Honeywell Thermostat RM7895A User Manual - Honeywell Thermostat Manual Download

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Honeywell Thermostat RM7895A User Manual

7800 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. The Yamatake Honeywell EC7895A and RM7895 is a microprocessor ¥ Sequence status at the time of the fault. based integrated burner control for automatically fired gas, oil, or ¥ Sequence time at the time of the fault. combination fuel single burner applications. The RM7895 consists of — Diagnostic information: the Relay Module. Subbase, Amplifier and Purge Card. Options ¥Device type. include Keyboard Display Module, Personal Computer Interface, ¥ Flame amplifier type. DATA CONTROLBUS MODULEª, Remote Display Module, and ¥ Flame failure response time. COMBUSTION SYSTEM MANAGERª Software. ¥ Manufacturing code. ¥ On/Off status of all digital inputs and outputs. The EC7895 and RM7895 are programmed to provide a level of ¥ Selected prepurge time. safety, functional capability and features beyond the capacity of ¥ Software revision and version of EC7895 and RM7895 conventional controls. and optional Keyboard Display Module. ¥ Status of configuration jumpers. 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 ......................................................................................... 1 Features ........................................................................................ 1 ¥ Safety features: Specifications ................................................................................ 2 — Airflow switch check. Ordering Information ..................................................................... 2 — Closed loop logic test. Principal Technical Features ......................................................... 8 — Dynamic AMPLI-CHECK¨. Safety Provisions .......................................................................... 8 — Dynamic input check. Installation ..................................................................................... 9 — Dynamic safety relay test. Wiring ............................................................................................ 11 — Dynamic self-check logic. Assembly ...................................................................................... 14 — Internal hardware status monitoring. Operation ...................................................................................... 17 —Tamper resistant timing and logic. Checkout ....................................................................................... 20 ¥ Access for external electrical voltage checks. Troubleshooting ............................................................................ 26 ¥ Application flexibility. ¥ Communication interface capability. Copyright © 1996 Honeywell Inc. ¥ All Rights Reserved X-XX UL 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE Electrical Ratings, see Table 1A: SPECIFICATIONS Voltage and Frequency: 100 Vac (+10/-15%), 50 or 60 Hz (+/- 10%). 1 Model: Power Dissipation: RM7895: 10W maximum. RM7895A 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 Earth G Earth Ground2 L2(N) Line Voltage Common 3 Alarm 100 Vac, 1A pilot duty. 4 Burner Motor 100 Vac, 9.8 AFL, 58.8 ALR (inrush). 5 Line Voltage Supply (L1) 100 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).3,4 6 Burner Controller and Limits 100 Vac, 1 mA. 7 Airflow Interlock 100 Vac, 9A. 8 Pilot Valve/Ignition 100 Vac, 4.5A ignition and 50VA pilot duty.4 9 Main Fuel Valve 100 Vac, 2A pilot duty.5 10 Ignition 100 Vac, 4.5A ignition.4 F(11) Flame Sensor 60 to 220 Vac, current limited. 12 Unused 13 Unused 14 Unused 15 Unused 16 Unused 17 Unused 18 Unused 19 Unused 20 Unused 21 Unused 22 Shutter 100 Vac, 0.5A 1 Range of allowable operating frequency: 45 to 66 Hz. 2 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 2000 VA maximum connected load to 7895 Assembly. 4 Can also be 100 Vac, 1A pilot duty. 5 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. Your local Home and Building Control Sales Office (check white pages of your phone directory). 2. 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 2 7800 SERIES EC7895A, RM7895A RELAY MODULE Model: Electrical Ratings, see Table 1B: EC7895 Voltage and Frequency: 200 Vac (+10/-15%), 50 or 60 Hz (+/- 10%). 1 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 Ratings G Flame Sensor Ground Earth G Earth Ground2 L2 (N) Line Voltage Common 3 Alarm 200 Vac, 1A pilot duty. 4 Burner Motor 200 Vac, 4A at pF = 0.5, 20A inrush4 5 Line Voltage Supply (L1) 200 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).3,4 6 Burner Controller and Limits 200 Vac, 1 mA. 7 Airflow Interlock 200 Vac, 9A. 8 Pilot Valve/Ignition 200 Vac, 4A at pF = 0.5, 20A inrush4 9 Main Fuel Valve 200 Vac, 4A at pF = 0.5, 20A inrush4 10 Ignition 200 Vac, 4A at pF = 0.5, 20A inrush4 F(11) Flame Sensor 60 to 220 Vac, current limited. 12 Unused 13 Unused 14 Unused 15 Unused 16 Unused 17 Unused 18 Unused 19 Unused 20 Unused 21 Unused 22 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 2000 VA maximum connected load to EC7895 Assembly. 4 Total load current excluding burner/boiler motor and firing rate outputs cannot exceed 5A, 25A inrush. 3 65-0205 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. IMPORTANT Humidity: 85% RH continuous, noncondensing. Flame Detection System available for use with Vibration: 0.5G environment. EC7895 and RM7895. To select your Plug-in Flame Signal Amplifier and applicable Flame Detector, see Dimensions: Table 2 and Fig. 3 through 5. 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 Self- Response Type Color Checking Model Time Fuel Type Models Rectification Green No R7847A .8 or 3 sec Gas Rectifying Flame C7004, C7007, C7011 Rod Holdersa Complete Assemblies: C7008, C7009, Q179. No R7847A .8 or 3 sec Oil Rectifying C7003, C7010, C7013, Photocell C7014b No R7847A 3 sec Gas, Ultraviolet C7012A,C.c Oil, Coal (Purple Peeper) Dynamic R7847Bd .8 or 3 sec Gas Rectifying Flame C7004, C7007, C7011 AMPLI- Rod Holdersa Complete Assemblies: CHECK¨ C7008, C7009, Q179. Dynamic R7847Bd .8 or 3 sec Oil Rectifying C7003, C7010, C7013, AMPLI- Photocell C7014b CHECK¨ Dynamic R7847Bd 3 sec Gas, Ultraviolet C7012A,C.c AMPLI- Oil, Coal (Purple Peeper) CHECK¨ Dynamic R7847Ce 3 sec Gas, Ultraviolet C7012E,F. Self-Check Oil, Coal (Purple Peeper) Infrared Red No R7848A 3 sec Gas, Infrared C7015 Oil, Coal (Lead Sulfide) Dynamic R7848Bd 3 sec Gas, Infrared C7015 AMPLI- Oil, Coal (Lead Sulfide) CHECK¨ Ultraviolet Purple No R7849A .8 or 3 sec Gas, Oil Ultraviolet C7027, C7035, (MiniPeeper) C7044.c Dynamic R7849Bd .8 or 3 sec Gas, Oil Ultraviolet C7027, C7035, AMPLI- (MiniPeeper) C7044.c CHECK¨ Dynamic R7861A 3 sec Gas, Ultraviolet C7061 Self-Checkf Oil, Coal Blue Dynamic R7886Ae 3 sec Gas, Ultraviolet C7076 Self-Checkg Oil, Coal (Adjustable Sensitivity) a Order flame rod separately; see holder Instructions. b Use only Honeywell Photocell, part no. 38316. c 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. d Circuitry tests the flame signal amplifier at least 12 times a minute during burner operation and shuts down the burner if the amplifier fails. e 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. f When R7861 is used with EC7895, the application requires a step down transformer. See Fig. 14. g Use with RM7895A only. 65-0205 4 7800 SERIES EC7895A, RM7895A RELAY MODULE Sequence Timing For Normal Operation: Flame Establishing Period Device Initiate Standby Purge Pilot Main EC7895A/RM7895A 10 sec. * ** 4 or 10 sec. No *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, Network Interface Unit, Guide no. MCCZ. Part No. Q7700A1014, 120V 50/60 Hz Factory Mutual approved. Part No. Q7700B1004, 100V to 200V 50/60 Hz EC7895A: Network Interface ControlBus Module, Factory Mutual approved. Part No. QS7800A1001. COMBUSTION SYSTEM MANAGERª, 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 MODULEª, Plug-in Flame Signal Amplifier, see Table 2. Part No. S7810A1009. Plug-in Purge Timer Cards: Selectable ST7800A, two Dust Cover, Part No. 221729A. 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 (127) 5-1/4 (133) 1 REMOVE ONLY FOR TERMINAL TEST ACCESS. M11135 Fig. 1. Mounting dimensions of EC7895/RM7895 Relay Module and Q7800A Subbase in in. (mm). 