Honeywell RM7895A Thermostat User Manual

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7
800 SERIES EC7895A, RM7895A  
Relay Module  
PRODUCT DATA  
Dependable, long-term operation provided by microcomputer  
technology.  
First-out annunciation and system diagnostics provided by a 2  
row by 20 column Vacuum Fluorescent Display (VFD) located  
on the optional Keyboard Display Module.  
Five (LEDs) for sequence information.  
Interchangeable plug-in flame amplifiers.  
Local or remote annunciation of EC7895 and RM7895  
operation and fault information.  
Nonvolatile memory; EC7895 and RM7895 retain history files  
and sequencing status after loss of power.  
Remote reset (optional).  
Report generation (optional).  
Selectable recycle or lockout on loss of airflow.  
Selectable recycle or lockout on loss of flame.  
Shutter drive output.  
Burner controller data (optional):  
Flame signal strength.  
Hold status.  
Lockout/alarm status.  
Sequence status.  
Sequence time.  
Total cycles of operation.  
Total hours of operation.  
Fault history providing for the six most recent faults:  
GENERAL  
Cycles of operation at the time of the fault.  
Fault message and code.  
Hours of operation at the time of the fault.  
Sequence status at the time of the fault.  
Sequence time at the time of the fault.  
The Yamatake Honeywell EC7895A and RM7895 is a microprocessor  
based integrated burner control for automatically fired gas, oil, or  
combination fuel single burner applications. The RM7895 consists of  
the Relay Module. Subbase, Amplifier and Purge Card. Options  
include Keyboard Display Module, Personal Computer Interface,  
DATA CONTROLBUS MODULE™, Remote Display Module, and  
COMBUSTION SYSTEM MANAGER™ Software.  
Diagnostic information:  
Device type.  
Flame amplifier type.  
Flame failure response time.  
Manufacturing code.  
On/Off status of all digital inputs and outputs.  
Selected prepurge time.  
Software revision and version of EC7895 and RM7895  
and optional Keyboard Display Module.  
Status of configuration jumpers.  
The EC7895 and RM7895 are programmed to provide a level of  
safety, functional capability and features beyond the capacity of  
conventional controls.  
Functions provided by the EC7895 and RM7895 include automatic  
burner sequencing, flame supervision, system status indication,  
system or self-diagnostics and troubleshooting.  
Contents  
FEATURES  
General .........................................................................................  
Features ........................................................................................  
Specifications ................................................................................  
Ordering Information .....................................................................  
Principal Technical Features .........................................................  
Safety Provisions ..........................................................................  
Installation .....................................................................................  
Wiring ............................................................................................ 11  
Assembly ...................................................................................... 14  
Operation ...................................................................................... 17  
Checkout ....................................................................................... 20  
Troubleshooting ............................................................................ 26  
1
1
2
2
8
8
9
Safety features:  
Airflow switch check.  
Closed loop logic test.  
Dynamic AMPLI-CHECK®.  
Dynamic input check.  
Dynamic safety relay test.  
Dynamic self-check logic.  
Internal hardware status monitoring.  
Tamper resistant timing and logic.  
Access for external electrical voltage checks.  
Application flexibility.  
Communication interface capability.  
Copyright © 1996 Honeywell Inc.  
All Rights Reserved  
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Electrical Ratings, see Table 1A:  
SPECIFICATIONS  
Voltage and Frequency: 100 Vac (+10/-15%), 50 or 60 Hz  
1
(+/- 10%).  
Model:  
RM7895A  
Power Dissipation: RM7895: 10W maximum.  
Maximum Total Connected Load: 2000 VA.  
Fusing Total Connected Load: 20A maximum, type FRN or  
equivalent.  
Table 1A. RM7895A Terminal Ratings.  
Terminal No.  
Description  
Ratings  
G
Flame Sensor Ground  
2
Earth G  
Earth Ground  
L2(N)  
Line Voltage Common  
Alarm  
3
4
5
6
7
8
9
100 Vac, 1A pilot duty.  
Burner Motor  
Line Voltage Supply (L1)  
Burner Controller and Limits  
Airflow Interlock  
Pilot Valve/Ignition  
Main Fuel Valve  
Ignition  
100 Vac, 9.8 AFL, 58.8 ALR (inrush).  
100 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).  
100 Vac, 1 mA.  
3,4  
100 Vac, 9A.  
100 Vac, 4.5A ignition and 50VA pilot duty.  
100 Vac, 2A pilot duty.  
100 Vac, 4.5A ignition.  
4
5
4
10  
F(11)  
Flame Sensor  
Unused  
60 to 220 Vac, current limited.  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Shutter  
100 Vac, 0.5A  
1
2
Range of allowable operating frequency: 45 to 66 Hz.  
The 7895 must have an earth ground providing a connection between the subbase and the control panel or the equipment.  
The earth ground wire must be capable of conducting the current to blow the 20A fuse (or breaker) in event of an internal short  
circuit. The 7895 needs a low impedance ground connection to the equipment frame which, in turn, needs a low impedance  
connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be made with  
minimum length conductors that have maximum surface areas. Wide straps or brackets rather than leadwires are preferred.  
Be careful to verify that mechanically tightened joints along the ground path, such as pipe or conduit threads or surfaces held  
together with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion.  
3
2
000 VA maximum connected load to 7895 Assembly.  
4
5
Can also be 100 Vac, 1A pilot duty.  
Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.  
ORDERING INFORMATION  
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the  
TRADELINE® Catalog or price sheets for complete ordering number.  
If you have additional questions, need further information, or would like to comment on our products or services, please write or  
phone:  
1
2
.
.
Your local Home and Building Control Sales Office (check white pages of your phone directory).  
Home and Building Control Customer Relations  
Honeywell, 1885 Douglas Drive North  
Minneapolis, Minnesota 55422-4386  
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.  
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,  
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.  
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Model:  
EC7895  
Electrical Ratings, see Table 1B:  
Voltage and Frequency: 200 Vac (+10/-15%), 50 or 60 Hz  
1
(+/- 10%).  
Power Dissipation: EC7895: 10W maximum.  
Maximum Total Connected Load: 2000 VA.  
Fusing Total Connected Load: 20A maximum, type FRN or  
equivalent.  
Table 1B. EC7895A Terminal Ratings.  
Terminal No.  
Description  
Flame Sensor Ground  
Earth Ground2  
Line Voltage Common  
Alarm  
Ratings  
G
Earth G  
L2 (N)  
3
4
5
6
7
8
9
200 Vac, 1A pilot duty.  
Burner Motor  
Line Voltage Supply (L1)  
Burner Controller and Limits  
Airflow Interlock  
Pilot Valve/Ignition  
Main Fuel Valve  
Ignition  
200 Vac, 4A at pF = 0.5, 20A inrush4  
200 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).3,4  
200 Vac, 1 mA.  
200 Vac, 9A.  
200 Vac, 4A at pF = 0.5, 20A inrush4  
200 Vac, 4A at pF = 0.5, 20A inrush4  
200 Vac, 4A at pF = 0.5, 20A inrush4  
60 to 220 Vac, current limited.  
10  
F(11)  
Flame Sensor  
Unused  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Unused  
Shutter  
200 Vac, 0.5A  
1
Range of allowable operating frequency 45 through 66 Hz.  
2
The EC7895 must have an earth ground providing a connection between the subbase and the control panel or the equipment.  
The earth ground wire must be capable of conducting the current to blow the 20A fuse (or breaker) in event of an internal short  
circuit. The RM7895 needs a low impedance ground connection to the equipment frame which, in turn, needs a low  
impedance connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be  
made with minimum length conductors that have maximum surface areas. Wide straps or brackets rather than leadwires are  
preferred. Be careful to verify that mechanically tightened joints along the ground path, such as pipe or conduit threads or  
surfaces held together with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion.  
3
2
000 VA maximum connected load to EC7895 Assembly.  
Total load current excluding burner/boiler motor and firing rate outputs cannot exceed 5A, 25A inrush.  
4
3
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Environmental Ratings:  
Weight:  
Ambient Temperature:  
RM7895 with Dust Cover: 1 pound 15 ounces, unpacked.  
Operating: -40° F to 140° F.  
Storage: -60° F to 150° F.  
Humidity: 85% RH continuous, noncondensing.  
Vibration: 0.5G environment.  
IMPORTANT  
Flame Detection System available for use with  
EC7895 and RM7895. To select your Plug-in Flame  
Signal Amplifier and applicable Flame Detector, see  
Table 2 and Fig. 3 through 5.  
Dimensions:  
Refer to Fig. 1 and 2.  
Table 2. Flame detection systems (Figs. 3, 4, 5).  
Plug-in Flame Signal Amplifiers  
Applicable Flame Detectors  
Flame  
Failure  
Response  
Time  
Self-  
Checking  
No  
Type  
Color  
Model  
Fuel  
Gas  
Type  
Models  
Rectification  
Green  
R7847A  
.8 or 3 sec  
Rectifying Flame C7004, C7007, C7011  
Rod Holders  
a
Complete Assemblies:  
C7008, C7009, Q179.  
No  
No  
R7847A  
R7847A  
R7847Bd  
.8 or 3 sec  
3 sec  
Oil  
Rectifying  
Photocell  
C7003, C7010, C7013,  
C7014  
C7012A,C.c  
b
Gas,  
Ultraviolet  
Oil, Coal (Purple Peeper)  
Dynamic  
AMPLI-  
CHECK®  
.8 or 3 sec  
Gas  
Rectifying Flame C7004, C7007, C7011  
a
Rod Holders Complete Assemblies:  
C7008, C7009, Q179.  
Dynamic  
AMPLI-  
CHECK®  
R7847Bd  
R7847Bd  
.8 or 3 sec  
3 sec  
Oil  
Rectifying  
Photocell  
C7003, C7010, C7013,  
C7014  
b
Dynamic  
AMPLI-  
Gas,  
Ultraviolet  
C7012A,C.c  
Oil, Coal (Purple Peeper)  
CHECK®  
Dynamic  
Self-Check  
R7847Ce  
R7848A  
R7848Bd  
3 sec  
3 sec  
3 sec  
Gas,  
Oil, Coal (Purple Peeper)  
Gas, Infrared  
Oil, Coal (Lead Sulfide)  
Gas, Infrared  
Ultraviolet  
C7012E,F.  
C7015  
Infrared  
Red  
No  
Dynamic  
AMPLI-  
C7015  
Oil, Coal (Lead Sulfide)  
CHECK®  
Ultraviolet  
Purple  
No  
R7849A  
.8 or 3 sec  
.8 or 3 sec  
Gas, Oil Ultraviolet  
C7027, C7035,  
C7044.  
c
(MiniPeeper)  
Dynamic  
AMPLI-  
R7849Bd  
Gas, Oil Ultraviolet  
(MiniPeeper)  
C7027, C7035,  
c
C7044.  
CHECK®  
Dynamic  
Self-Check  
R7861A  
3 sec  
3 sec  
Gas,  
Oil, Coal  
Ultraviolet  
Ultraviolet  
C7061  
C7076  
f
Blue  
Dynamic  
Self-Check  
R7886Ae  
Gas,  
g
Oil, Coal (Adjustable  
Sensitivity)  
a
b
c
Order flame rod separately; see holder Instructions.  
Use only Honeywell Photocell, part no. 38316.  
