FULTON RM7895A Manual

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RM7895A

Relay Module

APPLICATION

The RM7895A Relay Module is a microprocessor based

integrated burner control for automatically fired gas, oil or

combination fuel single burner applications. The

RM7895A consists of the Relay Module. Subbase,

Amplifier and Purge Card are required to complete the

system. Options include Keyboard Display Module (KDM),

Personal Computer Interface, Data ControlBus™* Module,

Remote Display Module, First-Out Expanded Annunciator

and Combustion System Manager™* Software.

The RM7895A is programmed to provide a level of safety,

functional capability and features beyond the capacity of

conventional controls.

Functions provided by the RM7895A include automatic

burner sequencing, flame supervision, system status

indication, system or self-diagnostics and

troubleshooting.

FEATURES

• Safety Features

—

Closed loop logic test.

—

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.

• Dependable, long-term operation provided by

microcomputer technology.

• First-out annunciation and system diagnostics

provided by an optional Keyboard Display Module.

• First-out expanded annunciation with 26 Light

Emitting Diodes (LEDs) for limit and interlocks

(optional).

• Five LEDs for sequence information.

• Interchangeable plug-in flame amplifiers.

• Local or remote annunciation of RM7895 operation

and fault information.

• Nonvolatile memory; RM7895 retains 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.

Contents

Application ............................................................................................

Features ..................................................................................................

Specifications ......................................................................................

Principal Technical Features ........................................................

Safety Provisions ................................................................................

Wiring .......................................................................................................

Assembly ................................................................................................ 10

Operation ............................................................................................... 12

Checkout ................................................................................................ 16

Troubleshooting ................................................................................. 21

SIL

Capable

PRODUCT DATA

32-00122-01

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Summary of Contents for FULTON RM7895A