5 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE BURNER CONTROL 5 (127) POWER PILOT 1 FLAME MAIN ALARM RESET 5 (127) 6-3/32 (155) 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 (42) (36) TARGET MOUNTING FLANGE 3/4Ð14 NPT 3/8 (10) 7-7/32 (183) 3-1/8 5-1/8 (130) 1-1/16 3-3/4 (79) 1/2 (13) (27) (95) 3-7/16 (87) 3/32 (2) 11/16 (18) 25/32 25/32 17/32 (20) (20) THREADED (14) 1/2Ð14 NPSM MOUNTING 5-1/4 (133) 2-25/32 HOLES (2)Ð LEADWIRES (62) 10-32 UNF 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 6 7800 SERIES EC7895A, RM7895A RELAY MODULE 4-1/8 (105) COLLAR WITH 2 (51) 1/2-14 NPSM 2 INTERNAL THREADS 1Ð11-1/2 NPSM 1-3/16 INTERNAL 1 (30) 4 (102) 6 FOOT (1.83 METER) THREADS LEADWIRES (2) 3-1/2 (89) 1 31/32 1-1/2 (25) (38) 1-1/16 (27) 2 2-5/8 (67) 6 FOOT [1.83 METER] INSERTION DEPTH LEADWIRES (2) 3 COLLAR WITH 1/2-14 NPSM INTERNAL THREADS 1 DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL THREADS. 1 MODEL AVAILABLE WITH 24 FOOT (7.32 METER) LEADWIRES. 2 DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL THREADS. 2 MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL THREADS) INSTEAD OF CLAMP TYPE CONNECTOR. M1943A 3 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 2-1/4 1-1/16 (27) 1 INCH NPT (57) 2-1/4 (57) 4 (102) 2-5/16 4 (102) (58) 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 2-11/16 7-5/8 (194) FOR LENS CLEANING OR SERVICING. (68) M5083A C7076A Fig. 4. Ultraviolet detectors in in. (mm). 7 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE 11-13/16 (300) 2-5/32 1-27/32 1 INCH NPT (55) 7-13/16 (198) (47) 5-13/16 (147) 15/16 [24] DIA. 5-13/16 6-7/32 (147) (158) 2-1/2 (64) 6-19/32 (168) 1 (25) 15/16Ð18 UNC (2 EACH) 2 (51) C7076D M5084A Fig. 4. Ultraviolet detectorsin in. (mm) (Continued). CELL MOUNT HEAT BLOCK d. Main valve terminal is energized. 1-5/8 (41) e. Internal system fault occurred. 2-3/4 f. Purge card is removed. 1-1/16 (27) (70) g. Purge card is bad. 4. Pilot Flame Establishing Period (PFEP) 1-1/4 1-1/4 a. Airflow lockout feature is enabled and the airflow (32) (32) switch opens. 2 LEADS IN A b. Ignition/pilot valve terminal is not energized. 48 INCH (1.2 METER) APERTURE c. No flame present at end of PFEP. FLEXIBLE CONDUIT 3/4-14 3/4-14 NPSM d. Main valve terminal is energized. BUSHING WITH NPSM INTERNAL MAGNIFYING LENS COLLAR, 3/4-14 NPSM THREADS e. Internal system fault occurred. INTERNAL THREADS f. Purge card is removed. C7015 M1982A g. Purge card is bad. 5. Run Period Fig. 5. Infrared detector in in. (mm). a. No flame present. b. Airflow lockout feature is enabled and the airflow switch opens. c. Main valve terminal is not energized. PRINCIPAL TECHNICAL FEATURES d. Internal system fault occurred. e. Purge card is removed. The EC7895 or RM7895 provides all customary flame f. Purge card is bad. safeguard functions while providing significant advancements in the areas of safety, annunciation and system diagnostics. SAFETY PROVISIONS Safety Shutdown (Lockout) Occurs If: 1. Initiate Period a. Purge card is not installed or removed. Internal Hardware Status Monitoring b. Purge card is bad. The EC7895 or RM7895 checks the purge card for correct c. Configuration jumpers have been changed (after parity to prevent purge timing shifts and circuitry failures. It 200 hours). also analyzes the integrity of the configuration jumpers and d. AC line power errors occurred, see Operation. internal hardware. The POWER LED blinks every four e. Four minute INITIATE period was exceeded. seconds, signifying an internal hardware check. 2. Standby Period a. Flame signal is present after 40 seconds. Closed Loop Logic Test b. Ignition/pilot valve/intermittent pilot valve terminal The test verifies the integrity of all safety critical loads, is energized. terminals 8, 9, 10 and 21. If the loads are not energized c. Main valve terminal is energized. properly; i.e., the main valve terminal is powered during d. Internal system fault occurred. PREPURGE, the EC7895 or RM7895 locks out on safety e. Purge card is not installed or removed. shutdown. The EC7895 or RM7895 must react to input f. Purge card is bad. changes but avoid the occurrence of nuisance shutdown 3. Prepurge Period events. Signal conditioning is applied to line voltage inputs to a. Airflow lockout feature is enabled and the airflow verify proper operation in the presence of normal electrical switch does not close after ten seconds or within line noise such as transient high voltage spikes or short the specified purge card timing. periods of line dropout. Signal conditioning is tolerant of b. Flame signal is detected after 30 seconds. synchronous noise (line noise events that occur at the same c. Ignition/pilot valve/intermittent pilot valve terminal time during each line cycle). is energized. 65-0205 8 7800 SERIES EC7895A, RM7895A RELAY MODULE Dynamic Ampli-Check¨ Verified Spark Termination Dynamic AMPLI-CHECK¨ circuitry tests the flame signal The ignition terminal is monitored to assure early spark amplifier during burner operation and shuts down the EC7895 termination (ten seconds ignition and pilot and ten seconds or RM7895 if the flame amplifier fails. 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 Sequence Status Lights (LEDs) provide positive visual flame detection system and amplifier 10 to 12 times per indication of the program sequence: POWER, PILOT, minute and shuts down the EC7895 or RM7895 if the FLAME, MAIN and ALARM. The green POWER LED blinks detection system fails. every four seconds, signifying that the RM7895 hardware is running correctly. Dynamic Input Check Optional multi-function Keyboard Display Module shows All system input circuits are examined to assure that the elapsed time during PREPURGE, PILOT IGN and MAIN IGN. EC7895 or RM7895 is capable of recognizing the true status As an additional troubleshooting aid, it provides sequence of external controls, limits and interlocks. If any input fails this timing, diagnostic information and historical information when test, a safety shutdown occurs and the fault is annunciated. a safety shutdown or hold or normal operation occurs. Dynamic Safety Relay Test First-out Annunciation reports the cause of a safety shutdown Checks the ability of the dynamic safety relay contact to open or identifies the cause of a failure to start or continue the and close. Verifies that the safety critical loads, terminals 8, 9, burner control sequence with text and numbered code via the 10 and 21, can be de-energized, as required, by the Dynamic optional Keyboard Display Module. It monitors all field input Self-Check logic. circuits, including the flame signal amplifier. The system distinguishes 43 modes of failure and detects and Dynamic Self-Check Safety Circuit annunciates difficult-to-find intermittent failures. The microcomputer tests itself and related hardware, and at Self-Diagnostics add to the First-out Annunciation by allowing the same time, the safety relay system tests the the EC7895 or RM7895 to distinguish between field (external microcomputer operation. If a microcomputer or safety relay device) and internal (system related) problems. Faults failure occurs and does not allow proper execution of the self- associated within the flame detection subsystem, EC7895 or check routine, safety shutdown occurs and all safety critical RM7895 or Plug-in Purge Card are isolated and reported by loads are de-energized. the optional Keyboard Display Module. See the 7800 SERIES System Annunciation Diagnostics and Troubleshooting, Expanded Safe-Start Check form 65-0118. The conventional safe-start check, which prevents burner start-up if flame is indicated at start-up, is expanded to Airflow Switch Interlock include a flame signal check during STANDBY, an airflow This interlock is typically connected to an airflow switch. The switch check and a safety critical load check. Airflow Interlock (ILK) input must close ten seconds into PREPURGE or within the specified purge card timing; Off Cycle (Standby or Prepurge) Flame otherwise, a recycle to the beginning of PRE-PURGE or lockout will occur, depending on how the airflow switch Signal Check selectable jumper is configured (see Table 3 in Operation The flame detection subsystem (flame detector and amplifier) section). 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 40 seconds of STANDBY, a safety shutdown occurs and is INSTALLATION 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. WARNING If a flame exists, a safety shutdown occurs. An AMPLI- FIRE OR EXPLOSION HAZARD CHECK¨ Amplifier is energized continually through CAN CAUSE PROPERTY DAMAGE, STANDBY and PREPURGE to detect any possibility of a SEVERE INJURY, OR DEATH runaway detector or a flame. If a flame exists, a safety To prevent possible hazardous burner operation, shutdown occurs. A standard amplifier is energized verification of safety requirements must be performed continually through STANDBY and PREPURGE; if a flame each time a control is installed on a burner. exists, a safety shutdown occurs. Tamper Resistant Timing and Logic Safety and logic timings are inaccessible and cannot be altered or defeated. 