The C7012A,C, C7027, C7035 and C7044 Flame Detectors should be used only on burners that cycle on-off at least once  
every twenty-four hours. Appliances with burners that remain on continuously for twenty-four hours or longer should use the  
C7012E,F Flame Detector with the R7847C Amplifier or the C7076A,D Flame Detector with the R7886A Amplifier or the C7061  
Flame detector with the R7861 Amplifier as the ultraviolet flame detection system.  
Circuitry tests the flame signal amplifier at least 12 times a minute during burner operation and shuts down the burner if the  
amplifier fails.  
Circuitry tests all electronic components in the flame detection system (amplifier and detector) 12 times a minute during burner  
operation and shuts down the burner if the detection system fails.  
When R7861 is used with EC7895, the application requires a step down transformer. See Fig. 14.  
Use with RM7895A only.  
d
e
f
g
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Sequence Timing For Normal Operation:  
Flame Establishing Period  
Device  
Initiate  
Standby  
Purge  
Pilot  
Main  
No  
EC7895A/RM7895A  
10 sec.  
*
**  
4 or 10 sec.  
*
*
STANDBY and RUN can be an infinite time period.  
* PURGE is determined by the ST7800A Purge Card selected.  
Approval Bodies:  
Accessories:  
RM7895A:  
Optional:  
Underwriters Laboratories Inc. listed: File no. MP268,  
Guide no. MCCZ.  
Network Interface Unit,  
Part No. Q7700A1014, 120V 50/60 Hz  
Factory Mutual approved.  
EC7895A:  
Factory Mutual approved.  
Part No. Q7700B1004, 100V to 200V 50/60 Hz  
Network Interface ControlBus Module,  
Part No. QS7800A1001.  
COMBUSTION SYSTEM MANAGER™,  
Mounting:  
Part No. ZM7850A1001.  
Q7800A for panel mount or Q7800B for wall or burner mount.  
ControlBus 5-Wire Electrical Connector,  
Part No. 203541.  
Required Components:  
DATA CONTROLBUS MODULE™,  
Part No. S7810A1009.  
Dust Cover, Part No. 221729A.  
Plug-in Flame Signal Amplifier, see Table 2.  
Plug-in Purge Timer Cards: Selectable ST7800A, two  
seconds to 30 minutes.  
Flame Simulators:  
Q7800A or Q7800B.  
UV Flame Simulator, Part No. 203659.  
Rectification Simulator, Part No. 123514A.  
Keyboard Display Module, Part No. S7800A1001,  
English.  
Keyboard Display Module, Part No. S7800A1118,  
Japanese.  
Remote Display Mounting Bracket, Part No. 203765.  
Remote Display Power Supply, Part No. 203968A Plug-in.  
Remote Reset Module, Part No. 57820A1007.  
Sixty-inch Extension Cable Assembly, Part No. 221818A.  
BURNER  
CONTROL  
5
127)  
1
(
POWER  
PILOT  
FLAME  
MAIN  
ALARM  
RESET  
5
-1/4 (133)  
5
(127)  
M11135  
1
REMOVE ONLY FOR TERMINAL TEST ACCESS.  
Fig. 1. Mounting dimensions of EC7895/RM7895 Relay Module and Q7800A Subbase in in. (mm).  
5
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
BURNER  
CONTROL  
5
(
127)  
POWER  
PILOT  
FLAME  
MAIN  
1
ALARM  
RESET  
6-3/32 (155)  
5
(127)  
1
REMOVE ONLY FOR TERMINAL TEST ACCESS.  
M11134  
Fig. 2. Mounting dimensions of EC7895/RM7895 Relay Module and Q7800B Subbase in in. (mm).  
IGNITION  
ELECTRODE  
FLAME ROD  
(Q179C ONLY)  
CERAMIC  
INSULATORS  
1
(25)  
1
-21/32  
1-13/32  
(36)  
(42)  
TARGET  
/8 (10)  
MOUNTING FLANGE  
-7/32  
183)  
3/4–14 NPT  
3
7
(
5-1/8 (130)  
3
(
-1/8  
79)  
1
-1/16  
3-3/4  
95)  
(27)  
1/2 (13)  
(
3-7/16  
(87)  
3/32 (2)  
11/16  
(
18)  
2
(
5/32  
20)  
25/32  
(20)  
1
(
7/32  
14)  
THREADED  
MOUNTING  
HOLES (2)–  
10-32 UNF  
1/2–14 NPSM  
5-1/4 (133)  
2
-25/32  
62)  
LEADWIRES  
(
FACEPLATE  
M1962A  
BRACKET  
M1983  
Q179  
C7012A,C,E,F  
13/16 (21)  
1-1/4 (32)  
1-3/8 (35)  
2
(
51)  
1
(
-3/4  
45)  
1-1/4 (32)  
1-5/16 (33)  
5
(
/16  
8)  
C7013A  
C7014A  
M1847  
Fig. 3. Rectification detectors.  
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
4-1/8 (105)  
COLLAR WITH  
–11-1/2 NPSM  
2 (51)  
-3/16  
(30)  
1/2-14 NPSM  
INTERNAL THREADS  
2
1
1
INTERNAL  
THREADS  
1
4
(102)  
6 FOOT (1.83 METER)  
LEADWIRES (2)  
3-1/2 (89)  
1
3
1/32  
1
(
-1/2 (25)  
38)  
1-1/16  
(27)  
2
6
[
FOOT  
1.83 METER]  
LEADWIRES (2)  
2-5/8 (67)  
INSERTION DEPTH  
3
COLLAR WITH 1/2-14 NPSM  
INTERNAL THREADS  
1
2
3
DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL THREADS.  
DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL THREADS.  
1
2
MODEL AVAILABLE WITH 24 FOOT (7.32 METER) LEADWIRES.  
MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL  
THREADS) INSTEAD OF CLAMP TYPE CONNECTOR.  
M1943A  
MODEL AVAILABLE WITH 12 FOOT [3.66 METER] LEADWIRES.  
M1945A  
C7027  
C7035  
6
FOOT [1.83 METER]  
LEADWIRES (2)  
MOUNTING BRACKET  
3/8  
(10)  
7/8  
(22)  
9/16  
(14)  
1/2  
(13)  
1-27/64  
3-5/8 (92)  
(36)  
M1944A  
C7044  
1-1/16 (27)  
2-1/4  
1
INCH NPT  
(57)  
2-1/4  
(57)  
4
102)  
(
2
(
-5/16  
58)  
4
(102)  
1-13/32 (188)  
4-27/32 (123)  
10-9/32 (261)  
7/8 (22) OPENING  
3/4 (19)  
FOR 1/2-INCH CONDUIT  
29/32 (23)  
1-19/32  
(41)  
3/8 INCH NPT  
1
ALLOW 9 INCHES (228 MILLIMETERS)  
CLEARANCE TO SWING OUT THE DETECTOR  
FOR LENS CLEANING OR SERVICING.  
2
-11/16  
7-5/8 (194)  
(68)  
M5083A  
C7076A  
Fig. 4. Ultraviolet detectors in in. (mm).  
7
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
11-13/16 (300)  
2
(
-5/32  
55)  
1-27/32  
(47)  
1
INCH NPT  
7-13/16 (198)  
5-13/16 (147)  
15/16 [24] DIA.  
5
-13/16  
6
(
-7/32  
158)  
(147)  
2
(
-1/2  
64)  
6-19/32  
(
168)  
1
(25)  
15/16–18 UNC  
(
2 EACH)  
2
(51)  
C7076D  
M5084A  
Fig. 4. Ultraviolet detectorsin in. (mm) (Continued).  
CELL MOUNT  
HEAT BLOCK  
d. Main valve terminal is energized.  
e. Internal system fault occurred.  
f. Purge card is removed.  
1-5/8 (41)  
2-3/4  
70)  
1-1/16 (27)  
(
g. Purge card is bad.  
4
. Pilot Flame Establishing Period (PFEP)  
1
(
-1/4  
32)  
a. Airflow lockout feature is enabled and the airflow  
switch opens.  
1
(
-1/4  
32)  
2
4
LEADS IN A  
8 INCH (1.2 METER)  
b. Ignition/pilot valve terminal is not energized.  
c. No flame present at end of PFEP.  
d. Main valve terminal is energized.  
e. Internal system fault occurred.  
f. Purge card is removed.  
APERTURE  
FLEXIBLE CONDUIT  
3
/4-14  
3/4-14 NPSM  
INTERNAL  
THREADS  
BUSHING WITH  
MAGNIFYING LENS  
NPSM  
COLLAR, 3/4-14 NPSM  
INTERNAL THREADS  
C7015  
Fig. 5. Infrared detector in in. (mm).  
M1982A  
g. Purge card is bad.  
. Run Period  
5
a. No flame present.  
b. Airflow lockout feature is enabled and the airflow  
switch opens.  
c. Main valve terminal is not energized.  
d. Internal system fault occurred.  
e. Purge card is removed.  
PRINCIPAL TECHNICAL FEATURES  
The EC7895 or RM7895 provides all customary flame  
safeguard functions while providing significant advancements  
in the areas of safety, annunciation and system diagnostics.  
f. Purge card is bad.  
SAFETY PROVISIONS  
Safety Shutdown (Lockout) Occurs If:  
1. Initiate Period  
Internal Hardware Status Monitoring  
a. Purge card is not installed or removed.  
b. Purge card is bad.  
c. Configuration jumpers have been changed (after  
The EC7895 or RM7895 checks the purge card for correct  
parity to prevent purge timing shifts and circuitry failures. It  
also analyzes the integrity of the configuration jumpers and  
internal hardware. The POWER LED blinks every four  
seconds, signifying an internal hardware check.  
200 hours).  
d. AC line power errors occurred, see Operation.  
e. Four minute INITIATE period was exceeded.  
. Standby Period  
2
a. Flame signal is present after 40 seconds.  
b. Ignition/pilot valve/intermittent pilot valve terminal  
is energized.  
c. Main valve terminal is energized.  
d. Internal system fault occurred.  
e. Purge card is not installed or removed.  
f. Purge card is bad.  
Closed Loop Logic Test  
The test verifies the integrity of all safety critical loads,  
terminals 8, 9, 10 and 21. If the loads are not energized  
properly; i.e., the main valve terminal is powered during  
PREPURGE, the EC7895 or RM7895 locks out on safety  
shutdown. The EC7895 or RM7895 must react to input  
changes but avoid the occurrence of nuisance shutdown  
events. Signal conditioning is applied to line voltage inputs to  
verify proper operation in the presence of normal electrical  
line noise such as transient high voltage spikes or short  
periods of line dropout. Signal conditioning is tolerant of  
synchronous noise (line noise events that occur at the same  
time during each line cycle).  
3
. Prepurge 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.  
65-0205  
8
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Dynamic Ampli-Check  
®
Verified Spark Termination  
Dynamic AMPLI-CHECK® circuitry tests the flame signal  
amplifier during burner operation and shuts down the EC7895  
or RM7895 if the flame amplifier fails.  
The ignition terminal is monitored to assure early spark  
termination (ten seconds ignition and pilot and ten seconds  
pilot and main only).  
Dynamic Flame Amplifier and Shutter Check  
First-Out Annunciation AND Self-Diagnostics  
Self-checking circuitry tests all electronic components in the  
flame detection system and amplifier 10 to 12 times per  
minute and shuts down the EC7895 or RM7895 if the  
detection system fails.  
