Honeywell RM7895A Primary Control With Pre And Post Purge Intermittent Pilot Instruction Manual

: September 27, 2024
: Honeywell

Table of Contents

RM7895A Primary Control With Pre And Post Purge Intermittent Pilot
Product Information
Specifications
Product Usage Instructions
Installation
Location and Humidity
- FAQ
Q: What should I do if I encounter a safety shutdown due to
Q: Can the relay modules be used in high-temperature

RM7895A Primary Control With Pre And Post Purge Intermittent Pilot

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Product Information

Specifications

Product Name: RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D 7800
SERIES Relay Modules
Functions: Automatic burner sequencing, flame supervision,
system status indication, system or self-diagnostics,
troubleshooting, postpurge function (RM7896)
Environmental Ratings: Ambient Temperature: Maximum 85%
relative humidity continuous, noncondensing, moisture
environment
Approvals: UL Listed, CSA Certified, Factory Mutual Approved,
IRI Acceptable, FCC Part 15 Class B Emissions

Product Usage Instructions

Installation

When Installing this Product…

Read the instructions carefully to prevent damage or hazardous
conditions.
Check ratings to ensure suitability for the application.
Installer must be a trained, experienced flame safeguard
service technician.
After installation, check product operation as per
instructions.

Warnings:

Fire or Explosion Hazard: Follow safety requirements to prevent
property damage or injury.
Electrical Shock Hazard: Disconnect power supply before
installation.

Important Notes:

Wiring connections are unique; refer to Fig. 2 and 3 or
appropriate Specifications for proper subbase wiring.
Wiring must comply with all codes, ordinances, and
regulations.
Wiring must comply with NEC Class 1 (Line Voltage) wiring
standards.

Location and Humidity

Install the relay module where humidity never reaches saturation
point. Operate in a maximum 85% relative humidity continuous,
noncondensing, moisture environment to prevent safety shutdown due
to condensing moisture.

FAQ

Q: What should I do if I encounter a safety shutdown due to

condensing moisture?

A: If a safety shutdown occurs due to
condensing moisture, immediately disconnect power supply and dry
out the affected area thoroughly before attempting to restart the
product.

Q: Can the relay modules be used in high-temperature

environments?

A: The relay modules are designed to operate
within specified ambient temperature limits. Ensure the ambient
temperature does not exceed the recommended range to prevent damage
or malfunction.

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RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D 7800 SERIES Relay Modules

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 ControlBusTM 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.
63-2278 65-0084
65-0090
65-0091
65-0095 65-0097 65-0101 65-0102
65-0109

Product
Q7700 Network Interface Unit Product Data
Q7800A,B 22-Terminal Wiring Subbase Product Data
S7800A Keyboard Display Module Product Data
S7810A Data ControlBus ModuleTM Product Data
S7820 Remote Reset Module Product Data
221729C Dust Cover Packing Instructions
S7830 Expanded Annunciator Product Data
ZM7850A Combustion System ManagerTM Operating Instructions
R7824, R7847, R7848, R7849, R7851, R7861, R7886 Flame Amplifiers for the 7800 Series Product Data

INSTALLATION INSTRUCTIONS

Publication No.
65-0131
65-0229
65-0092 65-0227

Product
221818A Extension Cable Assembly Product Data
7800 SERIES Relay Modules Checkout and Troubleshooting Product Data.
QS7800A ControlBusTM Module, Standard
QS7800B ControlBusTM 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.

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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, 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 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 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).

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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. 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 ControlBusTM 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 PROVIDE DISCONNECT MEANS AND

5

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

RUN/TEST SWITCH
RESET PUSHBUTTON

L1

L2

(HOT)

1

L2 RM7895, RM7896: 120 VAC, 50/60 HZ. EC7895A,C: 220-240 VAC, 50/60 HZ.