9 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE When Installing this Product… Humidity 1. Read these instructions carefully. Failure to follow them Install the EC7895 or RM7895 where the relative humidity could damage the product or cause a hazardous never reaches the saturation point. The EC7895 or RM7895 condition. is designed to operate in a maximum 85% RH continuous, 2. Check the ratings given in the instructions and marked noncondensing, moisture environment. Condensing moisture on the product to make sure the product is suitable for can cause a safety shutdown. your application. 3. Installer must be a trained, experienced, flame Vibration safeguard service technician. 4. After installation is complete, check out the product Do not install the EC7895 or RM7895 where it could be operation as provided in these instructions. subjected to vibration in excess of 0.5G continuous maximum vibration. Weather CAUTION The EC7895 or RM7895 is not designed to be weather tight. 1. Disconnect the power supply before beginning If installed outdoors, the EC7895 or RM7895 must be installation to prevent electrical shock and protected by an approved weather-tight enclosure. equipment damage. More than one power supply disconnect may be involved. 2. Wiring connections for the EC7895 or RM7895 Mounting Wiring Subbase are unique; therefore, refer to Fig. 7 or 8 for the correct Specifications for proper subbase wiring. NOTE: For installation dimensions, see Fig. 1 or 2. 3. Wiring must comply with all applicable codes, ordinances and regulations. 1. Mount the subbase in any position except horizontally 4. Wiring, where required, must comply with NEC with the bifurcated contacts pointing down. The standard Class 1 (Line Voltage) wiring. vertical position is recommended. Any other position 5. Loads connected to the EC7895 or RM7895 must decreases the maximum ambient temperature rating. not exceed those listed on the EC7895 or RM7895 2. Select a location on a wall, burner or electrical panel. The label or the Specifications, see Table 1A or 1B. Q7800 can be mounted directly in the control cabinet. Be 6. Limits and interlocks must be rated to carry and sure to allow adequate clearance for servicing, instal- break current simultaneously to the ignition lation, access and removal of the EC7895 or RM7895, transformer, pilot valve, and main fuel valve(s). Dust Cover, flame amplifier, flame amplifier signal voltage 7. All external timers must be listed or components probes, Run/Test Switch, electrical signal voltage probes recognized by authorities who have jurisdiction and electrical field connections. for specific purpose for which they are used. 3. For surface mounting, use the back of the subbase as a template to mark the four screw locations. Drill the pilot IMPORTANT holes. 1. For on-off gas-fired systems, some authorities who 4. Securely mount the subbase using four no. 6 screws. have jurisdiction prohibit the wiring of any limit or operating contacts in series between the flame safeguard control and the main fuel valve(s). 2. Two Detectors can be connected in parallel with the exception of Infrared Detectors (C7015). 3. 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 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 7800 SERIES EC7895A, RM7895A RELAY MODULE L1 (HOT) L2 1 5 L2 2 PLUG-IN PURGE CONFIGURATION TIMER CARD JUMPERS TEST FLAME SIGNAL JACK RUN/TEST F SWITCH PLUG-IN MICROCOMPUTER FLAME G TEST AMPLIFIER RESET 22 PUSHBUTTON 2K 3K RELAY RELAY 4K STATUS DRIVE FEEDBACK CIRCUIT 5K AND LINE 6K VOLTAGE 7K INPUTS SAFETY RELAY 1K CIRCUIT STATUS LEDs CONTROL POWER SUPPLY POWER LOCKOUT INTERLOCK LIMITS CONTROLLER 1K1 2K1 5K1 6 7 10 IGNITION 4K1 8 PILOT 7K1 21 PILOT/V2 2K2 9 MAIN VALVE 6K1 4 BLOWER 3K1 3 ALARM OPTIONAL KEYBOARD DDL DISPLAY MODULE INDICATES FEEDBACK SENSING RS485 OF RELAY CONTACT STATUS AND LINE VOLTAGE INPUTS 1 5 DDL 2 FIELD WIRING COMMUNICATIONS 3 REMOTE RESET INTERNAL WIRING 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M11128 2 RM7895:,100VAC; EC7895: 200VAC. 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 WIRING temperature. All leadwires must be moisture resistant. 5. Recommended grounding practices: 1. a. For proper wiring, refer to Fig. 7 or 8. a. Use the earth ground to provide a connection b. For proper remote wiring of the Keyboard Display between the subbase and the control panel or the Module, refer to the Specifications for the Keyboard equipment. The earth ground wire must be capable Display Module (65-0090), Communication Interface of conducting the current to blow the 20A fuse (or Base Unit (63-2278), DATA CONTROLBUS breaker) in event of an internal short circuit. The MODULEª (65-0091) or Extension Cable Assembly EC7895 or RM7895 needs a low impedance (65-0131). ground connection to the equipment frame which, 2. Disconnect the power supply from the main disconnect in turn, needs a low impedance connection to earth before beginning installation to prevent electrical shock ground. For a ground path to be low impedance at and equipment damage. More than one disconnect may RF frequencies, the connection must be made with be involved. minimum length conductors that have a maximum 3. All wiring must comply with all appropriate electrical codes, surface area. Wide straps or brackets are preferred ordinances and regulations. Wiring, where required, must rather than leadwires. Be careful to verify that comply with NEC Class 1 (Line Voltage) wiring. mechanically tightened joints along the ground 4. Recommended wire size and type: use no. 14, 16, or 18 path, such as pipe or conduit threads or surfaces copper conductor (TTW60C or THW75C or THHN90C) held together with fasteners, are free of noncon- 600 volt insulation wire for all Line Voltage terminals. For ductive coatings and are protected against mating high temperature installations, use wire selected for a surface corrosion. 11 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE b. For EC7895 or RM7895, each device has an 7. Maximum wire lengths: earth ground terminal that must be grounded to a. For the EC7895 or RM7895, the maximum length the metal control panel with wire as short as of leadwire to the terminal inputs is 300 feet practical. Each ground wire must be capable of (Control and Airflow Interlock). carrying a fault current equal to the rating of the b. For the flame detector leadwires, the maximum protective fuse (20A). A number 14 copper flame sensor leadwire length is limited by the conductor is adequate but wide straps or flame signal strength. brackets are preferred rather than leadwires. 8. Make sure loads do not exceed the terminal ratings. 6. Recommended wire routing for flame detector Refer to the label on the EC7895 or RM7895 or to the leadwires: ratings in the Specifications, see Table 1A or 1B. 1. Do not run high voltage ignition transformer wires 9. Check the power supply circuit. The voltage and in the same conduit with the flame detection wiring. frequency tolerance must match those of the EC7895 2. Do not route scanner wires in a conduit with line or RM7895. A separate power supply circuit may be voltage circuits. required for the EC7895 or RM7895 with the required 3. Enclose scanner wires without armor cable in disconnect means and overload protection added. metal cable or conduit. 10. Check all wiring circuits and complete the Static 4. Follow directions given in the flame detector Checkout, see Table 4, before installing the EC7895 or Instructions. RM7895 on the subbase. 11. Install all electrical connectors. 12. Restore power to the panel. Q7800 G 12 L2 13 100V ALARM 3 14 BURNER MOTOR (BLOWER) 4 15 5 (L1) 16 BURNER 6 17 CONTROLLER/LIMITS 2 AIRFLOW 7 18 INTERLOCK INTERMITTENT 8 19 PILOT/IGNITION MAIN FUEL 9 20 VALVE(S) IGNITION 10 21 F 22 RECTIFYING FLAME L1 ROD, RECTIFYING (HOT) PHOTOCELL, OR INFRA- 1 RED (LEAD SULFIDE) L2 FLAME DETECTOR MASTER SWITCH OR WHITE C7027A, C7035A, OR BLUE FOR DIRECT SPARK IGNITION C7044A ULTRAVIOLET (OIL OR GAS) FLAME DETECTOR IGNITION 10 OR TRANSFORMER L2 YELLOW C7012A,C,E,F OR BLUE 9 MAIN VALVE C7076A,D ULTRAVIOLET FLAME DETECTOR 8 WHITE WHITE L2 BLACK L1 BLACK L2 1 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. 