Sequence Status Lights (LEDs) provide positive visual  
indication of the program sequence: POWER, PILOT,  
FLAME, MAIN and ALARM. The green POWER LED blinks  
every four seconds, signifying that the RM7895 hardware is  
running correctly.  
Dynamic Input Check  
Optional multi-function Keyboard Display Module shows  
elapsed time during PREPURGE, PILOT IGN and MAIN IGN.  
As an additional troubleshooting aid, it provides sequence  
timing, diagnostic information and historical information when  
a safety shutdown or hold or normal operation occurs.  
All system input circuits are examined to assure that the  
EC7895 or RM7895 is capable of recognizing the true status  
of external controls, limits and interlocks. If any input fails this  
test, a safety shutdown occurs and the fault is annunciated.  
Dynamic Safety Relay Test  
First-out Annunciation reports the cause of a safety shutdown  
or identifies the cause of a failure to start or continue the  
burner control sequence with text and numbered code via the  
optional Keyboard Display Module. It monitors all field input  
circuits, including the flame signal amplifier. The system  
distinguishes 43 modes of failure and detects and  
Checks the ability of the dynamic safety relay contact to open  
and close. Verifies that the safety critical loads, terminals 8, 9,  
10 and 21, can be de-energized, as required, by the Dynamic  
Self-Check logic.  
annunciates difficult-to-find intermittent failures.  
Dynamic Self-Check Safety Circuit  
The microcomputer tests itself and related hardware, and at  
the same time, the safety relay system tests the  
microcomputer operation. If a microcomputer or safety relay  
failure occurs and does not allow proper execution of the self-  
check routine, safety shutdown occurs and all safety critical  
loads are de-energized.  
Self-Diagnostics add to the First-out Annunciation by allowing  
the EC7895 or RM7895 to distinguish between field (external  
device) and internal (system related) problems. Faults  
associated within the flame detection subsystem, EC7895 or  
RM7895 or Plug-in Purge Card are isolated and reported by  
the optional Keyboard Display Module. See the 7800 SERIES  
System Annunciation Diagnostics and Troubleshooting,  
form 65-0118.  
Expanded Safe-Start Check  
The conventional safe-start check, which prevents burner  
start-up if flame is indicated at start-up, is expanded to  
include a flame signal check during STANDBY, an airflow  
switch check and a safety critical load check.  
Airflow Switch Interlock  
This interlock is typically connected to an airflow switch. The  
Airflow Interlock (ILK) input must close ten seconds into  
PREPURGE or within the specified purge card timing;  
otherwise, a recycle to the beginning of PRE-PURGE or  
lockout will occur, depending on how the airflow switch  
selectable jumper is configured (see Table 3 in Operation  
section).  
Off Cycle (Standby or Prepurge) Flame  
Signal Check  
The flame detection subsystem (flame detector and amplifier)  
is monitored during STANDBY. If a flame simulating condition  
or an actual flame exists, a system hold occurs and start-up is  
prevented. If the flame signal exists at any time after the first  
INSTALLATION  
40 seconds of STANDBY, a safety shutdown occurs and is  
annunciated. A shutter-check amplifier and self-checking  
detector are energized for the first 40 seconds during  
STANDBY and the last two seconds before exiting STANDBY.  
If a flame exists, a safety shutdown occurs. An AMPLI-  
CHECK® Amplifier is energized continually through  
STANDBY and PREPURGE to detect any possibility of a  
runaway detector or a flame. If a flame exists, a safety  
shutdown occurs. A standard amplifier is energized  
continually through STANDBY and PREPURGE; if a flame  
exists, a safety shutdown occurs.  
WARNING  
CAN CAUSE PROPERTY DAMAGE,  
SEVERE INJURY, OR DEATH  
To prevent possible hazardous burner operation,  
verification of safety requirements must be performed  
each time a control is installed on a burner.  
FIRE OR EXPLOSION HAZARD  
Tamper Resistant Timing and Logic  
Safety and logic timings are inaccessible and cannot be  
altered or defeated.  
9
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
When Installing this Product…  
Humidity  
1
. Read these instructions carefully. Failure to follow them  
could damage the product or cause a hazardous  
condition.  
Install the EC7895 or RM7895 where the relative humidity  
never reaches the saturation point. The EC7895 or RM7895  
is designed to operate in a maximum 85% RH continuous,  
noncondensing, moisture environment. Condensing moisture  
can cause a safety shutdown.  
2
. Check the ratings given in the instructions and marked  
on the product to make sure the product is suitable for  
your application.  
3
. Installer must be a trained, experienced, flame  
safeguard service technician.  
Vibration  
Do not install the EC7895 or RM7895 where it could be  
subjected to vibration in excess of 0.5G continuous maximum  
vibration.  
4. After installation is complete, check out the product  
operation as provided in these instructions.  
Weather  
CAUTION  
The EC7895 or RM7895 is not designed to be weather tight.  
If installed outdoors, the EC7895 or RM7895 must be  
protected by an approved weather-tight enclosure.  
1.  
Disconnect the power supply before beginning  
installation to prevent electrical shock and  
equipment damage. More than one power supply  
disconnect may be involved.  
Mounting Wiring Subbase  
2
.
Wiring connections for the EC7895 or RM7895  
are unique; therefore, refer to Fig. 7 or 8 for the  
correct Specifications for proper subbase wiring.  
Wiring must comply with all applicable codes,  
ordinances and regulations.  
Wiring, where required, must comply with NEC  
Class 1 (Line Voltage) wiring.  
Loads connected to the EC7895 or RM7895 must  
not exceed those listed on the EC7895 or RM7895  
label or the Specifications, see Table 1A or 1B.  
Limits and interlocks must be rated to carry and  
break current simultaneously to the ignition  
transformer, pilot valve, and main fuel valve(s).  
All external timers must be listed or components  
recognized by authorities who have jurisdiction  
for specific purpose for which they are used.  
NOTE: For installation dimensions, see Fig. 1 or 2.  
3.  
4.  
5.  
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.  
. 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, instal-  
lation, access and removal of the EC7895 or RM7895,  
Dust Cover, flame amplifier, flame amplifier signal voltage  
probes, Run/Test Switch, electrical signal voltage probes  
and electrical field connections.  
2
6
.
.
7
3
. For surface mounting, use the back of the subbase as a  
template to mark the four screw locations. Drill the pilot  
holes.  
IMPORTANT  
4. Securely mount the subbase using four no. 6 screws.  
1. 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).  
. Two Detectors can be connected in parallel with  
the exception of Infrared Detectors (C7015).  
. This equipment generates, uses and can radiate  
radio frequency energy and, if not installed and  
used in accordance with the instructions, may  
cause interference to radio communications. It is  
designed to meet the requirements 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  
2
3
equipment in a residential area may cause  
interference; in which case, the user at their own  
expense may be required to take whatever  
measures are required to correct this interference.  
65-0205  
10  
href="
7800 SERIES EC7895A, RM7895A RELAY MODULE  
L1  
HOT) L2  
(
1
5
L2  
2
PLUG-IN PURGE  
TIMER CARD  
CONFIGURATION  
JUMPERS  
TEST  
JACK  
FLAME SIGNAL  
RUN/TEST  
SWITCH  
F
PLUG-IN  
FLAME  
G
MICROCOMPUTER  
AMPLIFIER  
TEST  
RESET  
PUSHBUTTON  
22  
2
3
4
K
K
K
RELAY  
RELAY  
DRIVE  
STATUS  
FEEDBACK  
AND LINE  
VOLTAGE  
INPUTS  
CIRCUIT 5K  
6
K
K
7
SAFETY RELAY  
CIRCUIT  
1K  
STATUS LEDs  
CONTROL  
POWER  
POWER SUPPLY  
LOCKOUT  
LIMITS CONTROLLER  
INTERLOCK  
1K1  
2K1 5K1  
6
7
10  
8
IGNITION  
4K1  
PILOT  
7
K1  
K2  
21  
PILOT/V2  
2
9
MAIN VALVE  
6K1  
4
3
BLOWER  
ALARM  
3K1  
OPTIONAL KEYBOARD  
DISPLAY MODULE  
DDL  
INDICATES FEEDBACK SENSING  
OF RELAY CONTACT STATUS  
AND LINE VOLTAGE INPUTS  
RS485  
1
5
DDL  
COMMUNICATIONS  
2
3
REMOTE  
RESET  
FIELD WIRING  
INTERNAL WIRING  
1
2
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.  
RM7895:,100VAC; EC7895: 200VAC.  
M11128  
Fig. 6. Internal block diagram of the EC7895 or RM7895 (see Fig. 7 and 8 for detailed wiring instructions).  
temperature rating above the maximum operating  
temperature. All leadwires must be moisture resistant.  
. Recommended grounding practices:  
WIRING  
5
1
. a. For proper wiring, refer to Fig. 7 or 8.  
a. Use the earth ground to provide a connection  
between the subbase and the control panel or the  
equipment. The earth ground wire must be capable  
of conducting the current to blow the 20A fuse (or  
breaker) in event of an internal short circuit. The  
EC7895 or RM7895 needs a low impedance  
ground connection to the equipment frame which,  
in turn, needs a low impedance connection to earth  
ground. For a ground path to be low impedance at  
RF frequencies, the connection must be made with  
minimum length conductors that have a maximum  
surface area. Wide straps or brackets are preferred  
rather than leadwires. Be careful to verify that  
mechanically tightened joints along the ground  
path, such as pipe or conduit threads or surfaces  
held together with fasteners, are free of noncon-  
ductive coatings and are protected against mating  
surface corrosion.  
b. For proper remote wiring of the Keyboard Display  
Module, refer to the Specifications for the Keyboard  
Display Module (65-0090), Communication Interface  
Base Unit (63-2278), DATA CONTROLBUS  
MODULE™ (65-0091) or Extension Cable Assembly  
(65-0131).  
2
. Disconnect the power supply from the main disconnect  
before beginning installation to prevent electrical shock  
and equipment damage. More than one disconnect may  
be involved.  
3
. All wiring must comply with all appropriate electrical codes,  
ordinances and regulations. Wiring, where required, must  
comply with NEC Class 1 (Line Voltage) wiring.  
. Recommended wire size and type: use no. 14, 16, or 18  
copper conductor (TTW60C or THW75C or THHN90C)  
4
6
00 volt insulation wire for all Line Voltage terminals. For  
high temperature installations, use wire selected for a  
1
1
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
b. For EC7895 or RM7895, each device has an  
earth ground terminal that must be grounded to  
the metal control panel with wire as short as  
practical. Each ground wire must be capable of  
carrying a fault current equal to the rating of the  
protective fuse (20A). A number 14 copper  
conductor is adequate but wide straps or  
7. Maximum wire lengths:  
a. For the EC7895 or RM7895, the maximum length  
of leadwire to the terminal inputs is 300 feet  
(Control and Airflow Interlock).  
b. For the flame detector leadwires, the maximum  
flame sensor leadwire length is limited by the  
flame signal strength.  
brackets are preferred rather than leadwires.  
. Recommended wire routing for flame detector  
leadwires:  
8. Make sure loads do not exceed the terminal ratings.  
Refer to the label on the EC7895 or RM7895 or to the  
ratings in the Specifications, see Table 1A or 1B.  
