Yamatake-Honeywell 7800 Series User manual

PRODUCT DATA
® U.S. Registered Trademark
Copyright © 1996 Honeywell Inc. • All Rights Reserved
•First-out annunciation and system diagnostics are
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 7890 operation and fault
information (optional).
•Nonvolatile memory; 7890 retains history files and
sequencing status after loss of power.
•Remote reset (optional).
•Report generation (optional).
•Selectable relight or lockout on loss of flame.
•Shutter drive output (EC7890B, RM7890B).
•Burner controller data (optional):
— Expanded annunciator status.
— Flame signal strength.
— Hold status.
— Lockout/alarm status.
— Sequence status.
— Sequence time.
— Total cycles of operation.
— Total hours of operation.
— Fault history providing the six most recent faults:
– Cycles of operation at the time of the fault.
– Fault message and code.
– Hours of operation at the time of the fault.
– Sequence status at the time of the fault.
– Sequence time at the time of the fault.
— Diagnostic information:
– Device type.
– Flame amplifier type.
– Flame failure response time.
– Manufacturing code.
– On/Off status of all digital inputs and outputs.
– Software revision and version of 7890 and optional
Keyboard Display Module.
– Status of configuration jumpers.
GENERAL
The Yamatake-Honeywell EC7890A,B/RM7890A,B is a micro-
processor based integrated burner control for automatically fired
gas, oil or combination fuel single-burner applications. Except where
necessary, the relay module will be called the 7890A,B throughout
this publication. The 7890A,B consists of the Relay Module.
Subbase and Amplifier are required to complete the system. Options
include Keyboard Display Module, Personal Computer Interface,
DATACONTROLBUS MODULE™, Remote Display Module and
COMBUSTION SYSTEM MANAGER® Software.
The 7890A,B is programmed to provide a level of safety,
functional capability and features beyond the capacity of
conventional controls.
Functions provided by the 7890A,B include automatic burner
sequencing, flame supervision, system status indication, system
or self-diagnostics and troubleshooting.
FEATURES
•Safety features:
—Closed loop logic test.
—Dynamic Ampli-Check®.
—Dynamic input check.
—Dynamic safety relay test.
—Dynamic self-check logic.
—Expanded safe-start check.
—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.
7800 SERIES EC7890A,B/
RM7890A,B Relay Module
Contents
General .................................................................................... 1
Features ................................................................................... 1
Specifications ........................................................................... 2
Ordering Information ................................................................ 2
Principle Technical Features .................................................... 8
Safety Provisions ..................................................................... 8
Installation ................................................................................ 9
Wiring ....................................................................................... 11
Assembly ................................................................................. 14
Operation ................................................................................. 17
Static Checkout ........................................................................ 18
Checkout .................................................................................. 20
Troubleshooting ....................................................................... 26
65-0204-1

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 2
SPECIFICATIONS
RM7890 Electrical Ratings, SeeTable 1A:
Voltage and Frequency: 100 Vac (+10/-15%), 50 or 60 Hz
(+/- 10%). 2
Power Dissipation: RM7890: 10W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing: Total Connected Load: 20Amaximum, type FRN
or equivalent.
Table 1A. RM7890Terminal Ratings.
ORDERING INFORMATION
When purchasing replacement and modernization products from your 7800 SERIES distributor, refer to the TRADELINE®
Catalog 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 Logistics
Honeywell Inc., 1985 Douglas Drive North
Minneapolis, Minnesota 55422-4386 [phone]
In Canada—Honeywell Limited/Honeywell Limitée, 155 Gordon Baker Road, North York, Ontario M2H 2C9 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.
EC7890 Electrical Ratings, SeeTable 1B:
Voltage and Frequency: 200 Vac (+10/-15%), 50 or 60 Hz
(+/- 10%). 2
Power Dissipation: EC7890: 10W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing: Total Connected Load: 20Amaximum, type FRN
or equivalent.
1The RM7890 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 RM7890 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 having 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.
2Range of allowable operating frequencies is 45 to 66 Hz.
32000 VA maximum connected load to 7890 Assembly.
4Can also be 100 Vac, 1A pilot duty.
5Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.
Terminal No. Description Ratings
G Flame Sensor Ground
Earth G Earth Ground1
L2(N) Line Voltage Common
3 Line Voltage Supply (L1) 100 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).2,3
4 Alarm 100 Vac, 1A pilot duty.
5 Unused
6 Burner Controller and Limits 100 Vac, 3A pilot duty or 1A pilot duty, 4.5A ignition.
7 Unused
8 Pilot Valve/Ignition 100 Vac, 4.5A Ignition and 50 VA 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 (RM7890B).

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
3
Table 1B. EC7890 Terminal Ratings.
1The EC7890 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 EC7890 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 having 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.
2Range of allowable operating frequencies is 45 to 66 Hz.
32000 VA maximum connected load to 7890 Assembly.
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to 140°F.
Storage: -60°F to 150°F.
Humidity: 85% RH continuous, noncondensing.
Vibration: 0.5G environment.
Dimensions:
Refer to Fig. 1 and 2.
Weight:
7890 with dust cover: 1 pound 13 ounces, unpacked.
IMPORTANT
Flame Detection System available for use with the
7890.To select your Plug-in Flame Signal Amplifier
and applicable Flame Detector, see Table 2 and
Fig. 3-5.
Terminal No. Description Ratings
G Flame Sensor Ground
Earth G Earth Ground1
L2(N) Line Voltage Common
3 Line Voltage Supply (L1) 200 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).2,3
4 Alarm 200 Vac, 1A pilot duty.
5 Unused
6 Burner Controller and Limits 200 Vac.
7 Unused
8 Pilot Valve/Ignition 200 Vac, 4A at PF = 0.5, 20A inrush.
9 Main Fuel Valve 200 Vac, 4A at PF = 0.5, 20A inrush.
10 Ignition 200 Vac, 4A at PF = 0.5, 20A inrush.
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 (EC7890B).