2 DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS. M5111A Fig. 7. Wiring the RM7895A. 65-0205 12 7800 SERIES EC7895A, RM7895A RELAY MODULE Q7800 G 12 L2 13 200 VAC ALARM 3 (L1) 14 BURNER MOTOR 4 15 (BLOWER) 5 16 BURNER 6 17 CONTROLLER/LIMITS 2 AIRFLOW INTERLOCK 7 18 INTERMITTENT 8 19 PILOT/IGNITION MAIN FUEL 9 20 VALVE(S) IGNITION 10 21 F 22 RECTIFYING FLAME ROD, RECTIFYING L1 PHOTOCELL, OR INFRA- (HOT) 1 RED (LEAD SULFIDE) L2 FLAME DETECTOR MASTER OR SWITCH C7027A, C7035A, OR WHITE BLUE C7044A ULTRAVIOLET FLAME DETECTOR FOR DIRECT SPARK IGNITION (OIL OR GAS) 4 OR IGNITION 10 YELLOW C7012A,C ULTRAVIOLET BLUE TRANSFORMER FLAME DETECTOR L2 BLACK 9 MAIN VALVE OR BLACK 3 YELLOW BLUE C7061A 1:2 8 WHITE OR WHITE 4 YELLOW C7012F OR BLUE C7076A ULTRAVIOLET FLAME DETECTOR WHITE WHITE 1 200V, 50/60 HZ EC7895 POWER SUPPLY. PROVIDE DISCONNECT BLACK MEANS AND OVERLOAD PROTECTION AS REQUIRED. BLACK 2 DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS. 3 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. 13 65-0205 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 Mounting RM7895 damage. More than one disconnect may be involved. 2. Align the amplifier circuit board edge connector with the NOTE: For installation dimensions, see Fig. 1 or 2. keyed receptacle on the EC7895 or RM7895. Ensure the amplifier nameplate faces away from the Relay Relay Module Mounting Module, see Fig. 13. 1. Mount the EC7895 or RM7895 vertically, see Fig. 9 or 3. Push in the amplifier until the circuit board is fully 10, or mount horizontally with the knife blade terminals inserted into the receptacle and then push the amplifier pointing downward. When mounted on the Q7800A, the toward the EC7895 or RM7895 retaining clasp. EC7895 or RM7895 must be in an electrical enclosure, 4. Verify the amplifier is firmly in place. see Fig. 9. 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, Installing the Flame Detector flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes and electrical NOTE: Table 2 lists the flame detection systems available connections. for use with the EC7895 or RM7895. Make sure the a. Allow an additional two inches below the EC7895 correct combination of amplifier and flame or RM7895 for the flame amplifier mounting. detector(s) is used. b. Allow an optional three-inch minimum to both sides of the EC7895 or RM7895 for electrical Proper flame detector installation is the basis of a safe and signal voltage probes. reliable flame safeguard installation. Refer to the Instructions 3. Make sure no subbase wiring is projecting beyond the packed with the flame detector and the equipment terminal blocks. Tuck wiring in against the back of the manufacturer instructions. subbase so it does not interfere with the knife blade terminals or bifurcated contacts. Keep the flame signal leadwires as short as possible from the 4. Mount the EC7895 or RM7895 by aligning the four L flame detector to the wiring subbase. Capacitance increases shaped corner guides and knife blade terminals with with leadwire length, reducing the signal strength. The the bifurcated contacts on the wiring subbase and maximum permissible leadwire length depends on the type of securley tightening the two screws without deforming flame detector, leadwire and conduit. The ultimate limiting factor the plastic. in the flame detector leadwire is the flame signal; see Table 5. 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 MODULEªor 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. Make sure that the ST7800 selected has the desired timing. 4. Insert the Purge Card into the opening of the RM7895 compartment, see Fig. 11. 5. Reinstall the Dust Cover, Keyboard Display Module, DATA CONTROLBUS MODULEª 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. Align the two interlocking ears of the Dust Cover with the two mating slots on the EC7895 or RM7895, see Fig. 12. 2. 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. 3. Be sure the Dust Cover is firmly in place. 65-0205 14 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. 15 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE C7076A,D ULTRAVIOLET DETECTOR INFRARED (C7015) REMOTE SENSOR 6 F 7 WHITE F EARTH 3a 3b 2b GROUND BROWN 5 G 8 G 2a 4 SHUTTER L1 1 C7076A OR 3 SHUTTER L2 2 C7076D TERMINAL BLOCK 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 SOLID STATE ULTRAVIOLET (C7012E,F) ULTRAVIOLET (C7012A,C) BLUE BLUE F F 2 YELLOW YELLOW G 2 G WHITE 22 BLACK WHITE L1 L2 BLACK BLACK L2 3 L1 BLACK L2 SOLID STATE SELF-CHECKING ULTRAVIOLET (C7061A) FLAME ROD X F X G PHOTOCELL X F BLUE F 2 YELLOW G G X 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 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. 3 WHEN USING A C7061A OR 200V VERSIONS OF THE C7012E,F, OR C7076A, A 2:1 STEP DOWN TRANSFORMER IS M11131 REQUIRED. SEE FIGURE 8. Fig. 14. Flame detector wiring. 65-0205 16 7800 SERIES EC7895A, RM7895A RELAY MODULE OPERATION Ignition Trials a. Pilot Flame Establishing Period (PFEP): 1. The pilot valve and ignition transformer, terminals 8 Sequence of Operation and 10, are energized. The EC7895 or RM7895A The EC7895 or RM7895 has the following operating has an intermittent pilot valve, terminal 8. 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. Initiate If flame is not proven by the end of PFEP, a safety shutdown occurs. The EC7895 or RM7895 enters the INITIATE sequence when 3. At the end of PFEP, the ignition, terminal 10, is the Relay Module is powered. The EC7895 or RM7895 can de-energized. also enter the INITIATE sequence if the Relay Module verifies b. Main Flame Establishing Period (MFEP): voltage fluctuations of +10/-15% or frequency fluctuations of 1. After the Ignition Trials, and with the presence of +/- 10% during any part of the operating sequence. The flame, the main fuel valve, terminal 9, is powered. INITIATE sequence lasts for ten seconds unless the voltage If a flameout occurs, the EC7895A or RM7895A or frequency tolerances are not met. When the tolerances are will lock out or recycle within .8 or 3 seconds, not met, a hold condition is initiated and is displayed on the depending on the Flame Failure Response Time optional VFD for at least five seconds. When the tolerances (FFRT) of the amplifier. 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 Run INITIATE sequence are: 1. The EC7895A or RM7895 is now in RUN and remains ¥ AC line dropout is detected. in RUN until the controller input, terminal 6, opens, ¥AC line noise that can prevent a sufficient reading of the indicating that the demand is satisfied or a limit opened. 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 Selectable Site-Configurable Jumpers AC line input or control input. 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 Standby removed from the Relay Module. The EC7895 or RM7895 is ready to start an operating sequence when the operating control input determines a call SERVICE NOTE: Clipping and removing a site-configurable for heat is present. The burner switch, limits, operating limit jumper enhances the level of safety. control and all microcomputer monitored circuits must be in the correct state for the EC7895 or RM7895 to continue into the PRE-PURGE sequence. Static Checkout Normal Start-Up Prepurge CAUTION The EC7895 or RM7895 provides a selectable PREPURGE 1. Use extreme care while testing the system. Line timing from two seconds to 30 minutes with power applied voltage is present on most terminal connections and the EC7895 or RM7895 operating control indicating a call when power is on. for heat. 2. Open the master switch before installing or a. Airflow Interlock, burner switch, and all microcomputer removing a jumper on the subbase. monitored circuits must be in the correct operating state. 3. Before continuing to the next test, be sure to re- b. The blower motor output, terminal 4, is powered to start move test jumper(s) used in the previous tests. the PREPURGE sequence. 4. Replace all limits and interlocks not operating c. The Airflow Interlock input must close ten seconds into properly. Do not bypass limits and interlocks. PREPURGE or within the specified purge card timing; 5. Close all manual fuel shutoff valve(s) before otherwise, a recycle to the beginning of PRE-PURGE starting these tests. or lockout occurs depending on how the airflow switch selectable jumper is configured. 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. 17 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE 5. For each test, open the master switch and install the Equipment Recommended jumper wire(s) between the subbase wiring terminals 1. Voltmeter (1M ohm/volt minimum sensitivity) set on the listed in the Test Jumpers column of Table 4. 0-300 Vac scale. 6. Close the master switch before observing operation. 2. Two jumper wires; no. 14 wire, insulated, 12 inches 7. Read the voltage between the subbase wiring terminals (304.8 mm) long, with insulated alligator clips at both listed in the Voltmeter column of Table 4. ends. 8. If there is no voltage or the operation is abnormal, check the circuits and external devices as described in General Instructions the last column. 