CONFIGURATION JUMPERS

PLUG-IN PURGE TIMER CARD
FLAME SIGNAL

TEST JACK

MICROCOMPUTER
2K RELAY 3K DRIVE 4K CIRCUIT 5K
6K 7K

F

PLUG-IN

TEST FLAME

G

AMPLIFIER

22

RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS

STATUS LEDs

SAFETY RELAY CIRCUIT

1K POWER SUPPLY

CONTROL POWER

DDL

OPTIONAL KEYBOARD DISPLAY MODULE
RS485

DDL COMMUNICATIONS
M23996

1

2

3

REMOTE RESET

1K1 2K1 5K1

6

7

10

IGNITION

LIMITS

CONTROLLER INTERLOCK (INCLUDING
AIRFLOW SWITCH)

2

4K1

8

PILOT

2K2 9 MAIN VALVE

6K1

4

BLOWER

3K1

3

ALARM

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

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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

3

Q7800

G

12

L2

13

3

14

4

15

5 (L1) 16

6

17

7

18

FOR DIRECT SPARK IGNITION (OIL OR GAS)

IGNITION 10 TRANSFORMER
L2

8

MAIN VALVE

2

8

19

9

20

10

21

F

22

MASTER SWITCH

L1 (HOT)
L2 1

LED DISPLAY

INITIATE POWER

00 STANDBY
POWER

00 TIMED

START

PURGE

00 PFEP
4 OR 10 SEC

POWER

RUN

7 POST PURGE
15 SEC

POWER

STANDBY POWER

PILOT FLAME MAIN

ALARM

BURNER START

BURNER/BLOWER MOTOR

4

7

10 IGN 5

IGN/ PILOT

8

MAIN VALVE 9

OPERATING CONTROLS AND INTERLOCKS
FLAME SIGNAL

LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6

6 AIRFLOW SW CHECK

LOCKOUT INTERLOCK CLOSED 6 TO 7

SAFE START CHECK

FLAME PROVING

AFSC SSC

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.

4 SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.

5 FOR RM7895A1048 (ONLY), IGNITION TERMINAL 10 IS DE-ENERGIZED WHEN FLAME IS PROVEN.

6 AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895B,RM7896B.

7 RM7896A,B ONLY.

M23997

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

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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 3

Q7800

G

12

L2

13

3

14

4

15

5 (L1) 16

FOR DIRECT SPARK IGNITION (OIL OR GAS)

10

IGNITION TRANSFORMER

8

L2

9

MAIN VALVE

6

17

2

7

18

8

19

9

20

DELAYED

10

21

(2ND STAGE) MAIN VALVE

F

22

MASTER SWITCH

L1 (HOT)
L2 1

LED DISPLAY
BURNER START

INITIATE POWER

00
STANDBY POWER

00

START

TIMED PURGE

PFEP 7 4 OR 10 SEC MFEP

POWER

PILOT

FLAME

MAIN

ALARM

RUN POWER

6
POST PURGE 15SEC POWER

STANDBY POWER

PILOT FLAME MAIN

ALARM

BURNER/BLOWER MOTOR 4

6

IGN. 10 8 10 SEC. IGN./ PILOT 8

MAIN VALVE

9

2ND STAGE MAIN 21

OPERATING CONTROLS AND INTERLOCKS
FLAME SIGNAL

LIMITS AND BURNER CONTROLLER CLOSED

L1 TO 6

5 AIRFLOW SW. CHECK

LOCKOUT INTERLOCK CLOSED

6 TO 7

SAFE START CHECK

FLAME PROVING

AFSC SSC

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.

5 AIRFLOW SWITCH CHECK FEATURE IS FOR THE RM7895D, RM7896D. 6 RM7896C,D ONLY.

2 DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.

7 RM7895C1020, RM7896C1036 PFEP 10 SECONDS ONLY;

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.

RM7895C1053 PFEP 4 SECONDS ONLY, 3 SECONDS ONLY SOFTWARE REVISION 4151.

4 SEE FLAME DETECTOR SPECIFICATIONS FOR CORRECT WIRING.

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.

M23998

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

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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.

Data ControlBusTM Modulea 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 22 AWG two-wire twisted pair with ground. ControlBusTM Modulea

Belden 8723 shielded cable or equivalent.