9. Check the power supply circuit. The voltage and  
frequency tolerance must match those of the EC7895  
or RM7895. A separate power supply circuit may be  
required for the EC7895 or RM7895 with the required  
disconnect means and overload protection added.  
10. Check all wiring circuits and complete the Static  
Checkout, see Table 4, before installing the EC7895 or  
RM7895 on the subbase.  
6
1.  
2.  
3.  
4.  
Do not run high voltage ignition transformer wires  
in the same conduit with the flame detection wiring.  
Do not route scanner wires in a conduit with line  
voltage circuits.  
Enclose scanner wires without armor cable in  
metal cable or conduit.  
Follow directions given in the flame detector  
Instructions.  
1
1. Install all electrical connectors.  
12. Restore power to the panel.  
Q7800  
G
L2  
3
12  
13  
14  
15  
16  
1
00V ALARM  
BURNER MOTOR  
4
5
(BLOWER)  
(L1)  
BURNER  
CONTROLLER/LIMITS  
6
17  
2
AIRFLOW  
INTERLOCK  
7
8
9
18  
19  
INTERMITTENT  
PILOT/IGNITION  
MAIN FUEL  
VALVE(S)  
20  
21  
22  
IGNITION  
10  
F
RECTIFYING FLAME  
ROD, RECTIFYING  
PHOTOCELL, OR INFRA-  
RED (LEAD SULFIDE)  
FLAME DETECTOR  
L1  
(HOT)  
1
L2  
MASTER  
SWITCH  
OR  
C7027A, C7035A, OR  
C7044A ULTRAVIOLET  
FLAME DETECTOR  
BLUE  
WHITE  
FOR DIRECT SPARK IGNITION  
OIL OR GAS)  
(
IGNITION  
10  
TRANSFORMER  
OR  
L2  
C7012A,C,E,F OR  
C7076A,D ULTRAVIOLET  
FLAME DETECTOR  
YELLOW  
BLUE  
9
MAIN VALVE  
8
WHITE  
WHITE  
BLACK  
BLACK  
L2  
L1  
L2  
1
2
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.  
DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.  
M5111A  
Fig. 7. Wiring the RM7895A.  
65-0205  
12  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Q7800  
G
L2  
3
12  
13  
14  
15  
16  
2
00 VAC ALARM  
(L1)  
BURNER MOTOR  
BLOWER)  
4
5
(
BURNER  
CONTROLLER/LIMITS  
6
17  
2
AIRFLOW INTERLOCK  
7
8
9
18  
19  
INTERMITTENT  
PILOT/IGNITION  
MAIN FUEL  
VALVE(S)  
20  
21  
22  
IGNITION  
10  
F
RECTIFYING FLAME  
ROD, RECTIFYING  
PHOTOCELL, OR INFRA-  
RED (LEAD SULFIDE)  
FLAME DETECTOR  
L1  
(HOT)  
1
L2  
MASTER  
SWITCH  
OR  
C7027A, C7035A, OR  
C7044A ULTRAVIOLET  
FLAME DETECTOR  
BLUE  
WHITE  
4
FOR DIRECT SPARK IGNITION (OIL  
OR GAS)  
OR  
IGNITION  
TRANSFORMER  
10  
YELLOW C7012A,C ULTRAVIOLET BLUE  
FLAME DETECTOR  
L2  
BLACK  
9
MAIN VALVE  
OR  
BLACK  
BLUE  
3
YELLOW  
C7061A  
1:2  
8
WHITE  
WHITE  
OR  
4
C7012F OR  
C7076A ULTRAVIOLET  
FLAME DETECTOR  
YELLOW  
BLUE  
WHITE  
WHITE  
BLACK  
BLACK  
1
200V, 50/60 HZ EC7895 POWER SUPPLY. PROVIDE DISCONNECT  
MEANS AND OVERLOAD PROTECTION AS REQUIRED.  
2
3
DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.  
USE 2:1 STEP DOWN POWER TRANSFORMER, 300 VA MINIMUM  
(STANCOR P8620 OR EQUIVALENT).  
4
VERIFY THAT THE OPERATING VOLOTAE OF THE FLAME  
DETECTOR IS THE SAME AS THE LINE VOLTAGE.  
M11074  
Fig. 8. Wiring the EC7895.  
1
3
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
ASSEMBLY  
Installing Plug-In Flame Signal Amplifier  
1
. Disconnect the power supply before beginning  
installation to prevent electrical shock and equipment  
damage. More than one disconnect may be involved.  
. Align the amplifier circuit board edge connector with the  
keyed receptacle on the EC7895 or RM7895. Ensure  
the amplifier nameplate faces away from the Relay  
Module, see Fig. 13.  
Mounting RM7895  
2
NOTE: For installation dimensions, see Fig. 1 or 2.  
Relay Module Mounting  
3
. Push in the amplifier until the circuit board is fully  
inserted into the receptacle and then push the amplifier  
toward the EC7895 or RM7895 retaining clasp.  
. Verify the amplifier is firmly in place.  
1. Mount the EC7895 or RM7895 vertically, see Fig. 9 or  
10, or mount horizontally with the knife blade terminals  
pointing downward. When mounted on the Q7800A, the  
EC7895 or RM7895 must be in an electrical enclosure,  
see Fig. 9.  
4
5
. Perform all required checkout tests.  
2
. Select the location in the electrical enclosure. Be sure  
to allow adequate clearance for servicing, installation  
and removal of the EC7895 or RM7895, Dust Cover,  
flame amplifier, flame amplifier signal voltage probes,  
electrical signal voltage probes and electrical  
connections.  
Installing the Flame Detector  
NOTE: Table 2 lists the flame detection systems available  
for use with the EC7895 or RM7895. Make sure the  
correct combination of amplifier and flame  
detector(s) is used.  
a. Allow an additional two inches below the EC7895  
or RM7895 for the flame amplifier mounting.  
b. Allow an optional three-inch minimum to both  
sides of the EC7895 or RM7895 for electrical  
signal voltage probes.  
Proper flame detector installation is the basis of a safe and  
reliable flame safeguard installation. Refer to the Instructions  
packed with the flame detector and the equipment  
manufacturer instructions.  
3
. Make sure no subbase wiring is projecting beyond the  
terminal blocks. Tuck wiring in against the back of the  
subbase so it does not interfere with the knife blade  
terminals or bifurcated contacts.  
. Mount the EC7895 or RM7895 by aligning the four L  
shaped corner guides and knife blade terminals with  
the bifurcated contacts on the wiring subbase and  
securley tightening the two screws without deforming  
the plastic.  
Keep the flame signal leadwires as short as possible from the  
flame detector to the wiring subbase. Capacitance increases  
with leadwire length, reducing the signal strength. The  
maximum permissible leadwire length depends on the type of  
flame detector, leadwire and conduit. The ultimate limiting factor  
in the flame detector leadwire is the flame signal; see Table 5.  
4
IMPORTANT  
Install the EC7895 or RM7895 with a plug-in motion  
rather than a hinge action.  
Installing ST7800 Purge Card  
1
. Remove the Dust Cover, Keyboard Display Module,  
DATA CONTROLBUS MODULE™or Extension Cable  
Assembly.  
2
. Remove the current ST7800 from the EC7895 or  
RM7895 by pulling upward on the plastic support cover,  
see Fig. 12.  
3
4
5
. Make sure that the ST7800 selected has the desired  
timing.  
. Insert the Purge Card into the opening of the RM7895  
compartment, see Fig. 11.  
. Reinstall the Dust Cover, Keyboard Display Module,  
DATA CONTROLBUS MODULE™ or Extension Cable  
Assembly onto the EC7895 or RM7895 and restore  
power to the device.  
Run the burner system through at least one complete cycle to  
verify the system is operating as desired.  
Mounting Dust Cover  
Fig. 9. Electrical panel installation.  
1
2
3
. Align the two interlocking ears of the Dust Cover with  
the two mating slots on the EC7895 or RM7895, see  
Fig. 12.  
. Insert the two interlocking ears into the two mating slots,  
and with a hinge action, push on the upper corners of the  
Dust Cover to secure it to the EC7895 or RM7895.  
. Be sure the Dust Cover is firmly in place.  
65-0205  
14  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Fig. 12. Dust Cover mounting.  
Fig. 10. Wall or burner installation.  
Fig. 13. Flame signal amplifier mounting.  
Fig. 11. ST7800 Purge Card installation.  
1
5
65-0205  
href="
7800 SERIES EC7895A, RM7895A RELAY MODULE  
C7076A,D ULTRAVIOLET DETECTOR  
INFRARED (C7015)  
REMOTE  
SENSOR  
6
5
4
3
F
7
8
WHITE  
F
EARTH  
GROUND  
3a  
3b  
2b  
G
BROWN  
G
2a  
SHUTTER  
SHUTTER  
L1  
L2  
1
C7076A  
OR  
C7076D  
TERMINAL  
BLOCK  
2
ULTRAVIOLET (C7027/C7035/C7044)  
L1 (HOT)  
L2 (COMMON)  
BLUE  
F
7800 SERIES  
1
WHITE  
G
F
G
L2  
5
22  
3
SOLID STATE SELF-CHECKING  
ULTRAVIOLET (C7012E,F)  
SOLID STATE  
ULTRAVIOLET (C7012A,C)  
BLUE  
F
BLUE  
F
2
YELLOW  
WHITE  
2
YELLOW  
G
G
22  
BLACK  
L1  
WHITE  
BLACK  
BLACK  
L2  
L1  
L2  
BLACK  
L2  
3
SOLID STATE SELF-CHECKING  
ULTRAVIOLET (C7061A)  
FLAME ROD  
PHOTOCELL  
X
X
F
G
X
F
BLUE  
F
2
YELLOW  
G
X
G
WHITE  
22  
3
WHITE  
N
1
FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE  
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN  
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.  
2
3
FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW  
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN  
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.  
WHEN USING A C7061A OR 200V VERSIONS OF THE C7012E,F, OR C7076A, A 2:1 STEP DOWN TRANSFORMER IS  
REQUIRED. SEE FIGURE 8.  
M11131  
Fig. 14. Flame detector wiring.  
65-0205  
16  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Ignition Trials  
OPERATION  
a. Pilot Flame Establishing Period (PFEP):  
1
.
The pilot valve and ignition transformer, terminals 8  
and 10, are energized. The EC7895 or RM7895A  
has an intermittent pilot valve, terminal 8.  
Sequence of Operation  
The EC7895 or RM7895 has the following operating  
sequences, see Fig. 15.  
2. Flame must be proven by the end of the 4 or 10  
sec-ond PFEP to allow the sequence to continue.  
If flame is not proven by the end of PFEP, a  
safety shutdown occurs.  
Initiate  
The EC7895 or RM7895 enters the INITIATE sequence when  
the Relay Module is powered. The EC7895 or RM7895 can  
also enter the INITIATE sequence if the Relay Module verifies  
voltage fluctuations of +10/-15% or frequency fluctuations of  
3.  
At the end of PFEP, the ignition, terminal 10, is  
de-energized.  
b. Main Flame Establishing Period (MFEP):  
1.  
After the Ignition Trials, and with the presence of  
flame, the main fuel valve, terminal 9, is powered.  
