SIL
3
RM7895A,B,C,D/EC7895A,C;
RM7896A,C,D
7800 SERIES Relay Modules
INSTALLATION INSTRUCTIONS
Edition 03.20 · 32-00156-03 · EN
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 Primar y
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:
1000-Series 2000-Series
• RM7895A1014 • RM7895A2014
• RM7895A10 48 • RM7895A2048
• RM7895B1013 • RM7895B2013
• RM7896A1012 • RM7896A2012
• RM7895C1020 • RM7895C2020
• RM7895C1012 • RM7895C2012
• RM7895D1011 • RM7895D2011
• RM7896C1010 • RM7896C2010
• RM7896D1019 • RM7896D2019
• EC7895A1010 • EC7895A2010
• EC7895C100 0 • EC7895C2000
This document provides installation and static checkout in-
structions. Other applicable publications are:
Publication
No.
32-0 0110 S7800A 2142 4 -line LCD Keyboard Display
Module Product Data
32-00166 204729A /C KDM NEMA4 Covers for 4-line
LCD KDM
32-00235 R7824, R7847, R7848, R78 49, R7861,
R7886 Flame Amplifiers for the 7800
SERIES 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
65-0 097 221729C Dust Cover Packing Instructions
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 Module (For CE ,
Modbus module S7810M1029 only).
65-0295 50023821-001/2 KDM NEMA4 Covers for
classic 2-line VFD KDM
65-0089 ST7800A,C Plug-In Purge Timer
Product
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: 20 00 VA.
Fusing Total Connected Load: 15A Fast Blow, type SC or equiv-
alent.
Capable
32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to 14 0°F (-40°C to +60°C). Storage:
-4 0°F to 150°F (-4 0°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 Sys-
tem. See form number 65-0312 for Certificate Agreement.
Approvals:
RM7895A/B/C/D AND RM7896A, C, D
Underwriters Laboratories Inc. Listed: File No. MP268.
ANSI/UL 60730-2-5 / CSA C22.2 No. 60730-2-5 Automatic Electrical Controls for Household and Similar
Use, Part 2-5: Particular Requirements for Automatic Electrical Burner Control Systems.
Factory Mutual Approved: Report No. 1V9A0. AF.
EAC: TC N RU д-US.Aи3O.B.04013
Federal Communications Commission: Part 15, Class B,
Emissions.
EC7895A/C
EAC: TC N RU д-US.Aи3O.B.04013
Federal Communications Commission: Part 15, Class B,
Emissions.
INSTALL ATION
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 opera-
tion 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
Electric 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, 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 (C7915).
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.
32-00156-03 2
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
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 star t with a 1 (example:
RM7840G1014/U) can be used with existing subbase
Q7800A1005/U. These relays can also be used on the Series
2000 subbase noted below.
Series 2000 Subbase
All relay product codes that star t with a 2 (example:
RM7840G2014/U) can be used with subbase Q7800A2005/U.
Subbase Compatibility
Any relay module in the 100 0 series is fully backward
compatible with any subbase already installed in the field
(Q7800A1005/U, Q7800B1003/U, Q7800A2005/U,
Q7800B2003/U).
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-compati-
ble 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.
WARNING
Electric Shock Hazard.
Can cause serious injury, death or equipment damage.
Disconnect 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), Data ControlBus™ Module
(65-0 091) 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.
3 32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
Fig. 1. RM7823 and EC7823 wiring for SIL 3 applications
32-00156-03 4
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
FOR RM7895A1028/2028 (ONLY), IGNITION TERMINAL 10
IS DE-ENERGIZED WHEN FLAME IS PROVEN.
FOR EC7895, A 220 TO 240 VAC TO 120 VAC,
10 VA MINIMUM STEPDOWN TRANSFORMER (NOT PROVIDED)
MUST BE USED TO DRIVE THE SHUTTER. THIS DOES NOT APPLY
TO UV FLAME SENSOR MODELS C7061A1020, C7061A1079 AND
C7061F1003 (COMBINED WITH R7861-SERIES FLAME AMPLIFIERS),
WHICH HAVE INTERNAL SELECTABLE TERMINAL BLOCK TO CONNECT
230V SHUTTER OUTPUT DIRECTLY.
Fig. 2. Wiring subbase and sequence chart for RM7895A,B/EC7895A; RM7896A,B.
5 32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
4
FOR EC7895, A 220 TO 240 VAC TO 120 VAC,
10 VA MINIMUM STEPDOWN TRANSFORMER (NOT PROVIDED)
MUST BE USED TO DRIVE THE SHUTTER. THIS DOES NOT APPLY
TO UV FLAME SENSOR MODELS C7061A1020, C7061A1079 AND
C7061F1003 (COMBINED WITH R7861-SERIES FLAME AMPLIFIERS),
WHICH HAVE INTERNAL SELECTABLE TERMINAL BLOCK TO
CONNECT 230V SHUTTER OUTPUT DIRECTLY.
SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.
Fig. 3. Wiring subbase and sequence chart for RM7895C,D/EC7895C; RM7896C,D.
32-00156-03 6
RM7895C1020/2020, RM7896C1036/2036 PFEP 10 SECONDS ONLY;
RM7895C1053/2053 PFEP 4 SECONDS ONLY
RM7895C1020/2020, RM7896C1036/2036: 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.
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
Table 1. Recommended Wire Sizes and Part Numbers.
Application Wire Size Recommended 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 Control-Bus™
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
22 AWG two-wire twisted pair with ground. Belden 8723 shielded cable or
equivalent.
18 AWG wire insulated for voltages and temperatures for
TTW60C, THW75C, THHN90C.
given application.
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 10 0 feet
(31 meter s).
Table 2. Recommended Grounding Practices.
Gro und Ty pe 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,
ControlBus™ Module interconnecting wire is 400 0 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.
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 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.
NOTE: A 13 Vdc power supply must be used any time more
than one KDM is used.
9. Maximum wire lengths:
a. RM7895A ,B,C,D/EC7895A,C; RM7896A,B,C,D lead-
wires: The maximum leadwire length is 300 feet to ter-
Final Wiring Check
1. Check the power supply circuit. The voltage and frequency tolerance must match those of the 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 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.Test (except 7823 models)
Functional test:
minal 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
100 0 feet (305 meters) to a Remote Reset pushbutton.
d. Data ControlBus Module™: The maximum Data Con-
trolBus™ Module cable length depends on the number
of system modules connected, the noise conditions
and the cable used. The maximum length of all Data
7 32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
Table 3. Terminal Ratings.
Terminal
Number
Description Ratings
RM7895/RM7896 EC7895
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
220 -240 Vac, 4A at PF = 0.5, 20A inrush.
(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 120 Vac
9 Main Fuel Valve 120 Vac
10 Ignition 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, 2 A 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
120 Vac
c
220 -240 Vac, 4A at PF = 0.5, 20A inrush.
(EC7895C, RM7895C,D;
RM7896C,D)
22 Shutter 120 Vac, 0.5A 220 -240 Vac
a See Table 2.
b 2000 VA maximum load connected to RM7895A ,B,C,D/EC7895A ,C/RM789 6A,B,C,D Assembly.
c See Tables 4 and 5.
d 220 -240 Vac to 120 Vac, 10 VA minimum stepdown transformer (not provided) must be used to drive the shutter. The transformer is NOT
needed for UV flame sensor models C7061A1020, C7061A1079 and C70 61F1003 (combined with R7861-series flame amplifiers), which
have an internal selectable terminal block to connect 230V shutter output from EC7895 models directly.
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 Fa No Load A No Load
4 F F A No Load
5 Fa No Load A F
6 D F A No Load
7 Da No Load A D
8 D D A No Load
9 Da No Load A D
a RM7895C,D: EC7895C, RM7896C,D only, jumper terminals 8 to 9.
Table 5. Composition of each Combination.
A B C D F
4.5A ignition 50 VA Pilot Duty
4.5A ignition.
a Pilot Duty refers to solenoid-t ype 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.
32-00156-03 8
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 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 Q780 0 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. (30 4.8 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 jump-
er 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 bet ween 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.
Tes t
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
9 32-00156-03
Relay
Module
Model
Tes t
Jumpers
Voltmeter Normal Operation If Operation is Abnormal,
starts.
2. Line voltage at terminal 7 within
10 seconds.
transformer is connected to
terminal 10).
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,C,D7800 SERIES Relay Modules
Table 6: Static Checkout. (Continued)
Tes t
Number
5 All 5-8 – 1. Ignition spark (if ignition
6 All 5-9 – Automatic fuel valve(s) open(s). If
7
8 All 5-3 – Alarm (if used) turns on. 1. Alarm.
Final All
Relay
Module
Model
EC7895C;
RM7895C
,D;
RM7896C
,D
Tes t
Jumpers
5-21 – Automatic second stage main fuel
Voltmeter Normal Operation If Operation is Abnormal,
transformer is connected to
terminal 8).
2. Automatic pilot valve opens (if
connected to terminal 8).
NOTE: Refer to wiring diagram of
system being tested.
using direct spark ignition, check
first stage fuel valve(s) instead of
pilot valve.
valve(s) open(s).
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.
Same as test 5. If using direct
spark ignition, check first stage
fuel valve(s) instead of pilot valve.