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 4
Table 2. Flame Detection Systems.
aA 0.8 sec Flame Failure Response Time Amplifier is required when the Relight option is (JR2 is intact, see Table 3). The RM7890
will lock out and indicates a Fault 46 when a 3.0 second FFRTis used and jumper JR2 (Lockout) is not clipped and removed.
bOrder flame rod separately; see holder Instructions.
cThe 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 R7886AAmplifier or the C7061
Flame Detector with the R7861 Amplifier as the ultraviolet flame detection system.
dUse with EC7890B or RM7890B only.
eCircuitry tests the flame signal amplifier at least 12 times a minute during burner operation and shuts down the burner if the
amplifier fails.
fUse
only Honeywell Photocell, part no. 38316.
gCircuitry 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.
hWhen an R7861A is used with an EC7890B, the application requires the use of a step-down transformer. See Fig. 14.
Plug-in Flame Signal Amplifiers Applicable Flame Detectors
Type Color Self-Checking Model
Flame
Failure
Response
Time
a
Fuel Type Models
Rectification Green No R7847A .8 or 3 sec Gas Rectifying Flame
Rod Holders
b
C7004, C7007, C7011.
Complete Assemblies:
C7008, C7009, Q179.
No R7847A .8 or 3 sec Oil Rectifying
Photocell C7003, C7010, C7013, C7014.
No R7847A 3 sec Gas, oil,
coal Ultraviolet (PurplePeeper) C7012A,C.
c,d
Dynamic
Ampli-Check® R7847B
e
.8 or 3 sec Gas Rectifying Flame
Rod Holders
b
C7004, C7007, C7011.
Complete Assemblies:
C7008, C7009, Q179.
Dynamic
Ampli-Check® R7847B
e
.8 or 3 sec Oil Rectifying
Photocell
f
C7003, C7010, C7013,
C7014.
Dynamic
Ampli-Check® R7847B
e
3 sec Gas, oil,
coal Ultraviolet (Purple Peeper) C7012A,C.
c
Dynamic
Self-Check
d
R7847C
g
3 sec Gas, oil,
coal Ultraviolet (Purple Peeper) C7012E,F.
Infrared Red No R7848A 3 sec Gas, oil,
coal Infrared (Lead Sulfide) C7015.
Dynamic
Ampli-Check® R7848B
e
3 sec Gas, oil
coal Infrared (Lead Sulfide) C7015.
Ultraviolet Purple No R7849A .8 or 3 sec Gas, oil Ultraviolet
(Minipeeper) C7027, C7035, C7044.
c
Dynamic
Ampli-Check® R7849B
e
.8 or 3 sec Gas, oil Ultraviolet
(Minipeeper) C7027, C7035, C7044.
c
Dynamic
Self-Check
d,h
R7861A 3 sec Gas, oil,
coal Ultraviolet C7061.
Blue Dynamic
Self-Check
d
R7886A
g
3 sec Gas, oil,
coal Ultraviolet (Adjustable
Sensitivity)
C7076.

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
5
Device Initiate Standby PilotFlame Establishing Period Run
7890A 10 sec * 4 or 10 sec *
* STANDBY and RUN can be an infinite time period.
SequenceTiming for Normal Operation:
Approvals:
RM7890:
Underwriters Laboratories Inc. Listed, File No. MP268,
Guide No. MCCZ.
Factory Mutual Approved: 0X4AS.AF.
EC7890:
Factory Mutual Approved: OX4AS.AF.
Mounting:
Q7800A for panel mount or Q7800B for wall or burner mount.
Required Components:
Plug-in Flame Signal Amplifier, see Table 2.
Q7800A or Q7800B.
Accessories:
Optional:
COMBUSTION SYSTEM MANAGER™, part no.
ZM7850A1001.
Network Interface Unit, part no. Q7700B1004.
Communication Interface ControlBus Module, part no.
QS7800A1001.
ControlBus 5-Wire Electrical Connector, part no. 203541.
DATA CONTROLBUS MODULE™, part no. S7810A1009.
Dust Cover, part no. 221729A.
Flame Simulators:
Flame Simulator, part no. 203659 UV.
Rectification Simulator, part no. 123514A .
Keyboard Display Module, part no. S7800A.
Remote Display Mounting Bracket, part no. 203765.
Remote Display Power Supply, part no. 203968A Plug-in.
Remote Reset Module, part no. S7820A1007.
Sixty-inch Extension CableAssembly, part no. 221818A.
Fig. 1. Mounting dimensions of 7890 Relay Module and Q7800A.Subbase in in. (mm).
POWER
PILOT
FLAME
MAIN
ALARM
RESET
5
(127)
5 (127)
M11135
(133)
BURNER 
CONTROL
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
5-1/4

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 6
Fig. 2. Mounting dimensions of 7890 Relay Module and Q7800B Subbase in in.(mm).
Fig. 3. Rectification detectors.
Q179
POWER
PILOT
FLAME
MAIN
ALARM
RESET
5
(127)
5 (127)
M11134
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
6-3/32 (155)
BURNER 
CONTROL
THREADED
MOUNTING 
HOLES (2)–
10-32 UNF
1 (25)
FLAME ROD
TARGET
CERAMIC
INSULATORS
IGNITION
ELECTRODE
(Q179C ONLY)
BRACKET M1983
3-1/8
(79)
1-21/32
(42) 1-13/32
(36)
3/8 (10)
1/2 (13)
1-1/16
(27)
25/32
(20) 25/32 (20)
2-25/32
(62)
3/32 (2) 11/16
(18)
17/32
(14)
MOUNTING FLANGE
1/2–14 NPSM
LEADWIRES FACEPLATE
3/4–14 NPT
M1962A
3-3/4
(95)
7-7/32
(183)
5-1/8 (130)
3-7/16
(87)
5-1/4 (133)
2
(51)
C7013A C7014A M1847
13/16 (21) 1-1/4 (32) 1-3/8 (35)
1-3/4
(45)
1-1/4 (32) 1-5/16 (33) 5/16
(8)
C7012A,C,E,F

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
7
Fig. 4. Ultraviolet detectors.
C7027
COLLAR WITH 1/2-14 NPSM 
INTERNAL THREADS
4 (102) 6 FOOT (1.83 METER)
LEADWIRES (2)
M1943A
MODEL AVAILABLE WITH 24 FOOT (7.32 METER) LEADWIRES.
MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL
THREADS) INSTEAD OF CLAMP TYPE CONNECTOR.
1
2
1
2
3-1/2 (89)
1-1/16
(27)
1/2-14 NPSM
INTERNAL THREADS
2
2 (51)
COLLAR WITH
1–11-1/2 NPSM
INTERNAL
THREADS 1
1DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL THREADS.
DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL THREADS.
MODEL AVAILABLE WITH 12 FOOT (3.66 METER) LEADWIRES.