If a flameout occurs, the EC7895A or RM7895A  
will lock out or recycle within .8 or 3 seconds,  
depending on the Flame Failure Response Time  
+
/- 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 the tolerances are  
not met, a hold condition is initiated and is displayed on the  
optional VFD for at least five seconds. When the tolerances  
are met, the INITIATE sequence restarts. If the condition is  
not corrected and the hold condition exists for four minutes,  
the RM7895 locks out. Causes for hold conditions in the  
INITIATE sequence are:  
(FFRT) of the amplifier.  
Run  
1. The EC7895A or RM7895 is now in RUN and remains  
in RUN until the controller input, terminal 6, opens,  
indicating that the demand is satisfied or a limit opened.  
AC line dropout is detected.  
AC line noise that can prevent a sufficient reading of the  
line voltage inputs.  
Brownouts caused by a low line voltage.  
See Table 6 for further details of Hold conditions.  
The INITIATE sequence also delays the burner motor starter  
from being energized and de-energized from an intermittent  
AC line input or control input.  
Selectable Site-Configurable Jumpers  
The EC7895 or RM7895 has three site-configurable jumper  
options, see Fig. 17 and Table 3. The site-configurable  
jumpers should be clipped with side cutters and the resistors  
removed from the Relay Module.  
Standby  
The EC7895 or RM7895 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 EC7895 or RM7895 to continue into  
the PRE-PURGE sequence.  
SERVICE NOTE: Clipping and removing a site-configurable  
jumper enhances the level of safety.  
Static Checkout  
Normal Start-Up Prepurge  
CAUTION  
The EC7895 or RM7895 provides a selectable PREPURGE  
timing from two seconds to 30 minutes with power applied  
and the EC7895 or RM7895 operating control indicating a call  
for heat.  
1. Use extreme care while testing the system. Line  
voltage is present on most terminal connections  
when power is on.  
2. Open the master switch before installing or  
a. Airflow Interlock, burner switch, and all microcomputer  
monitored circuits must be in the correct operating state.  
b. The blower motor output, terminal 4, is powered to start  
the PREPURGE sequence.  
c. The Airflow Interlock input must close ten seconds into  
PREPURGE or within the specified purge card timing;  
otherwise, a recycle to the beginning of PRE-PURGE  
or lockout occurs depending on how the airflow switch  
selectable jumper is configured.  
removing a jumper on the subbase.  
3. Before continuing to the next test, be sure to re-  
move test jumper(s) used in the previous tests.  
4. Replace all limits and interlocks not operating  
properly. Do not bypass limits and interlocks.  
5. Close all manual fuel shutoff valve(s) before  
starting these tests.  
After checking all wiring, perform this checkout before  
installing the EC7895 or RM7895 on the subbase. These  
tests verify the Q7800 Wiring Subbase is wired correctly, and  
that the exter-nal controllers, limits, interlocks, actuators,  
valves, transformers, motors and other devices are operating  
properly.  
NOTE: Do not perform a dielectric test with the EC7895 or  
RM7895 installed. Internal surge protectors will  
break down and conduct a current. This could cause  
the EC7895 or RM7895 to fail the dielectric test or  
possibly destroy the internal lightning and high  
current transient protection components.  
1
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
5
. For each test, open the master switch and install the  
jumper wire(s) between the subbase wiring terminals  
listed in the Test Jumpers column of Table 4.  
. Close the master switch before observing operation.  
. Read the voltage between the subbase wiring terminals  
listed in the Voltmeter column of Table 4.  
Equipment Recommended  
1
. Voltmeter (1M ohm/volt minimum sensitivity) set on the  
-300 Vac scale.  
. Two jumper wires; no. 14 wire, insulated, 12 inches  
304.8 mm) long, with insulated alligator clips at both  
ends.  
0
6
7
2
(
8
. If there is no voltage or the operation is abnormal,  
check the circuits and external devices as described in  
the last column.  
General Instructions  
9
. Check all wiring for correct connections, tight terminal  
screws, correct wire, and proper wiring techniques.  
Replace all damaged or incorrectly sized wires.  
1
2
3
4
. Perform all applicable tests listed in, Table 4, in the  
order listed.  
. MAKE SURE THAT ALL MANUAL FUEL SHUT-OFF  
VALVE(S) ARE CLOSED.  
. Perform only those tests designated for the specific  
RM7895 model being tested.  
1
0. Replace faulty controllers, limits, interlocks, actuators,  
valves, transformers, motors and other devices as  
required.  
11. Obtain normal operation for each required test before  
. Raise the set point of the operating controller to  
simulate a call for heat.  
continuing the checkout.  
1
2. After completing each test, be sure to remove the test  
jumper(s).  
00  
00  
00  
TIMED  
PURGE  
PFEP  
LED  
DISPLAY  
INITIATE  
POWER  
STANDBY  
POWER  
START  
4 OR 10 SEC  
RUN  
POWER  
STANDBY  
POWER  
POWER  
POWER POWER  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
ALARM  
ALARM  
ALARM  
BURNER/BLOWER MOTOR  
4
BURNER  
START  
10  
IGN.  
IGN./ PILOT  
8
MAIN VALVE  
LIMITS AND BURNER CONTROLLER CLOSED L1 TO  
AIRFLOW INTERLOCK CLOSED  
TO  
9
6
OPERATING  
CONTROLS  
AND  
6
7
INTERLOCKS  
FLAME  
SIGNAL  
FLAME  
PROVING  
SAFE START CHECK  
SSC  
M11130  
Fig. 15. 7895 sequence.  
CAPTIVE  
MOUNTING  
SCREW  
PLUG-IN  
PURGE  
CARD  
DUST  
COVER  
SEQUENCE  
STATUS  
LEDs  
RELAY  
MODULE  
RESET  
PUSHBUTTON  
FLAME  
AMPLIFIER  
FLAME  
SIMULATOR INPUT  
FLAME CURRENT  
TEST JACKS  
M11127  
Fig. 16. Sequence status LEDs.  
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
SELECTABLE CONFIGURATION JUMPERS  
Table 3. Site Configurable Jumper Options.  
Jumper  
Number  
Description  
Intact  
Clipped  
JR1  
Pilot Flame  
Establishing  
Period  
10 seconds  
4 seconds  
JR2  
JR3  
Flame Failure  
Action  
Recycle  
Recycle  
Lockout  
Lockout  
Airflow Switch  
(ILK) Failure  
M11126  
Fig. 17. Selectable site-configurable jumpers.  
Table 4. Static Checkout.  
Normal Operation  
Test  
No.  
Test  
Jumpers meter  
Volt-  
If Operation Is Abnormal,  
Check The Items Listed Below  
WARNING  
Make sure all manual fuel shutoff valves are closed.  
IMPORTANT  
Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if  
required).  
1
None  
5-L2  
Line voltage at terminal 5.  
1. Master switch.  
2
. Power connected to the master switch.  
. Overload protection (fuse, circuit breaker) has not  
opened the power line.  
3
2
3
None  
4-5  
6-L2  
7-L2  
Line voltage at terminal 6.  
1. Limits.  
. Burner controller.  
2
1. Burner motor (fan or blower) starts.  
1. Burner motor circuit.  
2
. Line voltage at terminal 7 within 10  
seconds.  
a. Manual switch of burner motor.  
b. Burner motor power supply, overload  
protection and starter.  
c. Burner motor.  
4
5
5-10  
5-8  
Ignition spark (if ignition transformer is  
connected to terminal 10).  
1. Watch for spark or listen for buzz.  
a. Ignition electrodes are clean.  
b. Ignition transformer is okay.  
1. Ignition spark (if ignition transformer is  
connected to terminal 8).  
1. Watch for spark or listen for buzz.  
a. Ignition electrodes are clean.  
b. Ignition transformer is okay.  
2. Listen for click or feel head of valve for activation.  
a. Actuator if used.  
2
. Automatic pilot valve opens  
(if connected to terminal 8).  
NOTE: Refer to wiring diagram of system  
being tested.  
b. Pilot valve.  
6
5-9  
Automatic fuel valve(s) opens. If using  
direct spark ignition, check the first stage  
fuel valve(s) instead of the pilot valve.  
Same as test no. 6. If using direct spark ignition,  
check the first stage fuel valve(s) instead of the pilot  
valve.  
7
5 -3  
Alarm (if used) turns on.  
1. Alarm  
Final  
CAUTION  
After completing these tests, open the master switch and remove all test jumpers from the subbase terminals.  
Also remove bypass jumpers from the low fuel pressure limits (if used).  
1
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CHECKOUT  
Checkout Summary  
Preliminary inspection—all installations.  
Flame signal measurement—all installations.  
Initial lightoff check for proved pilot—all installations using  
a pilot.  
WARNING  
Do not allow fuel to accumulate in the combustion  
chamber. If fuel is allowed to enter the chamber for  
longer than a few seconds without igniting, an  
explosive mixture could result. It is recommended that  
you limit the trial for pilot to ten seconds, and limit the  
attempt to light the main burner two seconds from the  
time the fuel has reached the burner nozzle. In any  
case, do not exceed the nominal lightoff time specified  
by the equipment manufacturer. Close the manual fuel  
shutoff valve(s) if the flame is not burning at the end of  
the specified time.  
Initial lightoff check for direct spark ignition of oil—all  
burners using DSI.  
Pilot turndown test—all installations using a pilot.  
Hot refractory saturation test—all installations using  
Infrared (lead sulfide) Flame Detectors.  
Hot refractory hold-in test—all installations.  
Ignition interference test—all installations using flame  
rods.  
Ignition spark pickup—all installations using Ultraviolet  
Flame Detectors.  
Response to other ultraviolet sources—all installations  
using Ultraviolet Flame Detectors.  
Flame signal with hot combustion chamber—all  
installations.  
CAUTION  
Safety shutdown tests—all installations.  
1.  
Use extreme care while testing the system. Line  
voltage is present on most terminal connections  
when power is on.  
See Fig. 1 and 2 for location of component parts and see Fig.  
or Q7800 Specifications for terminal locations.  
7
2
.
.
Open the master switch before removing or  
installing the EC7895 or RM7895.  
Make sure all manual fuel shutoff valve(s) are  
closed before starting the initial lightoff check and  
the Pilot Turndown tests.  
3
Preliminary Inspection  
Perform the following inspections to avoid common problems.  
Be sure:  
4.  
Do not put the system in service until you have  
satisfactorily completed all applicable tests in this  
section and any others required by the equipment  
manufacturer.  
1
2
3
. Wiring connections are correct and all terminal screws  
are tight.  
. Flame detector(s) is clean, installed and positioned  
properly. Consult the applicable Instructions.  
. Correct combination of amplifier and flame detector is  
used (see Table 2).  
CAUTION  
4
5
. Plug-in amplifier and purge card are securely in place.  
. Burner is completely installed and ready to fire; consult  
equipment manufacturer instructions. Fuel lines are  
purged of air.  
If an EC7895 or RM7895 is replaced with a lower  
or higher functioning 7800 SERIES Relay Module,  
the burner will not sequence unless wiring changes  
are made.  
6
7
8
9
. Combustion chamber and flues are clear of fuel and  
fuel vapor.  
. Power is connected to the system disconnect switch  
IMPORTANT  
. If the system fails to perform properly, refer to  
800 SERIES System Annunciation Diagnostics  
1
(master switch).  
7
. Lockout switch is reset (push in reset pushbutton) only  
if the 7895 is powered, see Fig. 1 and 2.  
