INSTALLATION & OPERATING MANUAL

(lOM)

50MMBTU/HR

ONOE THROUGH STEAM GENERATOR

FAHUD STEAM INJEOTION PROJEOT - PHASE I

Prepared for:

BOOK 9

Customer Reference Number : PAIP-00060

Customer P.O. Number: WPAI/2007.00060.05.5003

EN-FAB, Inc. Work Order Number: 207009

UNIT TAG NO: F-6101 A-D

Rev No. .J.'r~p.aJ:e.<lRy_ Jssue.Da le._ _......Re"isiDn.Desc~iptiDn- -Gheoked-By- --App'·Dved-By..-

0 RS ORIGINAL ISSUE MM

I I I I I I
(
.
...
!
PLC-HMI PANEL
TABLE OF CONTENT
W.O #207009
BOOK9

e HONEY WELL BMS SERIES 7800 MODULES

e ELCON 2700 MUL TIPLEXR UNIT
e ACM STEPDOWN TRANSFORMER
e ASCO TRANSFER SWITCH
• IDEC POWER SUPPLY
II BLACK BOX MEDIA CONVERTER SWITCH
• PUSH BUTTON/SWITCH
 Honeywell

\.
RM7800E,G,L,M; RM7840E,G,L,M
7800 SERIES Relay Modules

APPLICATION SPECIFICATIONS'
The Honeywell RM7800/RM7840 Relay ModulE'", arJ Erectricat Ratings, see Table 3: , •_ ,
micwprocessor-based integrated burner coptrQls'f9f ' Voltage and Frequency: 120 Vac (+1 Oi-15%Y;'SO. or 60 Hz
automatically fired gas, oil, or
".
cambinatipn fUel 'ojiPrgl'e'ourher'
' · t · " " "'-", . I'f'_" , hf" "1 . '. (±10%)~ .' '; t',."w .
applications. The RM7800/RM7840 Relay Maddie,! an,'us'$d Pp:r.er DiSiiip~ti?R: RM789RfltM{84P: 10W maxipium.
for UUCSA On/Off, UUCSA Modulating, and FM/IRI '
Modulating burner applications. The RM?aOOlRM7840 system MaximurT; Total Connected Load: 2000 VA.
consists of a Relay Module. Keyboard Display Modules
(standard with RM7800), Dust Cover (standard .with RM7840), Fusing: 15A maximum, Type SC or equivalent Fast Blow.
Subbase, Amplifier, and Purge Card. Options include
Personal Computer Interface, DATA CONTROLBUS Environmental Ratings:
MODULET", Remote Display Mounting, First~Out Expanded Ambient Temperature:
Annunciator and Combustion System Manager™ Software, Oper;,ting: -40°F to +140°F (-40°C to +60°C).
Storage: _40°F to+150'F (-40°C to +6WC).
Functions provided by the RM7800/RM7840 include Humidity: 85% relative humidity continuous, noncondensing.
automatic burner sequencing, flame supervision, system Vibration: 0.5G environment.
status indication, system or self-diagnostic~ and
troubleshooting . .TheRM7800/RM7840 is a solid state Approvals:
replacement for the electromechanical R4140 Automatic Underwriters Laboratories Inc. Listed: File No. MP268,
Programming Control. Guide No. 'MCCZ.
Canadian Standards Association Certified: LR9S329-3.
This document provides installation and static checkout Factory Mutual Approved: Report No. J.1.1V9AO.AF.
instructions. other applicable publications are: IRI Acceptable. '
Federal Communications Commission: Part 15,
65-0084:Q7800A,B 22-Terminal Wiring Subbase Product
Class 8-Emissions.
Data.
65-0089:ST7800A Plug-In Purge Timer Installation
Instructions.
65-0090:S7800A Keyboard Display Module Product Data. INSTALLATION
65-0091:S7810A Data ControlBus Module"" Product Data.
65-0095:S7820 Remote Reset Module p,roducf Data.
65-0097:221729C Dust Cover' Packing She'et. ' When Installing this Product...
65-0101 :S7830 Expanded Annunciator Product Data. 1. Read these instructions carefully. Failure to follow
65-0109:R7824, R7847,R7848, R7849, R7851 , R7861 , them could damage the product or cause a hazardous
R7886 Flame Amplifiers for the 7800 SERIES Product condition.
Data. 2. Check the ratings given in the instructions and marked
65-0131 :221818A Extension Cable Assembly Product on the product to make'sure the product is suitable for
Data. the application.
65-0228:7800 SERIES Multi-Drop Switch Module Product 3. Installer must be a trained, experienced, flame
Data. safeguard selViee technician.
65-0229:7800 SERIES RELAY MODULES Checkout and 4. Afler installation is complete, check out the product
Troubleshooting Product Data. operation as provided in these instructions.
65-0249:S7810M ModBus"" Module Product Data.