1. Perform all applicable tests listed in, Table 4, in the 9. Check all wiring for correct connections, tight terminal screws, correct wire, and proper wiring techniques. order listed. Replace all damaged or incorrectly sized wires. 2. MAKE SURE THAT ALL MANUAL FUEL SHUT-OFF 10. Replace faulty controllers, limits, interlocks, actuators, VALVE(S) ARE CLOSED. valves, transformers, motors and other devices as 3. Perform only those tests designated for the specific required. RM7895 model being tested. 11. Obtain normal operation for each required test before 4. Raise the set point of the operating controller to continuing the checkout. simulate a call for heat. 12. After completing each test, be sure to remove the test jumper(s). 00 00 00 TIMED PFEP LED INITIATE STANDBY START PURGE 4 OR 10 SEC RUN STANDBY DISPLAY POWER POWER POWER POWER POWERPOWER POWER PILOT PILOT PILOT FLAME FLAME FLAME MAIN MAIN MAIN ALARM ALARM ALARM BURNER/BLOWER MOTOR 4 BURNER START 10 IGN. IGN./ PILOT 8 MAIN VALVE 9 OPERATING LIMITS AND BURNER CONTROLLER CLOSED L1 TO 6 CONTROLS AND AIRFLOW INTERLOCK CLOSED 6 TO 7 INTERLOCKS FLAME SIGNAL FLAME SSC SAFE START CHECK PROVING M11130 Fig. 15. 7895 sequence. CAPTIVE MOUNTING SCREW PLUG-IN PURGE CARD DUST COVER SEQUENCE STATUS LEDs RELAY MODULE RESET FLAME PUSHBUTTON AMPLIFIER FLAME FLAME CURRENT SIMULATOR INPUT TEST JACKS M11127 Fig. 16. Sequence status LEDs. 65-0205 18 7800 SERIES EC7895A, RM7895A RELAY MODULE Table 3. Site Configurable Jumper Options. SELECTABLE CONFIGURATION JUMPERS Jumper Number Description Intact Clipped JR1 Pilot Flame 10 seconds 4 seconds Establishing Period JR2 Flame Failure Recycle Lockout Action JR3 Airflow Switch Recycle Lockout (ILK) Failure M11126 Fig. 17. Selectable site-configurable jumpers. Table 4. Static Checkout. Test Test Volt- If Operation Is Abnormal, No. Jumpers meter Normal Operation 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. 3. Overload protection (fuse, circuit breaker) has not opened the power line. 2 None 6-L2 Line voltage at terminal 6. 1. Limits. 2. Burner controller. 3 4-5 7-L2 1. Burner motor (fan or blower) starts. 1. Burner motor circuit. 2. Line voltage at terminal 7 within 10 a. Manual switch of burner motor. seconds. b. Burner motor power supply, overload protection and starter. c. Burner motor. 4 5-10 — Ignition spark (if ignition transformer is 1. Watch for spark or listen for buzz. connected to terminal 10). a. Ignition electrodes are clean. b. Ignition transformer is okay. 5 5-8 — 1. Ignition spark (if ignition transformer is 1. Watch for spark or listen for buzz. connected to terminal 8). a. Ignition electrodes are clean. 2. Automatic pilot valve opens b. Ignition transformer is okay. (if connected to terminal 8). 2. Listen for click or feel head of valve for activation. NOTE: Refer to wiring diagram of system a. Actuator if used. being tested. b. Pilot valve. 6 5-9 — Automatic fuel valve(s) opens. If using Same as test no. 6. If using direct spark ignition, direct spark ignition, check the first stage check the first stage fuel valve(s) instead of the pilot fuel valve(s) instead of the pilot valve. valve. 75 -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). 19 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE CHECKOUT Checkout Summary ¥ Preliminary inspection—all installations. ¥ Flame signal measurement—all installations. WARNING ¥ Initial lightoff check for proved pilot—all installations using Do not allow fuel to accumulate in the combustion a pilot. chamber. If fuel is allowed to enter the chamber for ¥ Initial lightoff check for direct spark ignition of oil—all longer than a few seconds without igniting, an burners using DSI. explosive mixture could result. It is recommended that ¥ Pilot turndown test—all installations using a pilot. you limit the trial for pilot to ten seconds, and limit the ¥ Hot refractory saturation test—all installations using attempt to light the main burner two seconds from the Infrared (lead sulfide) Flame Detectors. time the fuel has reached the burner nozzle. In any ¥ Hot refractory hold-in test—all installations. case, do not exceed the nominal lightoff time specified ¥ Ignition interference test—all installations using flame by the equipment manufacturer. Close the manual fuel rods. shutoff valve(s) if the flame is not burning at the end of ¥ Ignition spark pickup—all installations using Ultraviolet the specified time. Flame Detectors. ¥ Response to other ultraviolet sources—all installations using Ultraviolet Flame Detectors. ¥ Flame signal with hot combustion chamber—all CAUTION installations. 1. Use extreme care while testing the system. Line ¥ Safety shutdown tests—all installations. voltage is present on most terminal connections when power is on. See Fig. 1 and 2 for location of component parts and see Fig. 2. Open the master switch before removing or 7 or Q7800 Specifications for terminal locations. installing the EC7895 or RM7895. 3. Make sure all manual fuel shutoff valve(s) are closed before starting the initial lightoff check and Preliminary Inspection the Pilot Turndown tests. Perform the following inspections to avoid common problems. 4. Do not put the system in service until you have Be sure: satisfactorily completed all applicable tests in this 1. Wiring connections are correct and all terminal screws section and any others required by the equipment are tight. manufacturer. 2. Flame detector(s) is clean, installed and positioned properly. Consult the applicable Instructions. 3. Correct combination of amplifier and flame detector is CAUTION used (see Table 2). 4. Plug-in amplifier and purge card are securely in place. If an EC7895 or RM7895 is replaced with a lower 5. Burner is completely installed and ready to fire; consult or higher functioning 7800 SERIES Relay Module, equipment manufacturer instructions. Fuel lines are the burner will not sequence unless wiring changes purged of air. are made. 6. Combustion chamber and flues are clear of fuel and fuel vapor. IMPORTANT 7. Power is connected to the system disconnect switch 1. If the system fails to perform properly, refer to (master switch). 7800 SERIES System Annunciation Diagnostics 8. Lockout switch is reset (push in reset pushbutton) only and Troubleshooting, form 65-0118. if the 7895 is powered, see Fig. 1 and 2. 2. Repeat ALL required Checkout tests after all 9. System is in the STANDBY condition. POWER LED is adjustments are made. ALL tests must be satisfied energized. 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 20 7800 SERIES EC7895A, RM7895A RELAY MODULE Flame Signal Measurement (Fig. 18 and Table 5) Table 5. Flame Signal. Acceptable Flame Minimum Maximum Flame Detector Signal Amplifier Steady DC Voltagea Expected DC Voltage Flame Rod Photocell R7847A,Bb 1.25 Vdc C7012A,C 5.0 Vdc at the Keyboard Display Module C7012E,F R7847Cc C7015A R7848A,Bb OR C7027A R7849A,Bb C7035A C7044A C7061 R7861Ad C7076A,D R7886Ae 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. b The flame amplifiers are AMPLI-CHECK¨ type. c 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). d Requires seperate stepdown power transformer. See Fig. 14. e Use with RM7895A Only. If the signal is unstable or less than the minimum ac-ceptable POSITIVE (+) voltage, check the flame detector installation and circuitry. METER LEAD ONE 1. Check the supply voltages at terminals 5 (L1) and L2 NEGATIVE (-) MEGOHM/VOLT (N). Make sure the master switch is closed, METER LEAD METER 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. M7382 ¥Temperature at the flame rod insulator is no greater than 500° F (260° C). Fig. 18. Flame signal measurement. 4. For all optical detectors, clean the detector viewing window and inside of the sight pipe as applicable. Measure the flame signal at the appropriate times defined in 5. With the burner running, check the temperature at the the following checkout tests. Read the flame signal volts dc at detector. If it exceeds the detector maximum rated the flame amplifier test jacks + and - (Com). temperature: 1. Use a 1M ohm/voltmeter with a 0 to 10 Vdc capability. ¥ Add a heat block to stop conducted heat traveling 2. Set the 1M ohm/voltmeter to the 0 to 10 Vdc range. up the sight pipe. 3. Insert the positive (red) probe into the + jack of the ¥ Add a shield or screen to reflect radiated heat. flame amplifier. Insert the negative (black) probe into ¥ Add cooling (refer to sight pipe ventilation in the the - (Com) jack of the flame amplifier, see Fig. 19. detector Instructions). 4. Allow a few seconds for the meter reading to stabilize. 