. System is in the STANDBY condition. POWER LED is  
energized.  
and Troubleshooting, form 65-0118.  
2
. Repeat ALL required Checkout tests after all  
adjustments are made. ALL tests must be satisfied  
with the flame detector(s) in its FINAL position.  
10. All limits and interlocks are reset.  
Equipment Recommended  
Volt-ohmmeter (1M ohm/volt minimum sensitivity):  
0-300 Vac capability.  
0-6000 ohm capability.  
0-10 Vdc capability.  
65-0205  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Flame Signal Measurement (Fig. 18 and Table 5)  
Table 5. Flame Signal.  
Acceptable Flame  
Signal Amplifier  
Minimum Maximum  
Steady DC Voltagea  
Flame Detector  
Expected DC Voltage  
Flame Rod Photocell  
C7012A,C  
R7847A,Bb  
1.25 Vdc  
5.0 Vdc at the Keyboard Display Module  
C7012E,F  
C7015A  
R7847Cc  
R7848A,Bb  
R7849A,Bb  
OR  
C7027A  
C7035A  
C7044A  
C7061  
R7861Ad  
R7886Ae  
C7076A,D  
5.0 Vdc at a 1M ohm/volt meter  
a
This minimum or a stronger signal should easily be obtained if the detector is correctly installed and positioned to properly  
sense the flame. This voltage must be obtained before completing checkout.  
The flame amplifiers are AMPLI-CHECK® type.  
The flame signal amplifier circuitry is tested one-half second every five seconds during burner operation and shuts down the  
burner if the amplifier fails (all installations).  
b
c
d
e
Requires seperate stepdown power transformer. See Fig. 14.  
Use with RM7895A Only.  
If the signal is unstable or less than the minimum ac-ceptable  
voltage, check the flame detector installation and circuitry.  
POSITIVE (+)  
METER LEAD  
ONE  
MEGOHM/VOLT  
METER  
1. Check the supply voltages at terminals 5 (L1) and L2  
(N). Make sure the master switch is closed,  
NEGATIVE (-)  
METER LEAD  
connections are correct, and the power supply is of the  
correct voltage and frequency and is sinusoidal.  
2
. Check the detector wiring for defects including:  
Incorrect connections.  
Wrong type of wire.  
Deteriorated wire.  
Open circuits.  
Short circuits.  
Leakage paths caused by moisture, soot or  
accumulated dirt.  
3
. For a flame rod, make sure:  
Ground area is large enough.  
Flame rod is properly located in the flame.  
Temperature at the flame rod insulator is no  
greater than 500° F (260° C).  
M7382  
Fig. 18. Flame signal measurement.  
Measure the flame signal at the appropriate times defined in  
the following checkout tests. Read the flame signal volts dc at  
the flame amplifier test jacks + and - (Com).  
1
2
3
. Use a 1M ohm/voltmeter with a 0 to 10 Vdc capability.  
. Set the 1M ohm/voltmeter to the 0 to 10 Vdc range.  
. Insert the positive (red) probe into the + jack of the  
flame amplifier. Insert the negative (black) probe into  
the - (Com) jack of the flame amplifier, see Fig. 19.  
. Allow a few seconds for the meter reading to stabilize.  
. If using AMPLI-CHECK® or shutter check amplifiers,  
read the average stable voltage, disregarding the peaks  
caused by the self-checking operation.  
4
5
6
. The meter reading must be as specified in Table 5 after  
all tests are completed and all adjustments are made.  
Initial Lightoff Check for Proved Pilot  
Perform this check on all installations that use a pilot. It  
should immediately follow the preliminary inspection.  
As an option, the flame signal can be checked by using the  
optional Keyboard Display Module.  
2
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NOTE: Low fuel pressure limits, if used, could be open. If  
so, bypass them with jumpers during this check.  
9. When the MAIN IGN period is displayed by the MAIN  
LED, make sure the automatic main fuel valve is open;  
then smoothly open the manual main fuel shutoff  
valve(s) and watch for main burner flame ignition.  
When the main burner flame is established, proceed to  
step 16.  
10. If the main burner flame is not established within five  
seconds or the normal lightoff time specified by the  
equipment manufacturer, close the manual main fuel  
shut-off valve(s).  
1
. Open the master switch.  
2
. Make sure that the manual main fuel shutoff valve(s) is  
closed. Open the manual pilot shutoff valve. If the pilot  
takeoff is downstream from the manual main fuel  
shutoff valve(s), very slightly open the manual main  
valve to supply pilot gas flow. Make sure the main fuel  
is shutoff just upstream from the burner inlet, or  
disconnect power from the automatic main fuel  
valve(s).  
11. Recycle the system to recheck the lightoff and pilot  
flame signal.  
3
4
5
6
. Close the master switch and start the system with a call  
for heat by raising the set point of the operating  
controller, see Fig. 15. The primary sequence should  
start the ten-second INITIATE sequence.  
. Let the sequence advance through PREPURGE.  
Ignition spark should occur and the pilot should light. If  
the pilot ignites, the FLAME LED is energized. Proceed  
to step 7.  
. If the pilot flame is not established in four or ten  
seconds, safety shutdown occurs. Let the sequence  
complete its cycle. Consult the equipment operating  
manual for further information.  
12. Smoothly open the manual fuel shutoff valve(s) and try  
lightoff again. (The first reattempt may have been  
required to purge the lines and bring sufficient fuel to  
the burner.)  
13. If the main burner flame is not established within five  
seconds or the normal lightoff time specified by the  
equipment manufacturer, close the manual main fuel  
shut-off valves(s). Check all burner adjustments.  
14. If the main burner flame is not established after two  
attempts:  
a. Check for improper pilot size.  
b. Check for excess combustion air.  
c. Check for adequate fuel flow.  
d. Check for proper gas supply pressure.  
. Push the reset pushbutton, and let the system recycle  
once. If the pilot still does not ignite, make the following  
ignition/pilot adjustments:  
e. Check for proper valve operation.  
a. Open the master switch and remove the EC7895  
or RM7895 from the subbase.  
b. On the subbase, jumper terminal 5 to ignition  
terminals 8 or 10; refer to the appropriate wiring  
diagram to determine the proper terminal.  
Disconnect the leadwire to the pilot valve if it is  
connected to the same terminal.  
c. Close the master switch to energize only the  
ignition transformer.  
d. If the ignition spark is not strong and continuous,  
open the master switch and adjust the ignition  
electrode spark gap setting to the manufacturer  
recommendations.  
e. Make sure the ignition electrodes are clean.  
f. Close the master switch and observe the spark.  
g. After a continuous spark is obtained, open the  
master switch and add a jumper on the subbase  
from terminal 5 (L1) to the pilot terminal 8.  
Reconnect the leadwire from the pilot valve if it  
was disconnected in step b.  
f. Check for proper pilot flame positioning.  
15. Repeat steps 8 through 14 to establish the main burner  
flame; then proceed to step 16.  
16. With the sequence in RUN, make burner adjustments  
for flame stability and BTU input rating.  
17. Shut down the system by opening the burner switch or  
by lowering the set point of the operating controller.  
Make sure the main flame goes out. There may be a  
delay due to gas trapped between the valve(s) and the  
burner. Make sure all automatic fuel valve(s) close.  
18. Restart the system by closing the burner switch and/or  
raising the set point of the operating controller. Observe  
that the pilot is established during PILOT IGN and the  
main burner flame is established during MAIN IGN  
within the normal lightoff time.  
19. Measure the flame signal. Continue to check for the  
proper signal, see Table 5, through the RUN period.  
20. Run the burner through another sequence, observing  
the flame signal for:  
a. Pilot flame alone (unless using direct spark  
ignition).  
b. Pilot and main flame together.  
h. Close the master switch to energize both the  
ignition transformer and the pilot valve.  
i. If the pilot does not ignite and if the ignition spark  
is still continuous, adjust the pressure regulator  
until a pilot is established.  
j. When the pilot ignites properly and stays ignited,  
open the master switch and remove the jumper(s)  
from terminals 5 through 8 or 5 through 10 of the  
subbase.  
c. Main flame alone (unless monitoring an  
intermittent pilot).  
Also observe the time it takes to light the main flame. Ignition  
of main flame should be smooth.  
21. Return the system to normal operation.  
22. Make sure all readings are in the required ranges be-  
fore proceeding.  
k. Check for adequate bleeding of the fuel line.  
l. Reinstall the EC7895 or RM7895 on the subbase  
and close the master switch, then return to step 4.  
. When pilot ignites, measure the flame signal. If the pilot  
flame signal is unsteady or approaching the 1.25 Vdc  
minimum value, adjust the pilot flame size or detector  
sighting to provide a maximum and steady flame signal.  
. Recycle the system to recheck lightoff and pilot flame  
signal.  
7
8
NOTE: Upon completing these tests, open the master  
switch and remove all test jumpers from the subbase  
terminals, limits/controls or switches.  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
d. Make burner adjustments for flame stability and  
input rating.  
e. Shut down the system by lowering the set point of  
the operating controller. Make sure the burner  
flame goes out and all automatic fuel valve(s)  
close.  
Initial Lightoff Check for Direct Spark Ignition  
This check applies for gas and oil burners that do not use a  
pilot. It should immediately follow the preliminary in-spection.  
Refer to the appropriate sample block diagram of field wiring  
for the ignition transformer and fuel valve(s) hookup.  
1
9. Restart the system by closing the burner switch and/or  
raising the set point of the operating controller. Observe  
that the burner flame is established during PILOT IGN,  
within the normal lightoff time specified by the  
equipment manufacturer.  
NOTE: Low fuel pressure limits, if used, could be open. If  
so, bypass them with jumpers during this check.  
1
. Open the master switch.  
2
. Complete the normal checkout of the fuel supply and  
equipment as recommended by the equipment  
manufacturer.  
2
0. Measure the flame signal. Continue to check for the  
proper signal, see Table 5, through the RUN period.  
Any pulsating or unsteady readings require further  
attention.  
3
. Close all manual main fuel shutoff valve(s). Check that  
the automatic fuel valve(s) are closed. Make sure fuel is  
not entering the combustion chamber.  
21. Make sure all readings are in the required ranges be-  
fore proceeding.  
4
. Close the master switch and start the system with a call  
for heat by raising the set point of the operating  
controller, see Fig. 15. The primary sequence should  
start the ten-second INITIATE sequence.  
. Let the sequence advance through PREPURGE.  
Ignition spark should occur after the PREPURGE  
period. Listen for the click of the first stage fuel solenoid  
valve(s).  
NOTE: Upon completing these tests, open the master  
switch and remove all test jumpers from the subbase  
terminals, limits/control or switches.  
5
22. Return the system to normal operation.  
Pilot Turndown Test  
All Installations using a Pilot)  
6. Let the program sequence complete its cycle.  
7. Open the manual fuel shutoff valve(s).  
8. Reset the Lockout Switch and recycle the primary  
sequence through PREPURGE.  
(
Perform this check on all installations that use a pilot. The  
purpose of this test is to verify that the main burner can be lit  
by the smallest pilot flame that will hold in the flame amplifier  
and energize the FLAME LED. Clean the flame detector(s) to  
make sure that it detects the smallest acceptable pilot flame.  
If using AMPLI-CHECK® or Self-Checking Amplifier and 20K  
ohm/voltmeter, the flame signal will fluctuate every time the  
amplifier does a self-check or a shutter check.  