® U.S. Registered Trademark

Copyright © 2002 Honeywell· AU Rights Reserved
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES
, AWARNING
Fire or Explosion Hazard.
Can cause property damage, severe Injury:
or death.
To prevent possible hazardous burner operation, verify
safety requirements each time a control is installed on
a burner.
AWARNING
Electrical Shock Hazard.
Can cause serious injury or death.
Disconnect the power supply before beginning
installation. More than one power supply disconnect
may be required.
IMPORTANT . .
1. Wiring connections for the relay modules are unique;
therefore, cefer to Fig. 2. 3, 4, or the cqrrect
Specifications for proper subbase wiring, and
sequence charts.
2. Wiring must comply with all applicable codes,
ordinances and regulations.
3. Wiring must comply with NEC Class 1 (Line Voltage)
Wiring.
4. Loads connected to the RM7800lRM7840 must not
exceed those listed on the RM7800lRM7840 label or
the Specifications, see Table 1.
5. Limits and interlocks must be rated to simultaneously
carry and break current to the ignition transformer,
) pifot valve, and main fuel valve(s).
6. All external timers must be listed or component
recognized by authorities who have jurisdiction for
the specific purpose for which they are used.
7. For on-off gas-fired systems, some authorities who
have jurisdiction prohibit the wiring of any limit or
operating contacts in series between the flame
safeguard control and the main fuel valve(s).
a. Two Flame Detectors can be connected in parallel
with the exception of Infrared Flame Detectors
(C7015).
9. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used
in accordance with the instructions, may cause
interference to radio communications. It has been
tested and found to comply with the limits for a
Class B computing device of Part 15 of FCC rules
which are designed to provide reasonable protection
against such interference when operated in a
commercial environment. Operation of this
equipment in a re.sidential area may cause,
interference; in which case, the users at their own
expense may be required to take whatever
measures are required to correct this interference.
10. This digital apparatus does not exceed the Class B
limits for radio noise for digital apparatus set out in
the Radio Interference Regulations of the Canadian
Department of Commun;caUons.
66-10.85-3 2
Location
Humidity
'Install the-relay module where the relative humidity never
reaches the saturation point. The relay module is designed to
operate in a maximum 85 percent relative humidity
continuous, noncondensing, moisture environment.
Condensing moisture may cause a safety shutdown.
Vibration
Do not install the relay module where it could be subjected to
vibration in excess of 0.5G continuous ma_xit"!l~Hl] vibration.
Weather
The relaY_mo~~I~ is not dEi,si~n~d t9'B\'l,~e,~lh~i.til!bJ, ....."
Wh~n i.~~,\?il~,d ,9~\qqq% Pf9!ect,\Ae re\~Yc.m9,d_~lry~in~,~n,
,\pprRv~(I W~~lh,er-tigh\Ein.Glq~4'~.:.'" ,'!."". . j ..
Mouhting Wiring Subbase
1. Mount the subbase in any position except horizontally
with the bifurcated contacts pointing down. The
standard vertical position is recommended. Any other
position decreases the maximum ambient temperature
rating.
2. Select a location on a wall, burner or electrical panel.
The Q7800 can be mounted directly in the control
cabinet. Be sure to allow adequate Clearance for
servicing, installation, access or removal of the
RM7800/RM7840, Exp~nded Annunciator, Keyboard
Display Module, flame amplifier, flame amplifier signal
voltage probes, Runrrest Switch, electrical signal
voltage probes and electrical field connections.
3, For surface mounting, use the back of the subbase as a
template to mark the four screw locations. Drill the pilot
holes.
4, Securely mount the subbase using four no. 6 screws.
Wiring Subbase
AWARNING
Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
Disconnect the power supply before beginning
installation to prevent electrical shock, eqUipment
and control damage. More than one power supply
disconnect may be required.
1. For proper subbase wiring, refer to Figs. 2, 3, 4 or 5.
2, For proper remote wiring of the Keyboard Display
Module, through a 203541 5-wire Connector, refer to
the Specifications for the Keyboard Display Module
(65-0090), Network Interface Unit
(63-2278), Data ControlBus Module'" (65-0091) or
Extension Cable Assembly (65-0131).
3. Disconnect the power supply from the main disconnect
before beginning installation to prevent electrical shock
and equipment damage. More than one disconnect may
be required.
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