2
3
INSERTION DEPTH
6 FOOT 
[1.83 METER]
LEADWIRES (2) 3
M1945A
2-5/8 (67)
1-1/2
(38)
31/32
(25)
4-1/8 (105)
1-3/16
(30)
MOUNTING BRACKET
6 FOOT [1.83 METER]
LEADWIRES (2)
M1944A
3-5/8 (92)
1/2 
(13)
9/16
(14)
7/8
(22)
3/8
(10)
1-27/64
(36)
C7035
C7044
4
(102)
4 (102)
3/8 INCH NPT
1 INCH NPT
7/8 (22) OPENING
FOR 1/2-INCH CONDUIT
ALLOW 9 INCHES (228 MILLIMETERS) 
CLEARANCE TO SWING OUT THE DETECTOR 
FOR LENS CLEANING OR SERVICING.
1
M5083A
1-1/16 (27)
2-1/4 
(57)
2-1/4 
(57)
4-27/32 (123)
1-13/32 (188)
10-9/32 (261)
2-5/16
(58)
29/32 (23)
3/4 (19)
1-19/32
(41)
2-11/16
(68) 7-5/8 (194)
C7076A

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 8
Fig. 4. Ultraviolet detectors (Continued).
Fig. 5. Infrared detector.
PRINCIPAL TECHNICAL FEATURES
The 7890 provides all customary flame safeguard functions
while providing significant advancements in the areas of
safety, annunciation and system diagnostics.
Safety Shutdown (Lockout) Occurs If:
1INITIATE PERIOD
a. AC line power errors occurred, see Operation.
b. Configuration jumpers have been changed (after
200 hours).
c. Four minute INITIATE period has been exceeded.
2STANDBY PERIOD
a. Flame signal is present after 40 seconds.
b. Ignition/intermittent pilot valve terminal is
energized.
c. Internal system fault occurred.
d. Main valve terminal is energized.
e. Three second Flame Failure Response Time
(FFRT) Amplifier is installed and configuration
jumper is selected for relight (see Table 3).
C7076D
3SAFE START CHECK (EXCEPT 7890C)
a. Ignition/intermittent pilot valve terminal is
energized.
b. Internal system fault occurred.
c. Main valve terminal is energized.
4PILOT FLAME ESTABLISHING PERIOD (PFEP)
a. Ignition/intermittent pilot valve terminal is not
energized.
b. Internal system fault occurred.
c. Main valve terminal is energized.
d. No flame present at end of PFEP.
5RUN PERIOD
a. Ignition terminal is energized.
b. Internal system fault occurred.
c. Main valve terminal is not energized.
d. No flame present and configuration jumper is
selected for lockout.
e. Pilot valve terminal is not energized.
SAFETY PROVISIONS
Internal Hardware Status Monitoring
The 7890 analyzes the integrity of the configuration jumpers
and internal hardware. The POWER LED will blink every four
seconds, signifying an internal hardware check.
Closed Loop Logic Test
The test verifies the integrity of all safety critical loads,
terminals 8, 9 and 10. If the loads are not energized properly;
ie, the main valve terminal is powered during STANDBY, the
7890 will lockout on safety shutdown. The 7890 must react to
input changes but avoid the occurrence of
nuisance
shutdown events. Signal conditioning is applied to line
voltage inputs to verify proper operation in the presence of
normal electrical line noise such as transient high voltage
spikes or short periods of line dropout. Signal conditioning is
tolerant of synchronous noise (line noise events that occur at
the same time during each line cycle).
15/16 [24] DIA.
2 (51)
1 (25)
1 INCH NPT
15/16–18 UNC
(2 EACH)
M5084A
2-1/2
(64)
6-7/32
(158)
6-19/32
(168)
2-5/32
(55)
11-13/16 (300)
7-13/16 (198) 1-27/32
(47) 5-13/16 (147)
5-13/16
(147)
C7015
APERTURE
BUSHING WITH
MAGNIFYING LENS COLLAR, 3/4-14 NPSM
INTERNAL THREADS
3/4-14
NPSM 3/4-14 NPSM INTERNAL
THREADS
HEAT BLOCKCELL MOUNT
M1982A
2 LEADS IN A
48 INCH (1.2 METER)
FLEXIBLE CONDUIT
2-3/4 
(70)
1-1/4
(32)
1-5/8 (41)
1-1/16 (27)
1-1/4
(32)