6. Make sure that the flame adjustment is not too lean. 5. If using AMPLI-CHECK¨ or shutter check amplifiers, 7. Make sure that the detector is properly sighting the read the average stable voltage, disregarding the peaks flame. caused by the self-checking operation. 8. If necessary, resight or reposition the detector. 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 As an option, the flame signal can be checked by using the should immediately follow the preliminary inspection. optional Keyboard Display Module. 21 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE NOTE: Low fuel pressure limits, if used, could be open. If 9. When the MAIN IGN period is displayed by the MAIN so, bypass them with jumpers during this check. LED, make sure the automatic main fuel valve is open; then smoothly open the manual main fuel shutoff 1. Open the master switch. valve(s) and watch for main burner flame ignition. 2. Make sure that the manual main fuel shutoff valve(s) is When the main burner flame is established, proceed to closed. Open the manual pilot shutoff valve. If the pilot step 16. takeoff is downstream from the manual main fuel 10. If the main burner flame is not established within five shutoff valve(s), very slightly open the manual main seconds or the normal lightoff time specified by the valve to supply pilot gas flow. Make sure the main fuel equipment manufacturer, close the manual main fuel is shutoff just upstream from the burner inlet, or shut-off valve(s). disconnect power from the automatic main fuel 11. Recycle the system to recheck the lightoff and pilot valve(s). flame signal. 3. Close the master switch and start the system with a call 12. Smoothly open the manual fuel shutoff valve(s) and try for heat by raising the set point of the operating lightoff again. (The first reattempt may have been controller, see Fig. 15. The primary sequence should required to purge the lines and bring sufficient fuel to start the ten-second INITIATE sequence. the burner.) 4. Let the sequence advance through PREPURGE. 13. If the main burner flame is not established within five Ignition spark should occur and the pilot should light. If seconds or the normal lightoff time specified by the the pilot ignites, the FLAME LED is energized. Proceed equipment manufacturer, close the manual main fuel to step 7. shut-off valves(s). Check all burner adjustments. 5. If the pilot flame is not established in four or ten 14. If the main burner flame is not established after two seconds, safety shutdown occurs. Let the sequence attempts: complete its cycle. Consult the equipment operating a. Check for improper pilot size. manual for further information. b. Check for excess combustion air. 6. Push the reset pushbutton, and let the system recycle c. Check for adequate fuel flow. once. If the pilot still does not ignite, make the following d. Check for proper gas supply pressure. ignition/pilot adjustments: e. Check for proper valve operation. a. Open the master switch and remove the EC7895 f. Check for proper pilot flame positioning. or RM7895 from the subbase. 15. Repeat steps 8 through 14 to establish the main burner b. On the subbase, jumper terminal 5 to ignition flame; then proceed to step 16. terminals 8 or 10; refer to the appropriate wiring 16. With the sequence in RUN, make burner adjustments diagram to determine the proper terminal. for flame stability and BTU input rating. Disconnect the leadwire to the pilot valve if it is 17. Shut down the system by opening the burner switch or connected to the same terminal. by lowering the set point of the operating controller. c. Close the master switch to energize only the Make sure the main flame goes out. There may be a ignition transformer. delay due to gas trapped between the valve(s) and the d. If the ignition spark is not strong and continuous, burner. Make sure all automatic fuel valve(s) close. open the master switch and adjust the ignition 18. Restart the system by closing the burner switch and/or electrode spark gap setting to the manufacturer raising the set point of the operating controller. Observe recommendations. that the pilot is established during PILOT IGN and the e. Make sure the ignition electrodes are clean. main burner flame is established during MAIN IGN f. Close the master switch and observe the spark. within the normal lightoff time. g. After a continuous spark is obtained, open the 19. Measure the flame signal. Continue to check for the master switch and add a jumper on the subbase proper signal, see Table 5, through the RUN period. from terminal 5 (L1) to the pilot terminal 8. 20. Run the burner through another sequence, observing Reconnect the leadwire from the pilot valve if it the flame signal for: was disconnected in step b. a. Pilot flame alone (unless using direct spark h. Close the master switch to energize both the ignition). ignition transformer and the pilot valve. b. Pilot and main flame together. i. If the pilot does not ignite and if the ignition spark c. Main flame alone (unless monitoring an is still continuous, adjust the pressure regulator intermittent pilot). until a pilot is established. j. When the pilot ignites properly and stays ignited, Also observe the time it takes to light the main flame. Ignition open the master switch and remove the jumper(s) of main flame should be smooth. from terminals 5 through 8 or 5 through 10 of the subbase. 21. Return the system to normal operation. k. Check for adequate bleeding of the fuel line. 22. Make sure all readings are in the required ranges be- l. Reinstall the EC7895 or RM7895 on the subbase fore proceeding. and close the master switch, then return to step 4. 7. When pilot ignites, measure the flame signal. If the pilot NOTE: Upon completing these tests, open the master flame signal is unsteady or approaching the 1.25 Vdc switch and remove all test jumpers from the subbase minimum value, adjust the pilot flame size or detector terminals, limits/controls or switches. sighting to provide a maximum and steady flame signal. 8. Recycle the system to recheck lightoff and pilot flame signal. 65-0205 22 7800 SERIES EC7895A, RM7895A RELAY MODULE Initial Lightoff Check for Direct Spark Ignition d. Make burner adjustments for flame stability and input rating. This check applies for gas and oil burners that do not use a e. Shut down the system by lowering the set point of pilot. It should immediately follow the preliminary in-spection. the operating controller. Make sure the burner Refer to the appropriate sample block diagram of field wiring flame goes out and all automatic fuel valve(s) for the ignition transformer and fuel valve(s) hookup. close. 19. Restart the system by closing the burner switch and/or NOTE: Low fuel pressure limits, if used, could be open. If raising the set point of the operating controller. Observe so, bypass them with jumpers during this check. that the burner flame is established during PILOT IGN, within the normal lightoff time specified by the 1. Open the master switch. equipment manufacturer. 2. Complete the normal checkout of the fuel supply and 20. Measure the flame signal. Continue to check for the equipment as recommended by the equipment proper signal, see Table 5, through the RUN period. manufacturer. Any pulsating or unsteady readings require further 3. Close all manual main fuel shutoff valve(s). Check that attention. the automatic fuel valve(s) are closed. Make sure fuel is 21. Make sure all readings are in the required ranges be- not entering the combustion chamber. fore proceeding. 4. Close the master switch and start the system with a call for heat by raising the set point of the operating NOTE: Upon completing these tests, open the master controller, see Fig. 15. The primary sequence should switch and remove all test jumpers from the subbase start the ten-second INITIATE sequence. terminals, limits/control or switches. 5. Let the sequence advance through PREPURGE. Ignition spark should occur after the PREPURGE 22. Return the system to normal operation. period. Listen for the click of the first stage fuel solenoid valve(s). 6. Let the program sequence complete its cycle. Pilot Turndown Test 7. Open the manual fuel shutoff valve(s). (All Installations using a Pilot) 8. Reset the Lockout Switch and recycle the primary sequence through PREPURGE. Perform this check on all installations that use a pilot. The 9. Watch for the FLAME LED to help determine when the purpose of this test is to verify that the main burner can be lit first stage burner flame is established. If it is by the smallest pilot flame that will hold in the flame amplifier established, proceed to step 15. and energize the FLAME LED. Clean the flame detector(s) to 10. If the first stage burner flame is not established within make sure that it detects the smallest acceptable pilot flame. four seconds, or within the normal lightoff time specified If using AMPLI-CHECK¨ or Self-Checking Amplifier and 20K by the equipment manufacturer, close the manual fuel ohm/voltmeter, the flame signal will fluctuate every time the shutoff valve(s), and open the master switch. amplifier does a self-check or a shutter check. 