9
. Watch for the FLAME LED to help determine when the  
first stage burner flame is established. If it is  
established, proceed to step 15.  
1
0. If the first stage burner flame is not established within  
four seconds, or within the normal lightoff time specified  
by the equipment manufacturer, close the manual fuel  
shutoff valve(s), and open the master switch.  
1
1. Check all burner adjustments.  
NOTE: Low fuel pressure limits, if used, could be open. If  
so, bypass them with jumpers during this test.  
1
2. Wait about three minutes. Close the master switch,  
open the manual fuel shutoff valve(s), and try again to  
lightoff the burner. The first attempt may have been  
required to purge the lines and bring sufficient fuel to  
the burner.  
1
2
3
. Open the master switch.  
. Close the manual main fuel shutoff valve(s).  
. Connect a manometer (or pressure gauge) to measure  
pilot gas pressure during the turndown test.  
. Open the manual pilot shutoff valve(s).  
1
3. If the first stage burner flame is not established with-in  
four seconds, or within the normal lightoff time specified  
by the equipment manufacturer, close the manual fuel  
shutoff valve(s) and open the master switch.  
4. If necessary, repeat steps 8 through 13 to establish the  
first stage burner flame. Then proceed to step 15.  
5. When the first stage burner flame is established, the  
sequence will advance to RUN. Make burner  
adjustments for flame stability and input rating. If a  
second stage is used, proceed to step 18.  
4
5
. Close the master switch and start the system with a call  
for heat. Raise the set point of the operating controller.  
The primary sequence should start and PREPURGE  
should begin.  
1
1
6
. INTERMITTENT PILOT MODELS—After the sequence  
has entered the normal burner run period, turn down  
pilot gas pressure very slowly, reading the manometer  
(
or gauge) as the pressure drops. Stop immediately  
1
6. Shut down the system by opening the burner switch or  
by lowering the set point of the operating controller.  
Make sure the burner flame goes out and make sure all  
automatic fuel valve(s) close.  
when the FLAME LED goes out. Note the pressure at  
this point.  
a. If the Flame Failure Action jumper is not clipped,  
allow the EC7895 or RM7895A to recycle through  
PREPURGE. If the Flame Failure Action jumper  
is clipped, push the reset pushbutton and allow  
the EC7895 or RM7895A to recycle through  
PREPURGE.  
b. As the control attempts to relight the pilot, turn  
the pilot gas pressure back up slowly until the  
FLAME LED comes on. This step must be  
completed within 4 or 10 seconds, depending on  
the selected PFEP, or lockout will occur.  
17. If used, remove the bypass jumpers from the low fuel  
pressure limit and subbase.  
1
8. If a second stage is used, make sure the automatic  
second stage fuel valve(s) has opened and check the  
light-off as follows. Otherwise proceed to step 19:  
a. Open the manual second stage fuel valve(s).  
b. Restart the system by raising the set point of the  
operating controller.  
c. When the first stage burner flame is established,  
watch for the automatic second stage fuel  
valve(s) to open. Observe that the second stage  
lights off properly.  
2
3
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
c. Turn the pilot back down slightly but not enough  
to cause the FLAME LED to go out. (Keep the  
pilot gas pressure just above the reading noted in  
step 6 above.)  
Start the burner and monitor the flame signal during the  
warmup period. A decrease in signal strength as the  
refractory heats up indicates hot refractory saturation. If  
saturation is extreme, the flame signal will drop below 1.25  
Vdc and the system will shut down as though a flame failure  
has occurred.  
NOTE: Step d requires two people, one to open the manual  
main fuel valve(s) and one to watch for ignition.  
If hot refractory saturation occurs, the condition must be  
corrected. Add an orifice plate in front of the cell to restrict the  
viewing area, try to lengthen the sight pipe or decrease the  
pipe size (diameter). Continue adjustments until hot refractory  
saturation is eliminated.  
d. With the sequence in the normal burner run  
mode, make sure the automatic main fuel  
valve(s) is open. Smoothly open the manual main  
fuel shutoff valve(s) and watch for main burner  
lightoff.  
e. If the main flame is not established within five  
seconds or the normal lightoff period specified by  
the burner manufacturer, close the manual main  
fuel shutoff valve(s) and open the master switch.  
Return to step 6. If the burner flame is  
established in the normal lightoff period, proceed  
to step 16.  
Hot Refractory Hold-In Test (Rectifying  
Photocell or All Infrared Detectors)  
Test to be sure hot refractory is not delaying the flame  
detection system response to a flameout. This condition can  
delay response to flame failure and also can prevent a  
system restart as long as hot refractory is detected.  
7
. When the main burner lights reliably with the pilot at  
turndown, disconnect the manometer (or pressure  
gauge) and turn the pilot gas flow up to that  
recommended by the equipment manufacturer.  
. If used, remove the bypass jumpers from the subbase  
terminals, limits/controls or switches.  
. Run the system through another cycle to check for  
normal operation.  
0. Return the system to normal operation.  
To check rectifying photocells for hot refractory hold-in,  
operate the burner until the refractory reaches its maximum  
temperature. Then terminate the firing cycle by lowering the  
set point of the operating controller or setting the Fuel  
Selector Switch to OFF. Do not open the master switch.  
Visually observe when the burner flame or FLAME LED goes  
out. If this takes longer than .8 or 3 seconds (depending on  
the FFRT of the amplifier), the photocell is sensing hot  
refractory. This condition must be corrected as described in  
the last paragraph of this test.  
8
9
1
Ignition Interference Test (All Flame Rods)  
Test to be sure that a false signal from a spark ignition system  
is not superimposed on the flame signal.  
Infrared (lead sulfide) detectors can respond to infrared rays  
emitted by a hot refractory, even when the refractory has visibly  
stopped glowing. Infrared radiation from a hot refractory is  
steady, but radiation from a flame has a flickering characteristic.  
The infrared detection system responds only to flickering  
infrared radiation; it can reject a steady signal from hot  
refractory. The refractory steady signal can be made to  
fluctuate if it is reflected, bent or blocked by smoke or fuel mist  
within the combustion chamber. Be careful when applying an  
infrared system to verify its response to flame only.  
Ignition interference can subtract from (decrease) or add to  
increase) the flame signal. If it decreases the flame signal  
enough, it causes a safety shutdown. If it increases the flame  
signal, it could cause the FLAME LED to come on when the  
true flame signal is below the minimum accep-table value.  
(
Start the burner and measure the flame signal with both  
ignition and pilot (or main burner) on, and then with only the  
pilot (or main burner) on. Any significant difference (greater  
than .5 Vdc) indicates ignition interference.  
To check infrared (lead sulfide) detectors for hot refractory  
hold-in, operate the burner until the refractory reaches its  
maximum temperature. If the installation has a multi-fuel  
burner, burn the heaviest fuel that is most likely to reflect,  
bend or obscure the hot refractory steady infrared radiation.  
When the maximum refractory temperature is reached, close  
all manual fuel shutoff valve(s) or open the electrical circuits  
of all automatic fuel valve(s). Visually observe when the  
burner flame or FLAME LED goes out. If this takes more than  
three seconds, the infrared detector is sensing hot refractory.  
Immediately terminate the firing cycle. Lower the set point to  
the operating controller, or set the Fuel Selector Switch to  
OFF. Do not open the master switch.  
To Eliminate Ignition Interference  
1
2
. Be sure there is enough ground area.  
. Be sure the ignition electrode and the flame rod are on  
opposite sides of the ground area.  
. Check for correct spacing on the ignition electrode:  
a. 6,000V systems - 1/16 to 3/32 in. (1.6 to 2.4 mm).  
b. 10,000V systems - 1/8 in. (3.2 mm).  
. Make sure the leadwires from the flame rod and ignition  
electrode are not too close together.  
. Replace any deteriorated leadwires.  
3
4
5
6
. If the problem cannot be eliminated, the system may  
have to be changed to an ultraviolet or infrared flame  
detection system.  
NOTE: Some burners continue to purge oil lines between  
the valve(s) and nozzle(s) even though the fuel  
valve(s) is closed. Terminating the firing cycle  
(
instead of opening the master switch) allows  
Hot Refractory Saturation Test  
purging of the combustion chamber. This reduces  
fuel vapor buildup in the combustion chamber  
caused by oil line purging.  
(
All Infrared Detectors)  
Test to be sure that radiation from hot refractory does not  
mask the flickering radiation of the flame itself.  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
If the detector is sensing hot refractory, the condition must be  
corrected. Add an orifice plate in front of the cell to restrict the  
viewing area of the detector. If this does not correct the  
problem, resight the detector at a cooler, more distant part of  
the combustion chamber. While resighting the detector, be  
aware that it must also properly sight the flame. When using  
infrared detector, try lengthening the sight pipe or decreasing  
the pipe size (diameter). For details, refer to the detector  
Instructions and the equipment Operating Manual. Continue  
adjustments until hot refractory hold-in is eliminated.  
If the flame signal is too low or unsteady, check the flame  
detector temperature. Relocate the detector if the  
temperature is too high. If necessary, realign the sighting to  
obtain the proper signal and response time. If the response  
time is still too slow, replace the Plug-in Flame Signal  
Amplifier. If the detector is relocated or resighted, or the  
amplifier is replaced, repeat all required Checkout tests.  
Safety Shutdown Tests (All Installations)  
Perform these tests at the end of Checkout after all other  
tests are complete. If used, the external alarm should turn on.  
Press the RM7895 reset pushbutton to restart the system.  
Ultraviolet Sensor, Ignition Spark Response  
Test (All Ultraviolet Detectors)  
1. Close the Airflow Interlock during PREPURGE, PILOT  
IGN, MAIN IGN or RUN period.  
Test to be sure that the ignition spark is not actuating the  
FLAME LED:  
a. Safety shutdown occurs if the Airflow ILK Switch  
Failure configuration jumper (JR3) is clipped.  
. Detect flame 40 seconds after entry to STANDBY. Detect  
flame 30 seconds during measured PREPURGE time.  
a. Simulate a flame to cause the flame signal voltage  
level to be at least 1.25 Vdc for 40 seconds after  
entry to STANDBY and also simulate a flame  
signal for 30 seconds during PREPURGE.  
b. Safety shutdown occurs.  
1. Close the pilot and main burner manual fuel shutoff  
valve(s).  
2
2
. Start the burner and run through the PILOT IGN period.  
Ignition spark should occur, but the flame signal should  
not be more than 0.5 Vdc and the FLAME LED should  
not turn on.  
3
. If the flame signal is higher than 0.5 Vdc and the  
FLAME LED does come on, consult the equipment  
Operating Manual and resight the detector further out  
from the spark, or away from possible reflection. It may  
be necessary to construct a barrier to block the ignition  
spark from the detector view. Continue adjustments  
until the flame signal due to ignition spark is less than  
3. Failure to ignite pilot.  
a. Close the pilot and main fuel manual shutoff  
valve(s).  
b. Depress the reset push button.  
c. Start the system.  
d. Automatic pilot valve(s) should be energized but  
0.5 Vdc.  
the pilot cannot ignite.  
e. Safety shutdown occurs.  
. Failure to ignite main.  
NOTE: The Honeywell Q624A Solid State Spark Generator  
prevents detection of ignition spark when properly  
applied with the C7027, C7035 or C7044 Minipeeper  
Ultraviolet Flame Detectors. The Q624A is only for  
use with gas pilots.  