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
9
Dynamic Ampli-Check®
Dynamic Ampli-Check® circuitry tests the flame signal
amplifier during burner operation and shuts down the 7890 if
the flame amplifier fails.
Dynamic Flame Amplifier and Shutter Check
Self-checking circuitry tests all electronic components in the
flame detection system and amplifier 12 times per minute and
shuts down the 7890 if the detection system fails.
Dynamic Input Check
All system input circuits are examined to assure that the 7890
is capable of recognizing the true status of external controls,
limits and interlocks. If any input fails this test, a safety
shutdown occurs and the fault will be annunciated.
Dynamic Safety Relay Test
Checks the ability of the dynamic safety relay contact to open
and close. Verifies that the safety critical loads, terminals 8, 9
and 10, can be de-energized, as required, by the Dynamic
Self-Check logic.
Dynamic Self-Check Safety Circuit
The microcomputer tests itself and related hardware, and at
the same time, the safety relay system tests the
microcomputer operation. If a microcomputer or safety relay
failure occurs and does not allow proper execution of the self-
check routine, safety shutdown occurs and all safety critical
loads will be de-energized.
Expanded Safe-Start Check
The conventional safe-start check, which prevents burner
start-up if flame is indicated at start-up, is expanded to
include a flame signal check during STANDBY and a safety
critical load check.
Off Cycle (Standby) Flame Signal Check
The flame detection subsystem (flame detector and amplifier)
is monitored during STANDBY. If a flame simulating condition
or an actual flame exists for 40 seconds in STANDBY, a
system hold occurs and start-up is prevented. If the flame
signal exists at any time after the 40 seconds during
STANDBY, a safety shutdown occurs and is annunciated.A
shutter-check amplifier and self-checking detector are
energized for the first 40 seconds during STANDBY and the
last two seconds before exiting STANDBY. If a flame exists
after the first 40 seconds of STANDBY, the shutter-check
amplifier and self-checking detector are energized during the
last 10 seconds of the 40 second flame detection period. If a
flame exists, a safety shutdown occurs. An Ampli-Check®
Amplifier is energized continually through STANDBY to detect
any possibility of a runaway detector or a flame. If a flame
exists, a safety shutdown occurs. A standard amplifier is
energized continually through STANDBY, if a flame exists a
safety shutdown occurs.
Tamper Resistant Timing and Logic
Safety and logic timings are inaccessible and cannot be
altered or defeated.
Verified Spark Termination
The ignition terminal is monitored to assure early spark
termination (ten seconds ignition and pilot and ten seconds
pilot and main only ).
First-Out Annunciation and Self-Diagnostics
Sequence Status Lights (LEDs) provide positive visual
indication of the program sequence: POWER, PILOT,
FLAME, MAIN and ALARM. The green POWER LED blinks
every four seconds, signifying that the 7890 hardware is
running correctly.
Optional multi-function Keyboard Display Module shows
elapsed time during PILOT IGN. As an additional
troubleshooting aid, it provides sequence timing, diagnostic
information, and historical information during normal
operation or when a safety shutdown or hold occurs.
First-out Annunciation reports the cause of a safety shutdown
or identifies the cause of a failure to start or continue the
burner control sequence with text and numbered code via the
optional Keyboard Display Module. It monitors all field input
circuits, including the flame signal amplifier. The system
distinguishes 39 modes of failure and detects and
annunciates difficult-to-find intermittent failures.
Self-Diagnostics add to the First-out Annunciation by allowing
the 7890 to distinguish between field (external device) and
internal (system related) problems. Faults associated within
the flame detection subsystem or 7890 are isolated and
reported by the optional Keyboard Display Module. See the
7800 SERIES System Annunciation Diagnostics and
Troubleshooting, form 65-0118.
INSTALLATION
WARNING
FIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,SEVERE
INJURY, OR DEATH
To prevent possible hazardous burner operation,
perform verification of safety requirements
each time
a control is installed on a burner.
When Installing this Product…
1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and marked
on the product to make sure the product is suitable for
your application.
3. Installer must be a trained, experienced, flame
safeguard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 10
CAUTION
1. Disconnect the power supply before beginning
installation to prevent electrical shock and
equipment damage. More than one power supply
disconnect may be involved.
2. Wiring connections for the 7890 are unique;
therefore, refer to Fig. 7 or 8 for the correct
Specifications for proper subbase wiring.
3. Wiring must comply with all applicable codes,
ordinances and regulations.
4. Wiring, where required, must comply with NEC
Class 1 (Line Voltage) wiring.
5. Loads connected to the 7890 must not exceed
those listed on the 7890 label or the
Specifications, see Table 1.
6. Limits and interlocks must be rated to carry and
break current simultaneously to the ignition
transformer, pilot valve, and main fuel valve(s).
7. All external timers must be listed or component
recognized by authorities who have jurisdiction
for the specific purpose for which they are used.
IMPORTANT
1. For on-off gas-fired systems, some authorities who
have jurisdiction prohibit the wiring of any limit or
operating contacts in series between the flame
safeguard control and the main fuel valve(s).
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
has been tested and found to comply with the
limits for a Class A computing device pursuant to
subpart J 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 is likely to cause
interference; in which case, the users at their
own expense may be required to take whatever
measures are required to correct this
interference. Any unauthorized modification of
this equipment may result in the revocation of
the owners authority to continue its operation.
Humidity
Install the 7890 where the relative humidity never reaches
the saturation point. The 7890 is designed to operate in a
maximum 85% RH continuous, noncondensing moisture
environment. Condensing moisture can cause a safety
shutdown.
Vibration
Do not install the 7890 where it could be subjected to
vibration in excess of 0.5G continuous maximum vibration.
Weather
The 7890 is not designed to be weather tight. If installed
outdoors, the 7890 must be protected by an approved
weather-tight enclosure.
Fig. 6. Internal block diagram of the 7890 (see Fig. 7 for detailed wiring instructions).
CONFIGURATION 
JUMPERS
MICROCOMPUTER
RESET 
PUSH-
BUTTON
STATUS LEDs SAFETY RELAY 
CIRCUIT
POWER SUPPLY
OPTIONAL KEYBOARD 
DISPLAY MODULE
PLUG-IN
FLAME
AMPLIFIER
RELAY
DRIVE 
CIRCUIT
CONTROL
POWER
TEST
JACK
REMOTE
RESET
DDL
DDL
COMMUNICATIONS
INDICATES FEEDBACK SENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLTAGE INPUTS
FIELD WIRING
INTERNAL WIRING
IGNITION
PILOT
MAIN VALVE
1K
RELAY
STATUS 
FEEDBACK
AND LINE
VOLTAGE
INPUTS
LIMITS CONTROLLER 1K1 2K1
FLAME SIGNAL
TEST
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
RM7890: 100 VAC; EC7890: 200 VAC.
RS485
123
L1 
(HOT) L2
3
64K1
2K2
10
8
9
4K
3K
2K
F
G
22
ALARM
3K1 4
L2
1
M11193
1
2
2

