7

6

4

3

5

3

4

5

6

7

POST PURGE

15 SEC

POWER

6

7

7

AIRFLOW SW CHECK

4

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

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

5 32-00156—01