Page 1 Combustion System Manager™* Software. • Selectable recycle or lockout on loss of airflow. The RM7895A is programmed to provide a level of safety, • Selectable recycle or lockout on loss of flame. functional capability and features beyond the capacity of conventional controls.
Page 2 Total hours of operation. Model: — Fault history providing for the six most recent RM7895A Relay Module. Provides primary control. faults: Provides automatic burner sequencing, flame • Cycles of operation at the time of the fault. supervision, system status indication, system or self- •...
Page 3 RM7895A RELAY MODULE IMPORTANT: Flame Detection System available for use with RM7895. To select your Plug-In Flame Signal Amplifier and applicable Flame Detector, see Table 2 and Fig. 3 and 4. Table 2. Flame Detection Systems (Fig. 3 and 4).
Page 4 FLAME MAIN ALARM RESET 5-1/4 (133) 5 (127)] REMOVE ONLY FOR TERMINAL TEST ACCESS. M3529 Fig. 1. Mounting dimensions of RM7895A Relay Module and Q7800A Wiring Subbase in in. (mm). IGNITION ELECTRODE FLAME ROD MOUNTING FLANGE (Q179C ONLY) CERAMIC 3/4-14 NPT...
Page 5 RM7895A RELAY MODULE 4 (102) 8 FOOT (2.44 METER) 4-1/8 (105) LEADWIRES (2) 3-1/2 (89) COLLAR WITH 2 (51) 1/2-14 NPSM 1 - 1-1/2 NPSM INTERNAL THREADS 1-3/16 INTERNAL (30) THREADS 1-1/16 (27) 31/32 1-1/2 (25) (38) COLLAR WITH 1/2-14 NPSM...
Page 6 RM7895A RELAY MODULE Closed Loop Logic Test shutdown occurs. A standard amplifier is energized continually through STANDBY and PREPURGE; if a flame The test verifies the integrity of all safety critical loads, exists, a safety shutdown occurs. terminals 8, 9, 10 and 21. If the loads are not energized properly;...
Page 7 RM7895A RELAY MODULE INSTALLATION IMPORTANT WARNING 1. For on-off gas-fired systems, some authorities who have jurisdiction prohibit the wiring of any Fire or Explosion Hazard. limit or operating contacts in series between the Can cause severe injury, death or property flame safeguard control and the main fuel valve(s).
Page 8 RM7895A RELAY MODULE 3. For surface mounting, use the back of the subbase 4. Securely mount the subbase using four no. 6 screws. as a template to mark the four screw locations. Drill the pilot holes. (HOT) PROVIDE DISCONNECT MEANS AND RM7895, RM7896: 120 VAC, 50/60 HZ.
Page 9 RM7895A RELAY MODULE a. Do not run high voltage ignition transformer c. Remote Reset leadwires—The maximum length wires in the same conduit with the flame of wire is 1000 feet to a Remote Reset push but- detector, Data ControlBus™ Module, or Remote ton.
Page 10 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M3536B DO NOT WIRE TO ANY UNUSED TERMINALS. Fig. 5. Wiring the RM7895A Relay Module. ASSEMBLY Relay Module Mounting 1. Mount the RM7895 vertically (see Fig. 7) or mount...
Page 11 RM7895A RELAY MODULE a. Allow an additional two inches below the Installing the Flame Detector RM7895 for the flame amplifier mounting. b. Allow an optional three-inch minimum to both NOTE: Table 2 and Fig. 10 list the flame detection sides of the RM7895 for electrical signal voltage systems available for use with theRM7895.
Page 12 RM7895A RELAY MODULE Fig. 9. Flame Signal amplifier mounting. Fig. 8. Dust Cover mounting. ULTRAVIOLET (C7027/C7035/C7044) SOLID STATE ULTRAVIOLET (C7012A,C) BLUE WHITE FLAME ROD BLUE YELLOW BLACK BLACK 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.
Page 13 The pilot valve and ignition transformer, present. The burner switch, limits, operating limit control terminals 8 and 10, are energized. The RM7895A and all microcomputer monitored circuits must be in the has an intermittent pilot valve, terminal 8.
Page 14 RM7895A RELAY MODULE Table 6. Selectable site-configurable jumper status. Configuration Clipped and Jumper Intact Removed CAPTIVE MOUNTING 10 sec. limit. 4 sec. SCREW Recycle Lockout PLUG-IN Recycle Lockout PURGE CARD Static Checkout DUST COVER WARNING RELAY Electric Shock Hazard. MODULE Can cause severe injury, death or property damage.
Page 15 RM7895A RELAY MODULE 7. If there is no voltage or the operation is abnormal, 9. Replace faulty controllers, limits, interlocks, actua- check the circuits and external devices as described tors, valves, transformers, motors and other devices in the last column.
Page 16 RM7895A RELAY MODULE CHECKOUT • 0-10 Vdc capability. Checkout Summary WARNING • Preliminary inspection—all installations. Fire or Explosion Hazard. • Flame signal measurement—all installations. Can cause serious injury, death or property damage. • Initial lightoff check for proved pilot—all installations...
Page 17 RM7895A RELAY MODULE Table 8. Flame Signal. Minimum Maximum Acceptable Flame Signal Flame Detector Amplifier Steady dc Voltage Expected dc Voltage Flame Rod R7847A 1.25 Vdc 5.0 Vdc at the Keyboard C7012A,C Display Module C7027A R7849A 5.0 Vdc at a 1 Megohm/volt C7035A meter.
Page 18 RM7895A RELAY MODULE 3. Close the master switch and start the system with a 12. Smoothly open the manual fuel shutoff valve(s) and call for heat by raising the set point of the operating try lightoff again. (The first reattempt may have been controller, see Fig.
Page 19 If the Flame Failure Action jumper is not clipped: a. Open the manual second stage fuel valve(s). allow the RM7895A to recycle through PRE- b. Restart the system by raising the set point of the PURGE. If the Flame Failure Action jumper is operating controller.
Page 20 RM7895A RELAY MODULE d. With the sequence in the normal burner run the ignition spark from the detector view. Continue mode, make sure that the automatic main fuel adjustments until the flame signal due to ignition valve(s) is open. Smoothly open the manual main spark is less than 0.5 Vdc.
Page 21 RM7895A RELAY MODULE a. Simulate a flame to cause the flame signal volt- Keyboard Display Module. The 7800 SERIES provides a age level to be at least 1.25 Vdc for 40 seconds System Annunciation Diagnostics and Troubleshooting after entry to STANDBY and also simulate a manual, form 65-0233.
Page 22 RM7895A RELAY MODULE Table 9. Sequence and Status Hold Information. 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.
Page 23 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 (RM7895A). RESET/ALARM TEST The LED indicates the burner status, POWER and ALARM. This condition indicates that the reset push button is pressed.
Page 24 RM7895A RELAY MODULE ® U.S. Registered Trademark © 2018 Honeywell International Inc. 32-00122-01 M.S. Rev. 08-18 Printed in United States...