4. All wiring must comply with all applicable electrical
codes, ordinances and regulations. Wiring, where
required, must comply with NEC, Class 1 (Line Voltage)
wiring.
5. Recommended wire size and type: see Table 1.
6. Recommended grounding practices: see Table 2.
The Keyboard Display Module, Data Control Bus MOdlile 1M
(lor remote mounting or communications), through a 203541.
5-wire Connector, or Communication Interface ControlBus
Module must be wired in a daisy chain configuration,
(1 (a)-1 (a), 2(b )-2(b), 3(c)-3(c)). The orderol interconnection.of
all the devices listed above is not'important.,Be aware that'
modules on the closest and farthest end of the daisy chain'
configuration string require a 120 ohm (114 watt minimum)'
resistor termination across terminals 1 and 2. of the electrical
connectors, for connections over
100 feet.
7. Recommended wire routing of leadwires: " ~f.
a. Do not run high volt~'ge igniliori"fransformer wires'in
the same'conduitw!th the flame petector, Data
Control bus Module TM, or Remote Reset Module,
wiring.
b. Do not route flame detector, Data Controlbus
Module 1M, or Remote Reset Module leadwires in
conduit with line voltage circuits.
c. Enclose flame detector leadwires without armor
cable in metal cable or conduit.
d. Follow directions in flame detector, Data Controlbus
Module TM, or Remote Reset Moc;lule Instructions.
8. Keyboard Display Module (KDM): Because the KDM is
powered from a low voltage, energy limited source, it
( ) can be mounted outside of a control panel if it is
protected from mechanical damage.
NOTE: A 13 Vdc power supply must be used any time more
than one Keyboard Display Module is used.
9. Maximum wire lengths follow:
a. RM7800/RM7840 leadwires-The maximum length
of leadwire is 300 feet to terminal inputs (Control,
Preignition InterlocK, Running/Loc~out Interlock,
High Fire Switch and Low Fire Switch).
b. Flame Detector leadwires-The maximum flame
sensor leadwire length is limited by the flame signal
strength ... ,
c. Remote Reset leadwires-The maximum length of
wire is 1dO~ feet to a Remote R,?set pushbutton.
d. Data Controlb,us Module TM_The maximum Data
C:ontrolbus Module "'cable length depends on the
number of system modules connected, the noise
conditjoQs and the i«lll.le used. The maxlmuin length
, ,of al,l Da,ta CoptrolbuslModule""'il'ltercqpnecting
i~wireH~ toao f&,~t. __ , .)i,SY -!l,'~' '\ ~ !
10. Ma~e; sureloads·'donot:exceed the termina:1 ralings.
Reter; to tlie lalielon tn~' RM7800/RM7840 br t6 the
rati~gs in Tables 3, 4 and 5.
Final Wiring Check
1. Check the power supply circuit. The voltage and
frequency tolerance must match those of the
RM7800/RM7840, A separate powe! supply circuit may
be required for the RM7800/RM7840. Add the required
disconnect means and overload protection~
2. Check all wiring circuits and compleie the Static
Checkout, see Table 8, before installing the
3.
RM7800/RM7840 on the subbase.
Install all electrical connectors.
4. Restore power to the panel.

Table 1. Recommended Wire Sizes and Part Numbers.

Application Recommended Wire Size Recommended Part Nujnber(s)
Line voltage terminals 14, 16 or 18 AWG copper conductor, 600 TIW60C, THW7SC, THHN90C:
volt insulation, moisture-resistant
, - , -. wire.
. ",-.-,
:

Keyboard Display Module (KDM)
Data ControlBus Module 1M
, ground, or five wire.
Remote,Reset Module
Communiqations Interrace ControlBus ™
Module
13 Vdc full-wave rectified transformer
power input.
22 AWG two-wire twisted pair with' Belden 8723 shielded cable or equivalent.
ground, or five wire.
22 AWG two-wire twisted pair with Belden 8723'shielded cable or equivalent.
22 AWG two-wire twisted pair, in~ulated -
for low voltage.
22 AWG two-wire twisted pair with Belden 8723 shielded cable or equivalent.
ground.
18 AWG wire insulated for voltages and nW60C, THW75C, THHN90C.
temperatures for given application.

3 66-1085-3
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

L1
(HOT) L2

4r---------------------------------~120 Vac,
&
L-----------------------------~L2
SO/60rH_Z__-tPLUG.IN PURGE
CONFIGURATION
TIMER CARD
JUMPERS
TEST

r
FLA~M~E~S~I~G:N:AjLL-L--, JACK

RUNfTEST~.
SWITCH -I_....l:...._ _ _ _ _
r
.l-_, PLUG·1N
FLAME
-----0---+
--@---
Lr-"'~::::':::::::;:::::''::':'::::---~:;:T;;-ES;;T~ AMPLIFIER
RESET
PUSHBUTTON

'-NV'-
+-v\/V'--
'RELAY -NV'-
DRIVE
CIRCUIT
RELAY
STATUS
--vvv-
L-____ -I FEEDBACK -NV'-
o AND LINE --vvv-
o VOLTAGE -NV'-
~ r---;;::;;;:;;~~ INPUTS
--vvv-
o SAFETY RELAY
1K -NV'-
STATUS LEOs
CIRCUIT '--_--'--vvv-
CONTROL
POWER SUPPLY.
POWER

+---1-'+10-11-------(20

PRE-IGNITION
INTERLOCK

IGNITION

PILOT

PILOTN2

MAIN VALVE
6K1
5 BLOWER
3K1
L---------1r---------------------------{3 ALARM
HIGH FIRE
KEYBOARD
@
, -_ _.::D:.::D:.::L--l~ DISPLAY MODULE 8K11
COMMON
13 ~ INDICATES FEEDBACK SENSING
OF RELAY CONTACT STATUS
8K2 MODULATE@ AND LINE VOLT INPUTS
19K1 15
DOL 9K2
COMMUNICATIONS !:==..1.l LOW FIRE
14
- - - FIELD WIRING
- - INTERNAL WIRING

& PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M12258

Fig. 1. Internal block diagram of the RM7800URM7840L (See Fig. 2, 3, 4 or 5

for individual detailed wiring instructions).