11. Check all burner adjustments. 12. Wait about three minutes. Close the master switch, NOTE: Low fuel pressure limits, if used, could be open. If open the manual fuel shutoff valve(s), and try again to so, bypass them with jumpers during this test. lightoff the burner. The first attempt may have been required to purge the lines and bring sufficient fuel to 1. Open the master switch. the burner. 2. Close the manual main fuel shutoff valve(s). 13. If the first stage burner flame is not established with-in 3. Connect a manometer (or pressure gauge) to measure four seconds, or within the normal lightoff time specified pilot gas pressure during the turndown test. by the equipment manufacturer, close the manual fuel 4. Open the manual pilot shutoff valve(s). shutoff valve(s) and open the master switch. 5. Close the master switch and start the system with a call 14. If necessary, repeat steps 8 through 13 to establish the for heat. Raise the set point of the operating controller. first stage burner flame. Then proceed to step 15. The primary sequence should start and PREPURGE 15. When the first stage burner flame is established, the should begin. sequence will advance to RUN. Make burner 6. INTERMITTENT PILOT MODELS—After the sequence adjustments for flame stability and input rating. If a has entered the normal burner run period, turn down second stage is used, proceed to step 18. pilot gas pressure very slowly, reading the manometer 16. Shut down the system by opening the burner switch or (or gauge) as the pressure drops. Stop immediately by lowering the set point of the operating controller. when the FLAME LED goes out. Note the pressure at Make sure the burner flame goes out and make sure all this point. automatic fuel valve(s) close. a. If the Flame Failure Action jumper is not clipped, 17. If used, remove the bypass jumpers from the low fuel allow the EC7895 or RM7895A to recycle through pressure limit and subbase. PREPURGE. If the Flame Failure Action jumper 18. If a second stage is used, make sure the automatic is clipped, push the reset pushbutton and allow second stage fuel valve(s) has opened and check the the EC7895 or RM7895A to recycle through light-off as follows. Otherwise proceed to step 19: PREPURGE. a. Open the manual second stage fuel valve(s). b. As the control attempts to relight the pilot, turn b. Restart the system by raising the set point of the the pilot gas pressure back up slowly until the operating controller. FLAME LED comes on. This step must be c. When the first stage burner flame is established, completed within 4 or 10 seconds, depending on watch for the automatic second stage fuel the selected PFEP, or lockout will occur. valve(s) to open. Observe that the second stage lights off properly. 23 65-0205 7800 SERIES EC7895A, RM7895A RELAY MODULE c. Turn the pilot back down slightly but not enough Start the burner and monitor the flame signal during the to cause the FLAME LED to go out. (Keep the warmup period. A decrease in signal strength as the pilot gas pressure just above the reading noted in refractory heats up indicates hot refractory saturation. If step 6 above.) saturation is extreme, the flame signal will drop below 1.25 Vdc and the system will shut down as though a flame failure NOTE: Step d requires two people, one to open the manual has occurred. main fuel valve(s) and one to watch for ignition. If hot refractory saturation occurs, the condition must be d. With the sequence in the normal burner run corrected. Add an orifice plate in front of the cell to restrict the mode, make sure the automatic main fuel viewing area, try to lengthen the sight pipe or decrease the valve(s) is open. Smoothly open the manual main pipe size (diameter). Continue adjustments until hot refractory fuel shutoff valve(s) and watch for main burner saturation is eliminated. lightoff. e. If the main flame is not established within five Hot Refractory Hold-In Test (Rectifying seconds or the normal lightoff period specified by the burner manufacturer, close the manual main Photocell or All Infrared Detectors) fuel shutoff valve(s) and open the master switch. Test to be sure hot refractory is not delaying the flame Return to step 6. If the burner flame is detection system response to a flameout. This condition can established in the normal lightoff period, proceed delay response to flame failure and also can prevent a to step 16. 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 To check rectifying photocells for hot refractory hold-in, gauge) and turn the pilot gas flow up to that operate the burner until the refractory reaches its maximum recommended by the equipment manufacturer. temperature. Then terminate the firing cycle by lowering the 8. If used, remove the bypass jumpers from the subbase set point of the operating controller or setting the Fuel terminals, limits/controls or switches. Selector Switch to OFF. Do not open the master switch. 9. Run the system through another cycle to check for Visually observe when the burner flame or FLAME LED goes normal operation. out. If this takes longer than .8 or 3 seconds (depending on 10. Return the system to normal operation. the FFRT of the amplifier), the photocell is sensing hot refractory. This condition must be corrected as described in Ignition Interference Test (All Flame Rods) the last paragraph of this test. 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 Ignition interference can subtract from (decrease) or add to stopped glowing. Infrared radiation from a hot refractory is (increase) the flame signal. If it decreases the flame signal steady, but radiation from a flame has a flickering characteristic. enough, it causes a safety shutdown. If it increases the flame The infrared detection system responds only to flickering signal, it could cause the FLAME LED to come on when the infrared radiation; it can reject a steady signal from hot true flame signal is below the minimum accep-table value. refractory. The refractory steady signal can be made to fluctuate if it is reflected, bent or blocked by smoke or fuel mist Start the burner and measure the flame signal with both within the combustion chamber. Be careful when applying an ignition and pilot (or main burner) on, and then with only the infrared system to verify its response to flame only. 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 To Eliminate Ignition Interference burner, burn the heaviest fuel that is most likely to reflect, 1. Be sure there is enough ground area. bend or obscure the hot refractory steady infrared radiation. 2. Be sure the ignition electrode and the flame rod are on When the maximum refractory temperature is reached, close opposite sides of the ground area. all manual fuel shutoff valve(s) or open the electrical circuits 3. Check for correct spacing on the ignition electrode: of all automatic fuel valve(s). Visually observe when the a. 6,000V systems - 1/16 to 3/32 in. (1.6 to 2.4 mm). burner flame or FLAME LED goes out. If this takes more than b. 10,000V systems - 1/8 in. (3.2 mm). three seconds, the infrared detector is sensing hot refractory. 4. Make sure the leadwires from the flame rod and ignition Immediately terminate the firing cycle. Lower the set point to electrode are not too close together. the operating controller, or set the Fuel Selector Switch to 5. Replace any deteriorated leadwires. OFF. Do not open the master switch. 6. If the problem cannot be eliminated, the system may have to be changed to an ultraviolet or infrared flame NOTE: Some burners continue to purge oil lines between detection system. the valve(s) and nozzle(s) even though the fuel valve(s) is closed. Terminating the firing cycle Hot Refractory Saturation Test (instead of opening the master switch) allows purging of the combustion chamber. This reduces (All Infrared Detectors) fuel vapor buildup in the combustion chamber Test to be sure that radiation from hot refractory does not caused by oil line purging. mask the flickering radiation of the flame itself. 