1. Listen for and obser ve 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 Q780 0 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 ser vicing, 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 and EC7895 Series provide 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.
32-00156-03 10
DUST
COVER
SUBBASE Q7800A1005/U SHOWN
MOUNTING
SEQUENCE
STATUS
LED PANEL
PURGE
TIMER
RELAY
MODULE
CONFIGURATION
JUMPERS
WIRING
SUBBASE
RUN/TEST (C,D ONLY)
SWITCH
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
HONEYWELL
RESET
BUTTON
BURNER 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.
f. Purge card is removed.
g. Purge card is bad.
h. Flame signal is detected.
4. PILOT FLAME ESTABLISHING PERIOD (PFEP)
POWER
PILOT
FLAME
MAIN
ALARM
RESET
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 RM7895C1020/2020 and
RM7896C1036/2036, 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.
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.
CAPTIVE
SCREW
FLAME
AMPLIFIER
11 32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
f. No flame signal at end of Flame Failure
g. Response Time.
h. Purge card is removed.
i. Purge card is bad.
6. RUN PERIOD
a. No flame present.
b. Air flow lockout feature is enabled and the air flow 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 Re-
lay 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 INITI-
ATE 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 sec-
32-00156-03 12
onds 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 Air flow 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-ener-
gized.
NOTE: For the RM7895C1020/2020 and
RM7896C1036/2036, 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
ampli fier.
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.
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 deenergized. The blower motor, terminal 4, remains powered for 15 seconds.
Run/Test Switch (RM/EC7895C,D; RM7896C,D only)
SEQUENCE
STATUS
LEDs
RESET
PUSHBUTTO
CAPTIVE
MOUNTING
SCREW
DUST
COVER
RELAY
MODULE
E
AMPLIFIER
M7552A
PLUG-IN
RUN/TEST SWITCH
SELECTABLE CONFIGURATION JUMPERS
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 foursecond PFEP selection. It also allows for pilot turndown test and other burner
adjustments. This activates a fifteen-second 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.
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
RUNTEST SWITCH
(EC7895C; RM7895C,D; RM7896C,D)
M7553A
Fig. 6. Selectable site-configurable jumpers.
Table 7. Site-configurable jumper options.
N
FLAME
SIMULATOR INPUT
Fig. 5. Sequence Status LEDs.
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 siteconfigurable
jumpers with side cutters and remove the resistors from the
relay module.
SERVICE NOTE: Clipping and removing a siteconfigurable jumper enhances the level of safety.
FLAME CURRENT
TEST JACKS
PURGE
CARD
FLAM
Jumper
Description Intact Clipped
Number
JR1
JR2
a, b
c
Pilot Flame Establishing
Period (PFEP)
10
seconds4 seconds
Flame Failure Action Recycle Lockout
JR3 Airflow Switch (ILK) Failure Recycle Lockout
a The RM7895C1020/2020 and RM7896C1036/2036 have fixed
PFEP of ten seconds and do not have jumper JR1.
b The RM7895C1053/2053 has fixed PFEP of four seconds and
does not have jumper JR1.
c The RM7895C1053/2053 locks out on Flame Failure Action and
does not have jumper JR2.
IMPORTANT
Clipping and removing a jumper after 200 hours of operation
causes a nonresettable Fault 110. The relay module must
then be replaced.
SAFETY AND SECURITY
Physical device protection
Device shall be accessible to authorized personnel only – Installation on publicly accessible places is not recommended
as this could lead to unwanted and potentially unsafe changes to device (wiring, configuration, etc).
It is recommended to lock the device in an enclosed cabinet
with access allowed only to approved and trained personnel. Also, it is strongly advised to keep all the wiring of device
physically secure.
Physical protection of the device is applied via Run/Test
switch label/seal. It is intended to prevent and detect unauthorized access.
13 32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
Modbus & DDL Interface security
Any conducts critical to device functionality (DDL, Modbus
lines etc.) shall be physically protected (installed outside public access) since they could be damaged or tampered-with by
unauthorized people, either accidentally or for purpose.
Modbus RS-485 & DDL protocols do not support security features. For DDL interface - only DDL devices shall be connected to the Burner Controller DDL line.
License agreement
Copying and reverse engineering is prohibited by the law.
32-00156-03 14
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
15 32-00156-03
RM7895A,B,C,D/EC7895A,C; RM7896A,C,D7800 SERIES Relay Modules
For More Information
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Combustion Safety, Eclipse, Exothermics, Hauck, Kromschröder and
Maxon. To learn more about our products, visit ThermalSolutions.
honeywell.com or contact your Honeywell Sales Engineer.
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© 2020 Honeywell International Inc.
32-00156-03 Edition 03.20
Printed in United States
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