66-1085-3 4
 ·RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 2. Recommended Grounding Practices.

Ground Type ,Recomll)ended Practice
Earth ground (subbase and relay module). 1. Use to provide a connection between the subbase and
the control panel of the equipment. Earth ground must be
capable of conducting enough current to blow the 20A fuse
(or breaker) in the event of an internal short circuit.

2. Use wide straps or brackets,to provide minimum lenglh,

maximum surface area ground cond.uctors. If a leadwire
must be used, use 14 AWG copper wire.

3. Make sure that mechanically tightened joints along the

ground path are free of nonconductive coatings and pro-
tected against corrosion on mating surfaces.
Signal ground (KDM, Data ControlS us Module TM,
Communications Interface ControlSus™ Module). . Use,the shield of the' signal wire to ground the device to the
Signal ground terminals [3(c)] of each device. Con,necnhe·'
"
.. 'lhield alQ9!h, e]lds pf th'LghajnJQ.~ailh.-9r.QunL~" ':, -~:c;"c'
:',:i'
,~> ,,'
"j""

T"ble 3.1'e'rminill'Raliligs.
.-,'~

Terminal No. Descriptio~ Ratings

G Flame Sensor Ground a -
Earth G Earth Ground 8 -
L2(N) Line Voltage Common ,

3 Alarm 120 Vac, 1Apilot duty.

4 Line Voltage Supply (L 1) 120Vae (+10%/-15%), 50 or 60 Hz (±10%)b.d
5 !3urner Motor 120 Vac, 9.8 AFL, 58.8 ALR (inrush).
6 Burner Controller and Limits 120 Vac, 1 rnA.
7 L<?ckoutiRunning Interlock 120 Vac,'8A run, 43A inrush.
8 Pilot Valve/Ignition 120 Vacc.
9 Main Fuel Valve 120Vace.
10 Ignition 120Vace.
F(11 ) Flame Sensor ,60 to 220 Vac, current limited.
12 Firing Rate High Fire 120 Vac, 75 VA pilot duty.
13 Firing Rate Common 120 Vac, 75 VA pilot duty.
14 Firing Rate Low Fire 120 Vac, 75 VA pilot duty.
15 Firing Rate Modulate 120 Vac, 75 VA pilot duty.
16 Unused -
17 Unused -
18 Low Fire Switch Input 120 Vac, 1 rnA.
19 High Fire Switch Input ,
120 Vac, 1 rnA.
20 Preignition Interlock Input 120 Vac, 1 rnA.
21 Interruptedllntermittent Pilot Valve/First Stage Oil Valve 120 Vace.
22 Shutter 120 Vac, 0.5A.

.aThe relay module 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 15A fuse (or breaker) in event of an
internal short circuit. The relay module requires a low impedance ground connection to the equipment frame, which, in turn,
requires a low impedance connection to earth ground.
b 2000 VA maximum connected load to relay module assembly.
e See tables 4 and 5.
d RM7800G,M/RM7840G,M operating frequency determined by relay module selection.

5 66-1085--3
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELA Y MODULES

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

Combination No. Pilot Fuel 8 Main 9 Ignition 10 I.ntermittent Pilot Valve 21
No Load (
,
1 C F No Load
2 B F No Load No Load
3 No Load F No Load B
4 F F A No Load
5 No Load F A F
6 D F A No Load
7 No Load D -A D
8 D D A No Load
9 No Load D A D

Table 5. Explanation of Each Combination.

A B C,
4.5A ignition. 50 VA Pilot Duty plus 180 VA ignition plus
4.5A ignition. moto,va!ye)«it)Ji1•
660 VA inrush, 360 VA
open, 260 VA hal):!.
D F
2A Pilot buty. 64 VA Pilot Duty plus motor
•• valves with:
3850 VA inrush, 700 VA
open, 250 VA hold.