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
11
Mounting Wiring Subbase
NOTE: For installation dimensions, see Fig. 1 or 2.
1Mount the subbase in any position except horizontally
with the bifurcated contacts pointing down. The standard
vertical position is recommended. Any other position
decreases the maximum ambient temperature rating.
2Select a location on a wall, burner or electrical panel.
The Q7800 can be mounted directly in the control
cabinet. Be sure to allow adequate clearance for
servicing, installation, access and removal of the 7890,
dust cover, flame amplifier, flame amplifier signal
voltage probes, electrical signal voltage probes and
electrical field connections.
3For surface mounting, use the back of the subbase as
a template to mark the four screw locations. Drill the
pilot holes.
4Securely mount the subbase using four no. 6 screws.
WIRING
1a. For proper subbase wiring, refer to Fig. 7.
b. For proper remote wiring of the Keyboard Display
Module; refer to the Specifications for the
Keyboard Display Module (65-0090),
Communication Interface Base Unit (63-2278),
DATA CONTROLBUS MODULE™ (65-0091) or
Extension Cable Assembly (65-0131).
2Disconnect the power supply from the main disconnect
before beginning installation to prevent electrical shock
and equipment damage. More than one disconnect
may be involved.
3All wiring must comply with all appropriate electrical
codes, ordinances and regulations. Wiring, where
required, must comply with NEC Class 1 (Line
Voltage) wiring.
4Recommended wire size and type: Use no. 14, 16, or 18
copper conductor (TTW60C or THW75C or THHN90C)
600 volt insulation wire for all line voltage terminals. For
high temperature installations, use wire selected for a
temperature rating above the maximum operating
temperature. All leadwires must be moisture resistant.
5Recommended grounding practices:
a. Use the earth ground to provide a connection
between the subbase and the control panel or the
equipment. The earth ground wire must be
capable of conducting the current to blow the 20A
fuse (or breaker) in event of an internal short
circuit. The 7890 needs a low impedance ground
connection to the equipment frame which, in turn,
needs a low impedance connection to earth
ground. For a ground path to be low impedance
at RF frequencies, the connection must be made
with minimum length conductors that have a
maximum surface area. Wide straps or brackets
are preferred rather than leadwires. Be careful to
verify that mechanically tightened joints along the
ground path, such as pipe or conduit threads or
surfaces held together with fasteners, are free of
nonconductive coatings and are protected
against mating surface corrosion.
b. The earth ground terminal for each 7890 must be
grounded to the metal control panel with wire as
short as practical. Each ground wire must be
capable of carrying a fault current equal to the
rating of the protective fuse (20A). A number 14
copper conductor is adequate but wide straps or
brackets are preferred rather than leadwires.
6Recommended wire routing for flame detector
leadwires:
• Do not run high voltage ignition transformer
wires in the same conduit with the flame
detection wiring.
• Do not route scanner wires in a conduit with line
voltage circuits.
• Enclose scanner wires without armor cable in
metal cable or conduit.
• Follow directions given in the flame detector
Instructions.
7Maximum wire lengths:
a. For the 7890, the maximum length of leadwire to
the control terminal input is 300 feet.
b. For the flame detector leadwires, the maximum
flame sensor leadwire length is limited by the
flame signal strength.
8Make sure loads do not exceed the terminal ratings.
Refer to the label on the 7890 or to the ratings in the
Specifications, see Table 1Aor 1B.
9Check the power supply circuit. The voltage and
frequency tolerance must match those of the 7890.A
separate power supply circuit may be required for the
7890 with the required disconnect means and overload
protection added.
JCheck all wiring circuits and complete the Static
Checkout, see Table 4, before installing the 7890 on the
subbase.
KInstall all electrical connectors.
LRestore power to the panel.

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 12
Fig. 7.Wiring the RM7890A,B.
M11194
G
L2
3
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
MASTER
SWITCH
IGNITION
MAIN FUEL
VALVE(S)
BURNER 
CONTROLLER/LIMITS
100 VAC
ALARM
INTERMITTENT 
PILOT/IGNITION
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR INFRA-
RED (LEAD SULFIDE)
FLAME DETECTOR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
C7012A,C,E,F OR
C7076A ULTRAVIOLET
FLAME DETECTOR
100V, 50/60 HZ (RM7890) POWER SUPPLY. PROVIDE DISCONNECT 
MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.
TERMINAL 22 IS ONLY ON THE RM7890B.
FOR A CONTINUOUS OR STANDING PILOT, INSTALL AN EXTERNAL RELAY TO SWITCH THE F LEAD. THE 
RELAY MUST HAVE GOLD-CLAD OR GOLD-FLASH CONTACTS AND A 120 VAC COIL. POWER THE RELAY
COIL FROM THE Q7800 SUBBASE TERMINAL 8. CONNECT THE RELAY CONTACTS BETWEEN THE F LEAD OF 
THE DETECTOR AND THE F TERMINAL OF THE Q7800 SUBBASE. THE R4222N1002 OR R4222V1002 RELAY IS
ACCEPTABLE TO USE IN THIS TYPE OF APPLICATION. USE THE N.O. PILOT DUTY CONTACTS.
INSTALL A LINE VOLTAGE CONTROLLER IN SERIES WITH THE LIMITS. IF USING A LOW VOLTAGE
CONTROLLER IS DESIRABLE, INSTALL AN EXTERNAL RELAY WITH THE N. O. CONTACTS IN SERIES WITH 
THE LIMITS. THE LOW VOLTAGE RELAY COIL WILL BE IN THE LOW VOLTAGE CONTROLLER CIRCUIT. NOTE 
THAT IT MAY BE NECESSARY TO PROVIDE AN EXTERNAL LOW VOLTAGE TRANSFORMER.