13 Vdc full-wave rectified transformer power input.

18 AWG wire insulated for voltages and temperatures TTW60C, THW75C, THHN90C. for given application.

a The KDM, Data ControlBusTM Module (for remote mounting or communications) or Communication Interface ControlBusTM 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 ControlBusTM Module, Communications Interface ControlBusTM 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.

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 ModuleTM, or Remote Reset Module wiring. b. Do not route flame detector, Data ControlBusTM 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 ControlBusTM 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 leadwires: The maximum leadwire length is 300 feet 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 ModuleTM: The maximum Data ControlBusTM Module cable length depends on the number of system modules connected, the noise conditions and the cable used. The maximum length of all Data ControlBusTM 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.
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.

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Table 3. Terminal Ratings.

Terminal Number

Description

RM7895/RM7896

Ratings

EC7895

G

Flame Sensor Ground

—

Earth G Earth Grounda

—

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

120 Vacc

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

9

Main Fuel Valve

120 Vacc

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

10

Ignition

120 Vacc

220-240 Vac, 2A at PF = 0.2

F(11) Flame Sensor

60 to 220 Vac, current limited.

12 to 20 Unused

—

21

2nd Stage Main Valve (EC7895C, 120 Vacc

RM7895C,D; RM7896C,D)

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

22

Shutter

120 Vac, 0.5A

220-240 Vacd

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.

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

Combination Number

1

C

2

B

3

Fa

4

F

5

Fa

6

D

7

Da

8

D

9

Da

Pilot Fuel 8

Main 9 F F No Load
F No Load F No Load D No Load

Ignition 10 No Load No Load A
A A A A A A

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

Delayed Main Valve 21 No Load No Load No Load
No Load F No Load D No Load D

Table 5. Composition of each Combination.

A 4.5A ignition

B
50 VA Pilot Dutya plus 4.5A ignition.

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

D 2A Pilot Duty.a

a Pilot Duty refers to solenoid-type valves.

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

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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 Relay Module Test Number Model Jumpers Voltmeter

Normal Operation

1

All

None 5-L2

Line voltage at terminal 5.

2

All

3

All

4

All

None 4-5

6-L2 7-L2

5-10

—

Line voltage at terminal 6.
1. Burner motor (fan or blower) starts.
2. Line voltage at terminal 7 within 10 seconds.
1. Ignition spark (if ignition transformer is connected to terminal 10).

If Operation is Abnormal, Check Items Listed Below
1. Master switch. 2. Power connected to master switch. 3. Overload protection (fuse, circuit breaker,
etc.) has not opened power line.
1. Limits. 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.

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Table 6. Static Checkout (Continued).

Test Relay Module Test Number Model Jumpers Voltmeter

Normal Operation

5

All

5-8

—

1. Ignition spark (if ignition 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.

6
7
8 Final

All
EC7895C; RM7895C,D; RM7896C,D
All All

5-9 5-21 5-3

NOTE: Refer to wiring diagram of system being tested.

—

Automatic fuel valve(s) open(s). If Same as test 5. If using direct spark

using direct spark ignition, check ignition, check first stage fuel valve(s)

first stage fuel valve(s) instead of instead of pilot valve.

pilot valve.

—

Automatic second stage main fuel 1. Listen for and observe operation of

valve(s) open(s).

second stage main fuel valve(s) and

actuator(s).

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

—

Alarm (if used) turns on.

1. Alarm.

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.

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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
RESET BUTTON
DUST COVER

POWER PILOT FLAME MAIN ALARM
RESET

HONEYWELL
CAPTIVE MOUNTING SCREW

BURNER CONTROL

FLAME AMPLIFIER

M15122

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) 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.

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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

CAPTIVE MOUNTING
SCREW

PLUG-IN PURGE CARD

SEQUENCE STATUS LEDs

DUST COVER
RELAY MODULE

RESET PUSHBUTTON
FLAME SIMULATOR INPUT

FLAME AMPLIFIER
FLAME CURRENT TEST JACKS M7552A

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 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 JR1a, b
JR2c JR3

Description Pilot Flame Establishing Period (PFEP) Flame Failure Action
Airflow Switch (ILK) Failure

Intact 10 seconds Recycle
Recycle

Clipped 4 seconds
Lockout Lockout

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
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