Mounting RM7800/RM7840 3. Make sure no subbase wiring is projecting beyond the

terminal blocks. Tuck in wiring against the back of the
Relay Module (Fig. 5) subbase so it does not interfere with the knife blade
1. Mount the RM7800/RM7840 vertically on the 07800 terminals or bifurcated contacts.
Subbase, or mount horizontally with the knife blade
terminals pointing downward. When mounted on the IMPORTANT
07800A, the RM7800/RM7840 must be In an electrical The RM7800lRM7840 must be installed with a
enclosure. plug-in motion rather than a hinge action.
) 2. When mounting in an electrical enclosure, provide
4. Mount the RM7800/RM7840 by aligning the four
adequate clearance for servicing, installation and
removal of the RM7800/RM7840, Keyboard Display L-shaped corner guides and knife blade terminals with
Module, flame amplifier, flame amplifier signal voltage the bifurcated contacts on the wiring subbase and
probes, electrical Signal voltage probes, and electrical securely tighten the two screws without deforming the
connections. plastic.
a. Allow an additional two inches below the
RM7800/RM7840 for the. flame amplifier mounting.
b. Allow an optional three-inch minimum to both sides
of the RM7800/RM7840 for electrical signal voltage
probes.

66-1085-3 6
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

SERIES 9Q
FIRING RATE SERIES 90
07800 MOTOR CONTROLLER
\. ....,.. r"::-
r ------- -- -,® @ .HIGH FIRE
0-:0 . fOR DIRECT SPARK IGNITION (OIL
~
2
0 COMMON
:0 10 OR GAS) ..",,,,,,,,,,._-,,

- - ; 120V AlARM
-0 ®
lOW fiRE

MODUtATE
re·
'--
fe·
'--
~Ll) (,5)

1 HBURNER MOTOR
(BLOWER) I- ~ ®
1 .,
1 B(JR~ER ,- 'I- ~ 10 &. ,
·9.9I'Jr~q~Erop~ITS
1 . , ... • ~ -'.• " "'" f
LOCKciut.ll\ltERlcO:CKS 1 k
1
1
(1~_C;/~t8,l;b9.W)~~ITCH) . 1-6! ®- -1 ~OW FIRE d6: ~ "
STAfIT SWITCH: '~.', ;; , ':" i ~,:,_,,:~~::~~~~.:~J~:~l~~~~J ,1 i '
,"1';--1[',. -', ""-;c'
ii,120V, S01~O..H~.f'qWER:,SUeeJ;.'!::~f~QVI[)~:QIS~$~NEC:r
1 10SEC:;INrERS(!PTED,
H P(lqT((!3f:·(ITJbt:L·~ . .
'8
~ ®- "4 ~IGH.F-lRE_~ 'il;
p'~~g~ SW~t~~. ~
,; MEANS A~~,'oyErlOAf PROTEq~,9~iAs.~~~l!1~ED' ""
1. &RM7 80017840E'p~LY: HiGH,F.IRE~lIRG"r;SWITCH
1
H MAIN FUEL VALVE(S) I- 9 @- '1 rREJ~,N!TION
INTERLOCK
CONNECTEDTO €I
(L1), NOT@.
1
1
1
-i\
SECOND 'IGNITION
(EARLY SpARK
TER!AI~AT[ON) j- -® ®- 15 \,\e.
INT RRUPTEO
&. .&SEE FLAME DETECTOR INSTAw.ATION INSTRUCTIONS

.&00
FOR CORRECT;WlRING.
NOT WIRE TO ANY UNUSED TERMINAL,S.
PILOT VALVE
1
1 FlAME DETECTOR t - -0 ®- 1
1
&RM7 840L1026, RP.!7600),:1053 HAVE'INTERMITTENT
PILO T VALVE FUNCTIOt-JS.

1,&
~T~
::t- ~t' .
..,..<2
(HOTh
'
~ - ------- _I
SWITCH
Mt2261C

RM7800/RM7840E,l

LEO
DISPLAY

BURNER

CONTROLS
AND
IIITERLOCKS

FtAME
SIGNAL

FIRING
RATE
MOTOR

--
& FOR THE R7800IR7840E: THE HIGH FIRE SWITCH MUST BE WIRED CORRECTlY TO PERFORM ENERGY SAVING PURGE
FUNCTIONS. THE BURNERIBLOWER MOTOR DOES NOT START UNTIL THE HIGH FIRE SWITCH MAKES.

£ RM7800L 1053, RM7840L 1026: TERMINAL 21 PROVIDES INTERMITTENT PILOT FUNCTION. Mt226JD

Fig. 2. Wiring subbase and sequence for RM7800E,URM7840E,L.

7 66-1085-3
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES flELA Y MODULES

07BOO

(L 1) €.e)-l~M~O~O~U~LA:::::TE,-_ _, -_ _ _...I

.& 120V, 50/50 Hz POWER SUPPLY. PROVIDE DISCONNECT

MEANS AND OVERLOAD PROTECTION AS REQUIRED.

&ADD JUMPER FOR 30 SECOND MAIN FLAME

1- ESTABLISHING PERIOD (MFEP).

&00 NOT WIRE TO ANY UNUSED TERMINALS.

,&,SEE FlAME DETECTOR INSTAlLATION INSTRUCTIONS

FOR CORRECT WIRING.