FOR DIRECT SPARK IGNITION (OIL
OR GAS)
L1 
(HOT)
L2 1
OR
OR
BLUE
BLUE
WHITE
YELLOW
WHITE
WHITE
BLACK
BLACK
9
8
10 IGNITION
TRANSFORMER
MAIN VALVE
1
Q7800
2
2
3
3
5
4
L2
4
5
4
C7061

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
13
Fig. 8.Wiring the EC7890A,B.
M11300
G
L2
3
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
MASTER
SWITCH
IGNITION
MAIN FUEL
VALVE(S)
BURNER 
CONTROLLER/LIMITS
200 VAC
ALARM
INTERMITTENT 
PILOT/IGNITION
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL, OR INFRA-
RED (LEAD SULFIDE)
FLAME DETECTOR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
C7012A,C,E,F OR
C7076A ULTRAVIOLET
FLAME DETECTOR
200V, 50/60 HZ (EC7890) POWER SUPPLY. PROVIDE DISCONNECT 
MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.
TERMINAL 22 IS ONLY ON THE EC7890B.

FOR DIRECT SPARK IGNITION (OIL
OR GAS)
L1 
(HOT)
L2 1
OR
OR
BLUE
BLUE
BLUE
WHITE
YELLOW
YELLOW
YELLOW
WHITE
WHITE
WHITE
WHITE
BLACK
BLACK
BLACK
BLACK 9
8
10 IGNITION
TRANSFORMER
MAIN VALVE
1
Q7800
2
2
3
3
5
4
L2
FOR A CONTINUOUS OR STANDING PILOT, INSTALL AN EXTERNAL RELAY TO 
SWITCH THE F LEAD. THE RELAY MUST HAVE GOLD-CLAD OR GOLD-FLASH 
CONTACTS AND A 230 VAC COIL. POWER THE RELAY COIL FROM THE 
Q7800 SUBBASE TERMINAL 8. CONNECT THE RELAY CONTACTS BETWEEN 
THE F LEAD OF THE DETECTOR AND THE F TERMINAL OF THE Q7800 SUBBASE. 
THE RELAY IS ACCEPTABLE TO USE IN THIS TYPE OF APPLICATION. 
USE THE N.O. PILOT DUTY CONTACTS.
INSTALL A LINE VOLTAGE CONTROLLER IN SERIES WITH THE LIMITS. IF USING 
A LOW VOLTAGE CONTROLLER IS DESIRABLE, INSTALL AN EXTERNAL RELAY 
WITH THE N. O. CONTACTS IN SERIES WITH THE LIMITS. THE LOW VOLTAGE 
RELAY COIL WILL BE IN THE LOW VOLTAGE CONTROLLER CIRCUIT. NOTE THAT 
IT MAY BE NECESSARY TO PROVIDE AN EXTERNAL LOW VOLTAGE TRANSFORMER.
USE 2:1 STEP DOWN POWER TRANSFORMER, 300 VA MINIMUM (STANCOR P8620
OR EQUIVALENT). FOR C7012E,F; C7061A; C7076A,C FLAME DETECTORS ONLY.

4
5
6
6
4
C7012A,C ULTRAVIOLET
FLAME DETECTOR
BLUE
C7061A 1:2

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 14
ASSEMBLY
Mounting 7890
NOTE: For installation dimensions, see Fig. 1 or 2.
Relay Module Mounting
1Mount the 7890 vertically, see Figs. 9 or 10, or mount
horizontally with the knife blade terminals pointing
downward. When mounted on the Q7800A, the 7890
must be in an electrical enclosure.
2Select the location in the electrical enclosure. Be sure
to allow adequate clearance for servicing, installation
and removal of the 7890, dust cover, flame amplifier,
flame amplifier signal voltage probes, electrical signal
voltage probes and electrical connections.
a. Allow an additional two inches below the 7890 for
the flame amplifier mounting.
b. Allow an optional three-inch minimum to both
sides of the 7890 for electrical signal voltage
probes.
3Make sure no subbase wiring is projecting beyond the
terminal blocks. Tuck in wiring against the back of the
subbase so it does not interfere with the knife blade
terminals or bifurcated contacts.
IMPORTANT
The 7890 must be installed with a plug-in motion
rather than a hinge action.
4Mount the 7890 by aligning the four L shaped corner
guides and knife blade terminals with the bifurcated
contacts on the wiring subbase and securely tightening
the two screws without deforming the plastic.
Fig. 9. Electrical panel installation.
Fig. 10.Wall or burner installation.
Fig. 11. Dust Cover mounting.
Mounting Dust Cover
1Align the two interlocking ears of the dust cover with the
two mating slots on the 7890, see Fig. 11.
2Insert 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 7890.
3Be sure the dust cover is firmly in place.

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
15
Installing Plug-In Flame Signal Amplifier
1Disconnect the power supply before beginning
installation to prevent electrical shock and equipment
damage. More than one disconnect may be involved.
2Align the amplifier circuit board edge connector with
the keyed receptacle on the 7890. Verify that the
amplifier nameplate faces away from the Relay
Module, see Fig. 12.
3Push in the amplifier until the circuit board is fully
inserted into the receptacle and then push the amplifier
toward the 7890 retaining clasp.
4Verify the amplifier is firmly in place.
5Perform all required checkout tests.
Installing The Flame Detector
NOTE: Table 2 and Fig. 13 list the flame detection systems
available for use with the 7890. Make sure the
correct combination of amplifier and flame
detector(s) is used.
Proper flame detector installation is the basis of a safe and
reliable flame safeguard installation. Refer to the Instructions
packed with the flame detector and the equipment
manufacturer instructions.
Keep the flame signal leadwires as short as possible from the
flame detector to the wiring subbase. Capacitance increases
with leadwire length, reducing the signal strength. The
maximum permissible leadwire length depends on the type of
flame detector, leadwire and conduit. The ultimate limiting
factor in the flame detector leadwire is the flame signal, see
Table 5.
Fig. 12. Flame signal amplifier mounting.