65-0205 24 7800 SERIES EC7895A, RM7895A RELAY MODULE If the detector is sensing hot refractory, the condition must be If the flame signal is too low or unsteady, check the flame corrected. Add an orifice plate in front of the cell to restrict the detector temperature. Relocate the detector if the viewing area of the detector. If this does not correct the temperature is too high. If necessary, realign the sighting to problem, resight the detector at a cooler, more distant part of obtain the proper signal and response time. If the response the combustion chamber. While resighting the detector, be time is still too slow, replace the Plug-in Flame Signal aware that it must also properly sight the flame. When using Amplifier. If the detector is relocated or resighted, or the infrared detector, try lengthening the sight pipe or decreasing amplifier is replaced, repeat all required Checkout tests. the pipe size (diameter). For details, refer to the detector Instructions and the equipment Operating Manual. Continue Safety Shutdown Tests (All Installations) adjustments until hot refractory hold-in is eliminated. Perform these tests at the end of Checkout after all other tests are complete. If used, the external alarm should turn on. Ultraviolet Sensor, Ignition Spark Response Press the RM7895 reset pushbutton to restart the system. 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 a. Safety shutdown occurs if the Airflow ILK Switch FLAME LED: Failure configuration jumper (JR3) is clipped. 1. Close the pilot and main burner manual fuel shutoff 2. Detect flame 40 seconds after entry to STANDBY. Detect valve(s). flame 30 seconds during measured PREPURGE time. 2. Start the burner and run through the PILOT IGN period. a. Simulate a flame to cause the flame signal voltage Ignition spark should occur, but the flame signal should level to be at least 1.25 Vdc for 40 seconds after not be more than 0.5 Vdc and the FLAME LED should entry to STANDBY and also simulate a flame not turn on. signal for 30 seconds during PREPURGE. 3. If the flame signal is higher than 0.5 Vdc and the b. Safety shutdown occurs. FLAME LED does come on, consult the equipment 3. Failure to ignite pilot. Operating Manual and resight the detector further out a. Close the pilot and main fuel manual shutoff from the spark, or away from possible reflection. It may valve(s). be necessary to construct a barrier to block the ignition b. Depress the reset push button. spark from the detector view. Continue adjustments c. Start the system. until the flame signal due to ignition spark is less than d. Automatic pilot valve(s) should be energized but 0.5 Vdc. the pilot cannot ignite. e. Safety shutdown occurs. NOTE: The Honeywell Q624A Solid State Spark Generator 4. Failure to ignite main. prevents detection of ignition spark when properly a. Open the manual pilot valve(s); leave the main applied with the C7027, C7035 or C7044 Minipeeper fuel manual shutoff valve(s) closed. Ultraviolet Flame Detectors. The Q624A is only for b. Depress the reset pushbutton. use with gas pilots. c. Start the system. d. Pilot should ignite and the flame signal should be Response To Other Ultraviolet Sources at least 1.25 Vdc but the main burner cannot light. Under certain conditions, an ultraviolet detector responds to e. Close the manual pilot valve(s). other ultraviolet sources as if it is sensing a flame. These f. Flame signal should drop below 1.25 Vdc within ultraviolet sources include artificial light, such as .8 or 3 seconds (depending on the FFRT of the incandescent or fluorescent bulbs, mercury and sodium vapor amplifier) after the pilot goes out. lamps or daylight. To check for proper detector operation, g. Safety shutdown occurs. check the Flame Failure Response Time (FFRT) and conduct 5. Loss of flame during RUN. Safety Shutdown tests under all operating conditions. 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. Flame Signal With Hot Combustion Chamber c. Start the system. Startup should be normal and (All Installations) the main burner should light normally. After all initial start-up tests and burner adjustments are d. After the sequence is in the normal RUN period completed, operate the burner until the combustion chamber for at least ten seconds with the main burner is at the maximum expected temperature. Observe the firing, close the manual main and pilot fuel shutoff equipment manufacturer warmup instructions. Recycle the valve(s) to extinguish the main burner flame. burner under these hot conditions and measure the flame e. The flame signal should drop below 1.25 Vdc signal. Check the pilot alone, the main burner flame alone, within .8 or 3 seconds (depending on the FFRT of and both together (unless monitoring only the pilot flame the amplifier) after the main flame goes out. when using an intermittent pilot, or only the main burner flame f. Safety shutdown occurs. when using DSI). IMPORTANT Check the FFRT of the Flame Amplifier. Lower the set point of 1. If the EC7895 or RM7895 fails to shut down on the operating controller and observe the time it takes for the any of these tests, take corrective action (refer to burner flame to go out. This should be within .8 or 3 seconds Troubleshooting, EC7895 or RM7895 diagnostics maximum depending on the amplifier selected. and return to the beginning of all Checkout tests). 2. When all Checkout tests are complete, reset all switches to original states. 25 65-0205 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 EC7895 or RM7895 System Diagnostics most recent lockouts. Each of the six lockout files retains the Troubleshooting control system equipment failures is easier cycle when the fault occurred, the hour of operation when the with the 7895 self-diagnostics and first-out annunciation. In fault occurred, and the fault message and burner status when addition to an isolated spst alarm relay (audible annunciation), the fault occurred. The Historical Information can be viewed the 7895 provides visual annunciation by displaying the by the optional S7800A Keyboard Display Module ALARM LED. Specifications. Self-diagnostics of the 7895 enable it to detect and annunciate SERVICE NOTE: A Lockout condition or restart of a EC7895 both external and internal system problems. Ex-ternal faults or RM7895 can be accomplished by such as interlock failures, flame failures and false flame signals pressing the reset push-button on the are annunciated by the 7895, which energizes the ALARM LED EC7895 or RM7895, or by pressing a or by using the optional Keyboard Display Module. The 7800 remote reset pushbutton wired through an SERIES provides a System Annunciation Diagnostics and optional Keyboard Display Module, DATA Troubleshooting manual, form 65-0118. CONTROLBUS MODULEª, Extension Cable Assembly or Remote Reset Module. The 7895 provides diagnostic information to aid the service A power-up reset causes an electrical reset mechanic to obtain information when troubleshooting the of the EC7895 or RM7895 but does not system, see Table 6. reset a lockout condition. The optional Keyboard Display Module displays sequence SERVICE NOTE: Remove the access slot covers on the status messages indicating: STANDBY, PRE-PURGE, PILOT sides of the Q7800A,B to check voltages. 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 CAUTION Hours, Fault History, and Diagnostic Information. With this Reinstall access slot covers on the Q7800A,B information most problems can be diagnosed without Subbase after performing voltage checks. extensive trial and error testing. Information available in the Diagnostic Information file includes: Device Type, Device SERVICE NOTE: Maximum ambient operating temperature Suffix, Software Revision, Manufacturing Code, Flame of a C7012E,F Series 1 through 6 is Amplifier Type, Flame Failure Response Time, Selectable reduced to 125° F because of the duty Jumper Configuration Status, and Terminal Status. 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 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) 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. INITIATE HOLD: (Low Line Voltage) 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. STANDBY 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. 27 65-0205 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 Home and Building Control Honeywell Asia Pacific Inc. Honeywell Inc. Honeywell Limited-Honeywell Limitée Room 3213-3225 Honeywell Plaza 155 Gordon Baker Road Sun Hung Kai Centre P.O. Box 524 North York, Ontario No. 30 Harbour Road Minneapolis MN 55408-0524 M2H 2C9 Wanchai Hong Kong Honeywell Latin American Division Honeywell Europe S.A. Miami Lakes Headquarters 3 Avenue du Bourget 14505 Commerce Way Suite 500 B-1140 Brussels Belgium Miami Lakes FL 33016 Helping You Control Your World¨ 65-020565-0205 G.R. 1-97 Printed in U.S.A. 28 www.honeywell.com/bbc

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