~--------------- Ml2260B

RM7800GiRM7840G
INITIATE j'REPUIRGE
(INITIAL
POWERUP

LEO 0 o ":!lOT
DISPLAY
0 o FLAME

0 o MAIN
0 o AlARM
BURNER

FLAME
SIGNAL

FIRING
RATE
MOTOR

M12264A

Fig. 3. Wiring subbase and sequence for RM7800G/RM7840G.

66·1085-3 8
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Q7BOO

\ ,-------------- ®
I
COMMON
: r------------------+{L
FOR DIRECT SPARK IGNITION
I (OIL OR GAS)
I
I 120VALARM
I I &
I ., MODULATE' DAMPER
I MOTOR
I I
I I-
I @) I
I
I I
I ® ,:,1.
!
I
.,:i.
I
I
I
I
I " l&,'.,{DISCONNECT
~.
20V. 50/GO tiz-POWER 5UPP',LY. PROVIDE;
MEANS AND oveRLOAD
I
" :; :'" ,;':-PROTECTION AS REQUIRED.
I
I
I
&. WHEN NO DAMPER MOTOR OR LOWFIRE
SWITCH IS USED, JUMPER TERMINAL 14
I TO TERMINAL 18.00 NOT WIRE TERMINAL 15.
I
I &.00 NOT WIRE TO ANY UNUSED TERMINALS.
I
&,SEE FlAME DETECTOR INSTALLATION
INSTRUCTIONS FOR CORRECT WIRING.

MI1262A
~-------------~~~

RM7800M/RM7840M

• POWER • POWER • POWER

LEQ
OISPLAY
• 'PILOT 0 o
• FLAME 0 o
• MAIN 0 o
BURNER

OPERATING
CONTROLS
AND

FLAME
SIGNAL

DAMPER
MOTOR
-- M122fi5A

Fig. 4. Wiring subbase and sequence for RM7800M/RM7840M.

9 66-1085-3
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELA Y MODULES

I I
(
HONEYWELL

RELAY

CONFIGURATION
JUMPERS

PURGE
TIMER

SeQUENCE
STATUS
LED PAN'oL-______

RESET
BUTTON

KEYBOARD
DISPLAY
MODULE
(STANDARD ON
RM7800E,G,l,M)

HoneyWell BURNER CONTROL

FLAME
AMPLIFIER

Fig. 5. RM7800lRM7840 Relay r:,odule exploded view.

SAFETY SHUTDOWN d. Ignition/pilot valve/intermittent pilot valve terminal is

Safety Shutdown (Lockout) occurs if any of
the following occur during the indicated
period:
1. INITIATE Period:
a. Purge card is not installed or is removed.
b. Purge card is bad.
c. Configuration jumpers are changed (after 200 hours
of operation).
d. Ac line power errors occurred, see Operatio.n
section.
e. Four minute INITIATE period has been exceeded.
2. STANDBY Period:
a. Flame signal is present after 40 seconds.
b. Preignition Interlock is open an accumulative time
of 30 seconds.
c. Interlock check feature is enabled and the
Interlock String (including airflow switch) is closed
for 120 seconds with controller closed.
energized.
e. Main valve terminal is energized.
f. Internal system fault occurred.
g. Purge card is not installed or is removed.
h. Purge card is bad.
3. PREPURGE Period:
a. Preignition Interlock opens anytime during
PREPURGE period (RM7840E,L).
b. Flame signal is detected after first ten seconds
during PREPURGE (RM7840E,L).
c. High Fire Switch fails to close within four minutes
and fifteen seconds after the firing rate motor is
commanded to drive to the high fire position at the
start of PREPURGE (RM7840E,L).
d. Low Fire Switch fails to close within four minutes
and fifteen seconds after the firing rate motor is
commanded to drive to the low fire position at the
end of PREPURGE.
. e. Running Interlock does not close within 30 seconds
(RM7840G,M).
f. Lockout Interlock does not close within 10 seconds
(RM7840E,L).