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 16
Fig. 13. Flame detector wiring.
BLUE
YELLOW
WHITE
WHITE
WHITE
WHITE
BLACK
BLACK
F
G
22
L2
L1
L2
M11131A
BLUE
WHITE
F
G
WHITE
BROWN
F
G
INFRARED (C7015)
ULTRAVIOLET (C7027/C7035/C7044)
SOLID STATE SELF-CHECKING 
ULTRAVIOLET (C7012E,F)
BLUE
YELLOW
BLACK
BLACK
F
G
L1
L2
SOLID STATE 
ULTRAVIOLET (C7012A,C)
1
22
BLUE
YELLOW
F
G
SOLID STATE SELF-CHECKING 
ULTRAVIOLET (C7061A)
2
F G
4
5
3
L2
C7076A,D ULTRAVIOLET DETECTOR
522
6
SHUTTER
G
SHUTTER
F
1
8
2
7
7800 SERIES
L1
L2
3a 3b
REMOTE
SENSOR
2b
2a
EARTH
GROUND
C7076A
OR
C7076D
TERMINAL
BLOCK
L2 (COMMON)
L1 (HOT)
G
F
X
X
FLAME ROD
G
F
X
X
PHOTOCELL
1FLAME 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.
FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW 
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN 
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
WHEN USING A C7061A OR 200V VERSION OF THE C7012E,F, OR C7076A, A 2:1 STEP DOWN TRANSFORMER IS
REQUIRED. SEE FIGURE 8.
2
3
3
3
3
22
N

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
17
OPERATION
Sequence of Operation
The 7890 has the following operating sequences, see Fig. 14
and 16.
Initiate
The 7890 enters the INITIATE sequence if the Relay Module
verifies voltage fluctuations of +10/-15% or frequency
fluctuations of +/- 10% during any part of the operating
sequence. The INITIATE sequence lasts for ten seconds
unless the voltage or frequency tolerances are not met. When
the tolerances are not met, a hold condition will be initiated
and will be displayed on the optional VFD for at least five
seconds. When the tolerances are met, the INITIATE
sequence will restart. If the condition is not corrected and the
hold condition exists for four minutes, the 7890 will lockout.
Causes for hold conditions in the INITIATE sequence are:
• AC line dropout detected.
• AC line frequency error caused by using a 60 Hz device
on a 50 Hz line or vice versa.
• AC line noise can prevent a sufficient reading of line
voltage inputs.
• Brownouts caused by low line voltage.
Standby
The 7890 is ready to start an operating sequence when the
operating control input determines a
call for heat is present.
The burner switch, limits, operating limit control and all
microcomputer monitored circuits must be in the correct state
for the 7890 to continue into the Safe-Start Check.
Normal Start-Up Safe-Start Check
The 7890 verifies that a flame does not exist and proceeds
into the Ignition Trial. If a flame is present, the 7890 will
recycle to the STANDBY period. If the critical loads are not in
the correct state, a safety shutdown occurs.
Ignition Trials
1Pilot Flame Establishing Period (PFEP):
a. The pilot valve and ignition transformer, terminals
8 and 10, are energized. The 7890A,B has an
intermittent pilot valve, terminal 8.
b. Flame must be proven by the end of the 4 or 10
second PFEP to allow the sequence to continue.
If flame is not proven by the end of PFEP, a
safety shutdown occurs.
c. With flame proven, the ignition, terminal 10, is
de-energized and the main valve, terminal 9, is
energized.
Run
The 7890 is now in RUN and will remain in RUN until the
controller input, terminal 6, opens, indicating that the demand
is satisfied or a limit has opened.
Selectable Site-Configurable Jumpers
The 7890 has two site-configurable jumper options, see
Fig. 17 andTable 3. The site-configurable jumpers should be
clipped with side cutters and the resistors removed from the
Relay Module.
Fig. 14. 7890A,B sequence.
POWER
00
LED
DISPLAY
OPERATING
CONTROLLER 
AND LIMITS
BURNER
START
FLAME
SIGNAL
INITIATE
ALARM
POWER
STANDBY
POWER POWER
PILOT
FLAME
MAIN
PFEP 
4 OR 10 SEC
PILOT
FLAME
MAIN
POWER
RUN STANDBY
4/10
IGNITION
INTERMITTENT PILOT
MAIN VALVE
LIMITS AND BURNER CONTROL CLOSED
9
8
10
36
TO
M11191
00
POWER
SAFE-
START
MAIN FUEL VALVE WILL BE ENERGIZED DURING PFEP IF FLAME IS PROVEN.1
1
ALARM
S S C
SAFE START CHECK FLAME PROVING

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 18
Fig. 15. Sequence status LEDs.
Jumper
Number Description Intact Clipped 7890 Type
JR1 Pilot Flame
Establishing
Period
10 sec 4 sec All
JR2 Flame Failure
Action RelightaLockout All
Table 3. Site-Configurable Jumper Options.
Fig. 16. LED sequence status display information (see Fig. 15).
Fig. 17. Selectable site-configurable jumpers.
SERVICE NOTE: Clipping and removing a site-
configurable jumper enhances the level
of safety. If using a 3-second amplifier,
site-configurable jumper JR2 must be
clipped and removed. If not removed, an
F46 lockout will occur.
STATIC CHECKOUT
CAUTION
1. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
2. Open the master switch before installing or
removing a jumper on the subbase.
3. Before continuing to the next test, be sure to
remove the test jumper(s) used in the
previous tests.
4. Replace all limits and interlocks not operating
properly. Do not bypass limits and interlocks.
5. Close all manual fuel shutoff valve(s) before
starting these tests.
SELECTABLE CONFIGURATION JUMPERS
M11197
SEQUENCE
STATUS
LEDs
RESET
PUSHBUTTON
CAPTIVE
MOUNTING
SCREW
DUST
COVER
RELAY
MODULE
FLAME
AMPLIFIER
M11192
FLAME
SIMULATOR INPUT FLAME 
CURRENT
TEST JACKS
INITIATE STANDBY
STANDBY 
HOLD: F/G 
(FLAME
DETECTED)
POWER
PILOT
FLAME
MAIN
POWER
PILOT
FLAME
MAIN
PILOT 
IGNITION
SAFE-
START 
CHECK
ALARM
POWER
FLAME
MAIN
PILOT
ALARM
ALARM
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARM
RESET/
ALARM
TEST
RUN
M3362
aThe Relight feature (JR2 intact) requires a 0.8 sec FFRT
Flame Amplifier. The 7890 will lockout and indicate a Fault
46 if a 3.0 second FFRT is used and jumper JR2 (Lockout)
is not clipped and removed.