4
a. Open the manual pilot valve(s); leave the main  
fuel manual shutoff valve(s) closed.  
b. Depress the reset pushbutton.  
c. Start the system.  
d. Pilot should ignite and the flame signal should be  
at least 1.25 Vdc but the main burner cannot light.  
e. Close the manual pilot valve(s).  
f. Flame signal should drop below 1.25 Vdc within  
Response To Other Ultraviolet Sources  
Under certain conditions, an ultraviolet detector responds to  
other ultraviolet sources as if it is sensing a flame. These  
ultraviolet sources include artificial light, such as  
.
8 or 3 seconds (depending on the FFRT of the  
amplifier) after the pilot goes out.  
g. Safety shutdown occurs.  
. Loss of flame during RUN.  
incandescent or fluorescent bulbs, mercury and sodium vapor  
lamps or daylight. To check for proper detector operation,  
check the Flame Failure Response Time (FFRT) and conduct  
Safety Shutdown tests under all operating conditions.  
5
a. Open the main fuel manual shutoff valve(s). The  
manual pilot shutoff valve(s) must also be opened.  
b. Depress the reset push button.  
c. Start the system. Startup should be normal and  
the main burner should light normally.  
d. After the sequence is in the normal RUN period  
for at least ten seconds with the main burner  
firing, close the manual main and pilot fuel shutoff  
valve(s) to extinguish the main burner flame.  
e. The flame signal should drop below 1.25 Vdc  
within .8 or 3 seconds (depending on the FFRT of  
the amplifier) after the main flame goes out.  
f. Safety shutdown occurs.  
Flame Signal With Hot Combustion Chamber  
(
All Installations)  
After all initial start-up tests and burner adjustments are  
completed, operate the burner until the combustion chamber  
is at the maximum expected temperature. Observe the  
equipment manufacturer warmup instructions. Recycle the  
burner under these hot conditions and measure the flame  
signal. Check the pilot alone, the main burner flame alone,  
and both together (unless monitoring only the pilot flame  
when using an intermittent pilot, or only the main burner flame  
when using DSI).  
IMPORTANT  
1
. If the EC7895 or RM7895 fails to shut down on  
any of these tests, take corrective action (refer to  
Troubleshooting, EC7895 or RM7895 diagnostics  
and return to the beginning of all Checkout tests).  
. When all Checkout tests are complete, reset all  
switches to original states.  
Check the FFRT of the Flame Amplifier. Lower the set point of  
the operating controller and observe the time it takes for the  
burner flame to go out. This should be within .8 or 3 seconds  
maximum depending on the amplifier selected.  
2
2
5
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
TROUBLESHOOTING  
Historical Information Index  
The EC7895 or RM7895 has nonvolatile memory that allows  
the Relay Module to retain Historical Information for the six  
most recent lockouts. Each of the six lockout files retains the  
cycle when the fault occurred, the hour of operation when the  
fault occurred, and the fault message and burner status when  
the fault occurred. The Historical Information can be viewed  
by the optional S7800A Keyboard Display Module  
Specifications.  
EC7895 or RM7895 System Diagnostics  
Troubleshooting control system equipment failures is easier  
with the 7895 self-diagnostics and first-out annunciation. In  
addition to an isolated spst alarm relay (audible annunciation),  
the 7895 provides visual annunciation by displaying the  
ALARM LED.  
Self-diagnostics of the 7895 enable it to detect and annunciate  
both external and internal system problems. Ex-ternal faults  
such as interlock failures, flame failures and false flame signals  
are annunciated by the 7895, which energizes the ALARM LED  
or by using the optional Keyboard Display Module. The 7800  
SERIES provides a System Annunciation Diagnostics and  
Troubleshooting manual, form 65-0118.  
SERVICE NOTE: A Lockout condition or restart of a EC7895  
or RM7895 can be accomplished by  
pressing the reset push-button on the  
EC7895 or RM7895, or by pressing a  
remote reset pushbutton wired through an  
optional Keyboard Display Module, DATA  
CONTROLBUS MODULE™, Extension  
Cable Assembly or Remote Reset Module.  
A power-up reset causes an electrical reset  
of the EC7895 or RM7895 but does not  
reset a lockout condition.  
The 7895 provides diagnostic information to aid the service  
mechanic to obtain information when troubleshooting the  
system, see Table 6.  
The optional Keyboard Display Module displays sequence  
status messages indicating: STANDBY, PRE-PURGE, PILOT  
IGN, MAIN IGN and RUN. The selectable messages also  
provide visual indication, current status and historical status  
of the equipment such as: Flame Signal, Total Cycles, Total  
Hours, Fault History, and Diagnostic Information. With this  
information most problems can be diagnosed without  
extensive trial and error testing. Information available in the  
Diagnostic Information file includes: Device Type, Device  
Suffix, Software Revision, Manufacturing Code, Flame  
Amplifier Type, Flame Failure Response Time, Selectable  
Jumper Configuration Status, and Terminal Status.  
SERVICE NOTE: Remove the access slot covers on the  
sides of the Q7800A,B to check voltages.  
CAUTION  
Reinstall access slot covers on the Q7800A,B  
Subbase after performing voltage checks.  
SERVICE NOTE: Maximum ambient operating temperature  
of a C7012E,F Series 1 through 6 is  
reduced to 125° F because of the duty  
cycle operation of the 7895 Relay Module.  
Diagnostic Information Index  
The EC7895 or RM7895 with the optional Keyboard Display  
Module can monitor input/output terminals and can display  
the status of the terminal at the VFD (example; Pilot Valve T8  
ON<), see S7800A Keyboard Display Module Specifications.  
A complete terminal description and number are provided.  
The display will show the actual status of the terminal. If  
voltage is detected at the terminal, ON is displayed; but if no  
voltage is detected at the terminal, OFF is displayed.  
65-0205  
26  
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Table 6. Sequence And Status Hold Information.  
NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type.  
Sequence  
Status  
INITIATE  
The LED indicates the burner status, POWER, which is a stabilization period  
for the RM7895 to check for any fluctuations in AC line voltage inputs or  
control input on power-up or during normal operation. The timing of the  
INITIATE period is ten seconds before entering STANDBY.  
If the EC7895 or RM7895 is in a HOLD status, the following conditions could exist:  
INITIATE HOLD: (AC Frequency/Noise)  
The LED indicates the burner status, POWER, and that it is waiting for  
excess line noise to clear up. The burner sequence does not advance into  
STANDBY until the excess line noise, which prevents sufficient reading of  
the line voltage inputs, ceases or a line frequency error is corrected.  
INITIATE HOLD: (AC Line Dropout)  
The LED indicates the burner status, POWER, and that AC Line power has  
momentarily dropped out. The burner sequence does not advance into  
STANDBY until the AC line voltage stabilizes throughout the INITIATE  
sequence.  
INITIATE HOLD: (AC Frequency)  
INITIATE HOLD: (Low Line Voltage)  
STANDBY  
The LED indicates the burner status, POWER, and that line frequency is  
faster than the expected value. The burner sequence does not advance into  
STANDBY until the line frequency returns to the proper value.  
The LED indicates the burner status, POWER, and that low line voltage has  
occurred. The burner sequence does not advance into STANDBY until the  
line voltage is at a sufficient level for proper operating parameters.  
The LED indicates the burner status, POWER. The burner can be placed in  
STANDBY by opening the burner switch or if the operating controller  
indicates its set point is satisfied. If a demand is present for burner  
operation, the burner sequence does not advance from STANDBY to  
PURGE until the recycle limits close.  
If the EC7895 or RM7895 is in a HOLD status, the following conditions could exist:  
STANDBY HOLD: F/G (Flame Detected)  
The LEDs indicate the burner status, POWER and FLAME, and that a flame  
is detected. A demand is present for burner operation. The burner sequence  
does not advance to PREPURGE because a flame is detected as being  
present. The sequence does not advance to PREPURGE until the flame  
signal clears. If the flame signal does not clear within 40 seconds, the  
RM7895 locks out.  
STANDBY HOLD: T7 (Airflow Interlock)  
The LED indicates the burner status, POWER, and that the Air-flow Interlock  
is closed. A demand is present for burner operation and the burner  
sequence does not advance to PREPURGE until the Airflow Interlock  
proves open.  
PURGE  
The LED indicates the burner status, POWER, and that it is the period of  
time before ignition during which time the blower motor is running. The  
timing of the PURGE period is selectable.  
2
7
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7800 SERIES EC7895A, RM7895A RELAY MODULE  
Table 6. Sequence And Status Hold Information. (Continued)  
NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type.  
Sequence Status  
If the EC7895 or RM7895 is in a HOLD condition, the following conditions could exist:  
PURGE HOLD: F/G (Flame Detected)  
The LEDs indicate the burner status, POWER and FLAME, and that a flame  
is detected. The burner sequence does not advance through PREPURGE  
because a flame is detected as being present. The sequence holds, waiting  
for the flame signal to clear. If the time exceeds 30 seconds, the EC7895 or  
RM7895 locks out.  
PURGE HOLD: T7 (Airflow Interlock)  
The LED indicates the burner status, POWER, and that the Air-flow Interlock  
is not closed. The sequence does not advance to ignition until the Airflow  
Interlock proves closed. If this time exceeds a 30 second HOLD, the  
EC7895 or RM7895 locks out.  
PILOT IGN  
The LEDs indicate the burner status, POWER, PILOT and FLAME, which is  
the period of time the EC7895 or RM7895 permits the pilot valve to be open  
and the pilot flame to be established.  
If the EC7895 or RM7895 is in a HOLD status, the following condition could exist:  
MAIN IGN  
The LEDs indicate the burner status, POWER, PILOT, FLAME and MAIN,  
which is the period of time the EC7895 or RM7895 permits the main valve to  
be open and the main flame to be established.  
RUN  
The LEDs indicate the burner status, POWER, PILOT, FLAME and MAIN,  
which is the period of time after the Ignition Trials and before the operating  
controller set point is reached. During this time, the burner is firing under the  
control of the operating controller (EC7895 or RM7895A).  
RUN  
The LEDs indicate the burner status, POWER, FLAME and MAIN, which is  
the period of time after the Ignition Trials and before the operating controller  
set point is reached.  
RESET/ALARM TEST  
The LED indicates the burner status, POWER and ALARM. This condition  
indicates the reset push button is pressed. If it is held for more than four  
seconds, the alarm output is energized. The alarm output will be de-  
energized after the reset pushbutton is released.  
Home and Building Control  
Honeywell Inc.  
Honeywell Plaza  
P.O. Box 524  
Minneapolis MN 55408-0524  
Home and Building Control  
Honeywell Limited-Honeywell Limitée  
155 Gordon Baker Road  
North York, Ontario  
Honeywell Asia Pacific Inc.  
Room 3213-3225  
Sun Hung Kai Centre  
No. 30 Harbour Road  
Wanchai  
M2H 2C9  
Hong Kong  
Honeywell Latin American Division  
Miami Lakes Headquarters  
Honeywell Europe S.A.  
3 Avenue du Bourget  
1
4505 Commerce Way Suite 500  
B-1140 Brussels Belgium  
Miami Lakes FL 33016  
Helping You Control Your World®  
6 5-0205 G.R. 1-97 Printed in U.S.A.  
www.honeywell.com/bbc  

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