66-1085-3 10

g. Lockout Interlock opens during PREPURGE
(RM7840E,L).
h. Ignition/pilot valve/intermittent pilot valve terminal is
energized.
i. Njain valv~ terminal is energized.
j. Internal system fault occurred.
k. Purge card is removed.
\. Purge card is bacj.
4. PILOT FLAME ESTABLISHING Period (PFEP):
a. Low Fire Switch opens.
b. Lockout Interlock opens (RM7840E,L).
c. Ignition/pilot valve/intermittent pilot valve terminans
not energiZed.
d. Early spark termi'nation terminal is energized after
five seconds.
e. No flame is present at the end of PFEP.
f. Main valve terminal is energized (RM7800G,M).
g. Internal system fault ac6urriid': . from being ener'6iz"cj.\lIla-9~;eri¢rg!t~q,!ji;iro.'iip intermittent
h. Purge card is removed,'
i. Purge card is -bad'.
5. MAIN FLAME ESTABLISHING Period (MFEP):
a. Low Fire Switch Opens.
b. Lockout Interlock opens. (R,M7840E,L).
c. Ignition/pilol yalveflnt~h'nittent pilot valve terminal is
not energized.
d. Main valve terminal is not energized.
e. No flame is piesent at the end of MFEP.
f. Internal syste.mfiiult occurred.
g. Purge card is removed.
h. Purge card is pad.
6. RUN Period:
a. No flame is present.
b. Lockout Interlock opens (RM7840E,L).
c. Interrupted pilot valve terminal Is energized
(RM7840G,M).
d. Main valve terminal is riot energized.
e. Internal system fault occurred.
f. Purge card is removed.
g. Purge card is bad.
7. POSTPURGE Period:
a. Preignition Interlock does not cloSe in five' seconds
and opens after five-second time period.
b. Ignition/pilot valve/intermittent pilot viilv'e terminal is
energized.
c. Main valve terminal is energiz~d.
d. Internal system fault occurred.
e. Purge card is removed.
f. Purge card is bad.
OPERATION
Sequence of Operation
The RM7800/RM7840 has the following operating sequences,
see Fig. 2, 3, 4, and Table 6. The RM7800/RM7840 LED
provide positive visual indication of the program sequence:
POWER, PILOT, FLAME, MAIN and ALARM.
Initiate
The RM7800/RM7840 enters the INITIATE sequence when
the Relay Module is powered. The RM7800/RM7840 can also
enter the INITIATE sequence if the Relay Module verifies
voltage fluctuations of +101-15 percent or frequency
RM7800E,G,L,M; RM7840E,G,L,M 7800 SER/ES RELAY MODULES
fluctuations of +1-10 percent during any part of the operating
sequence. The INITIATE sequence lasts for ten seconds
unless the voltage or frequency tolerances are not met. When
. the tolerances are not met, a hold condition is initiated and
displayed on the VFD for at least five seconds. When the
tolerances are met, the INITIATE sequence restarts. If the
condition is not corrected and the hold condition exists for four
minutes, the RM780a/RM7840 locks out. Causes for hold
conditions in the INITIATE sequen~e:
a. AC line dropout is deteCted.
b. AC line frequency error occurs caused by using a
60 Hz device on a 5d Hz line, Or vice versa.
c. AC line noise prevents a sufficient reading of the
line voltage inputs.
d. Low line volt"ge prow~outs occur.
The INITIATE seq~enQe'~r~q d~laY~. the ~urI1er_mptor starter
AC line in ut or~hi1tr6nh "uC)' '''. .'. '" ,,'"
j '" ' ." P. , ; '_~,," '.),>;;p. .,,-,>\ " k .
Standby"
The RM7800/RM7840 is ready to start an operating sequence
when the operating control determines a cali for heat is
present. The burner switch, limits, operating control and all
microcomputer monitored circuits must be in the correct state
for the RM7800/RM7840 to cantinue into the PREPURGE
sequence.
Normal Star:t:Up Prepurge
The RM7800/RM7840 provides a prepurge timing selectable
from two seconds to 30 minutes 'l/ith power applied and the
RM7800 operating Gontrol indicating a call for heat:
a. Running Interlocks, Preignition In.terlocks, Burner
Switch, Runrrest Switch, Lockout Interlocks and all
microcomputer monitored circuits must be in the
correct operating state.
b. The blower motor output, terminal 5, is powered to
start the PREPURGE sequence, except for the
RM7800E/RM7840. The firing rate motor is driven to
I the.highfire R9~itian. The PREPURGE timing for the
RM7800/RM7840E,L does not begin until the
Lockout Interlock String and High Fire Switch are
both closed. The blower motor output for the
RM7800E is not energized until the High Fire Switch
is closed.
c. The ,Preignition Interlock input must remain closed
throughout PREPURGE; otherwise, control returns
to the STANDBY state and holds (30 seconds) for
the RM7800/RM7840G,M or safety shutdown for the
RM7800/RM7840E,L occurs.
d. The Lockout Interlock or Running Interlock inputs
(interlock circuit including Airflow Switch) must close
by ten seconds into PREPURGE; otherwise, a
recycle to the beginning of PREPURGE for the
RM7800/RM7840G,M will happen ar a safety
shutdown for the RM7800/RM7840E,L occurs.
e. When PREPURGE timing is complete, the firing rate
motor drives t6 the low fire position,
RM7800/RM7840E,G,L.
f. When the firing rate motor reaches low fire position,
the Low Fire Switch, terminal 18, input must be
energized before entering the Ignition Trial state.
11 66-1085-3
RM7800E, G,L,M; RM7840E,G,L,M 7800 SERIES RELA Y MODULES