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1
19
Equipment Recommended
1Voltmeter (1M ohm/volt minimum sensitivity) set on the
0-300 Vac scale.
2Two jumper wires of insulated no. 14 wire, 12 inches
(304.8 mm) long, with insulated alligator clips at both
ends.
General Instructions
APerform all applicable tests listed in Table 4 in the
order listed.
BMAKE SURE THATALL MANUAL FUEL SHUTOFF
VALVE(S) ARE CLOSED.
CPerform only those tests designated for the specific
7890 model being tested.
DRaise the setpoint of the operating controller to
simulate a
call for heat.
EFor each test, open the master switch and install the
jumper wire(s) between the subbase wiring terminals
listed in the Test Jumpers column of Table 4.
FClose the master switch before observing operation.
GRead the voltage between the subbase wiring terminals
listed in the Voltmeter column of Table 4.
HIf there is no voltage or the operation is abnormal,
check the circuits and external devices as described in
the last column.
ICheck all wiring for correct connections, tight terminal
screws, correct wire, and proper wiring techniques.
Replace all damaged or incorrectly sized wires.
JReplace faulty controllers, limits, interlocks,
actuators, valves, transformers, motors and other
devices as required.
KObtain normal operation for each required test before
continuing the checkout.
LAfter completing each test, be sure to remove the test
jumper(s).
WARNING
Make sure all manual fuel shutoff valves are closed.
MPORTANT
Low fuel pressure limits, if used, can be open.
Bypass them with jumpers for the remaining Static
tests (if required).
Table 4. Static Checkout.
Test
No. 7890 Models Test Jumpers Voltmeter Normal Operation If Operation Is Abnormal, Check the Items Listed Below
1 All None 3-L2 Line voltage at terminal 3. 1. Master switch.
2. Power connected to the master switch.
3. Overload protection (fuse, circuit
breaker) has not opened the power line.
2 All None 6-L2 Line voltage at terminal 6. 1. Limits.
2. Burner controller.
3 All 3-10 — Ignition spark (if ignition
transformer is connected to
terminal 10).
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
4 All 3-8 — 1. Ignition spark (if ignition
transformer is connected to
terminal 8).
2. Automatic pilot valve opens (if
connected to terminal 8).
NOTE: Refer to wiring diagram
of system being tested.
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
2. Listen for click or feel head of valve for
activation.
a. Actuator if used.
b. Pilot valve.
5 All 3-9 — Automatic fuel valve(s) opens. If
using direct spark ignition, check
the first stage fuel valve(s)
instead of the pilot valve.
Same as test no. 5. If using direct spark
ignition, check the first stage fuel valve(s)
instead of the pilot valve.
6 All 3-4 — Alarm (if used) turns on. 1. Alarm
Final All 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).

7800 SERIES EC7890A,B/RM7890A,B RELAY MODULE
65-0204–1 20
CHECKOUT
WARNING
Do not allow fuel to accumulate in the combustion
chamber. If fuel is allowed to enter the chamber for
longer than a few seconds without igniting, an
explosive mixture could result. It is recommended that
you limit the trial for pilot to ten seconds, and limit the
attempt to light the main burner to two seconds from
the time the fuel has reached the burner nozzle. In
any case, do not exceed the nominal lightoff time
specified by the equipment manufacturer. Close the
manual fuel shutoff valve(s) if the flame is not burning
at the end of the specified time.
CAUTION
1. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
2. Open the master switch before removing or
installing the 7890.
3. Make sure all manual fuel shutoff valve(s) are
closed before starting the initial lightoff check and
the Pilot Turndown tests.
4. Do not put the system in service until you have
satisfactorily completed all applicable tests in
this section and any others required by the
equipment manufacturer.
CAUTION
If an 7890 is replaced with a lower or higher
functioning 7800 SERIES Relay Module, the burner
will not sequence unless wiring changes are made.
IMPORTANT
1. If the system fails to perform properly, refer to
7800 SERIES System Annunciation Diagnostics
and Troubleshooting, form 65-0118.
2. Repeat ALL required Checkout tests after all
adjustments are made. ALL tests must be
satisfied with the flame detector(s) in its FINAL
position.
Equipment Recommended
Volt-ohmmeter (1M ohm/volt minimum sensitivity).
• 0-300 Vac capability.
• 0-6000 ohm capability.
• 0-10 Vdc capability.
Checkout Summary
• Preliminary inspection—all installations.
• Flame signal measurement—all installations.
• Initial lightoff check for proved pilot—all installations using
a pilot.
• Initial lightoff check for direct spark ignition of oil—all
burners using DSI.
• Pilot turndown test—all installations using a pilot.
• Hot refractory saturation test—all installations using
Infrared (lead sulfide) Flame Detectors.
• Hot refractory hold-in test—all installations.
• Ignition interference test—all installations using flame rods.
• Ignition spark pickup—all installations using Ultraviolet
Flame Detectors.
• Response to other ultraviolet sources—all installations
using Ultraviolet Flame Detectors.
• Flame signal with hot combustion chamber—all installations.
• Safety shutdown tests—all installations.
See Fig. 15 for location of component parts and see Fig. 7 or
Q7800 Specifications for terminal locations.
Preliminary Inspection
Perform the following inspections to avoid common problems:
AWiring connections are correct and all terminal screws
are tight.
BFlame detector(s) is clean, installed and positioned
properly. Consult the applicable Instructions.
CCorrect combination of amplifier and flame detector(s)
is used. See Table 2 in the Specifications section.
DPlug-in amplifier is securely in place.
EBurner is completely installed and ready to fire; consult
equipment manufacturer instructions. Fuel lines are
purged of air.
FCombustion chamber and flues are clear of fuel and
fuel vapor.
GPower is connected to the system disconnect switch
(master switch).
HLockout switch is reset (push in reset pushbutton) only
if the 7890 is powered, see Fig. 1 and 2.
ISystem is in the STANDBY condition. POWER LED is
energized.
JAll limits and interlocks are reset.