Ignition Trials (a) Not turned off, or

1. Pilot Flame Establishing Period (PFEP):
a. With the firing rate motor at the low fire position:
(1) The pilot valve and ignition transformer,
terminals 8, 10 and 21, are energized. The
RM7800M has an intermittent pilot valve,
terminal 21. The RM7800/RM7840G has an
interrupted or intermittent pilot valve, terminal
21, depending on the selection of configuration
jumper 2. The RM7800/RM7840E,L has a
fifteen-second interrupted pilot valve, terminal
21. All of the RM7800/RM7840s haVe a
ten-second interrupted pilot valve/ignition,
terminal 8.
(2) During PFEP, the Low Fire Switch must remain
closed. If it opens, a safety shutdown occurs.
(3) The Preignition Interlock input is ignored
throughout the Ignition Trial state.
b. Flame must be proven by the end 6f the ten-second
PFEP (four if JR1 is clipped) to allow the seg~ence
to continue. If flame is not proven by the enoYif· .
PFEP, a safety shutdown occurs.
c. After five seconds, the ignition, terminal 10, is
de-energized for early spark termination.
2. Main Flame Establishing Period (MFEP):
a. Terminal 9 is energized when the presence.of flame
is verified at the end of a 10-second Pilot Flame
Establishing Period (PFEP) (four seconds if JR1 is
clipped).
b. Terminal 8 is turned off 10 seconds after Terminal 9
is energized.
c. Terminal.21 action:
(1) RM7800E,URM7840E,L: De-energized
15 seconds after Terminal 9 is energized.
(2) RM7840G:
(b)15 seconds after Terminal 9 is energized and
JR2 is clipped, or
(c)30 seconds after Terminal 9 is energized and
Terminals 5 and 19 are jumpered and jumper
JR2 is clipped.
(3) RM7800L 1053, RM7840L 1026,
RM7800M/RM7840M: Remain energized as
long as call for heat is present.
Run
1. A ten-second stabilization period occurs at the
beginning of the RUN period.
~. The firing rate motor releases to modulation
(RM7800/RM7840E,G,L). Damper motor is energized
(RM7800/RM7840M).
3. The RM7800/RM784P is now in RUN and. r"mains in
RUN until the controller input, terminal 6, .opens,
indicating that the demand is·satisfiedor a.limit opened.
Postpurge
The RM7800/RM7840 provides a fifteen-second
POSTPURGE following the completion of the RUN period.
The blower motor output is powered to drive all products of
combustion and any unburned fuel from the combustion
chamber. It also supplies combustion air to burn fuel being
purged from the fuel line downstream of the fuel shutoff valve.
1. The main fuel valve and intermittent pilot valve,
Terminals 9 and 21, are de-energized and the firing rate
motor is commanded to the low fire position to begin the
POSTPURGE period.
2. The Preignition Interlock closes within the first five
seconds of POSTPURGE.

Table 6. Sequence Timing for Normal Operation.

Flame Establishing
Period Post- Firing Energy Approval
Purge Interlock Rate Saving Code
Device Initiate Standby Purge Pilot Main a Run Timing Circuits Circuit Prepurge Bodies
RM7800El 10 sec .. • •• 4 or 10 10 or 15 • 15 sec. Preignition, 4-wire Yes FMIIRI
RM7840E sec. sec. Lockout, modulating Modulating
High and
.. Low Fire
RM7800GI 10,15 sec. Preignition, No UUCSA
RM7840G or Running, Modulating
intermittent Low Fire
RM7800U 10 or 15 Preignition, FMIIRI
RM7840L sec. b Lockout, Modulating
High and
Low Fire
RM7800MI 10 sec. or Preignition, 2-wire UUCSA
RM7840M intermittent Running, isolated On-Off
Low Fire On-Off-On
contacts
• STANDBY and RUN can be an mfinlte time penod.
"PURGE determined by which ST7800A purge card is selected.
a The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.
, See Fig. 2, 3,4, 5 and 6.
'b RM7800L 1053, RM7840L 1026: 10 second or intermittent.

66-1085-3 12
 RM7800E,G,L,M; RM7840E,G,L,M 7800 SER/ES RELAY MODULES

Keyboard Display Module (VFD)

The Keyboard Display Module (see Fig. 5) is provided with the
RM7800 Relay Module (but is not required for operation) and
is an option for the RM7840 Relay Module. The first line of the
Vacuum Fluorescent Display (VFD) provides:
Current status of the burner sequence (STANDBY,
PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE).
Timing information (PURGE, PILOT IGN, MAIN IGN and
POSTPURGE) in minutes and seconds.
Hold information (PURGE HOLD: T19).
Lockout information (Lockout, Fault Code, Message and
Sequence).
The extreme right side of the first line is either blank or shoWs
a small arrow pointing to the second line followed by a
two-letter code (DI-Diagnostic Information, Hn-Fault History.
Information, and EA-Expanded Annunciator). When thearr6w
and two-letter code are displayed, it iridicatesllie second line
is showing a selectable message submehu:The.'si;cor\(j line
displays/selectable or preemptive n:essages. ..
A selectable message supplies information for flame strength,
system status indication, system or self-diagnostics and
troubleshooting.
A preemptive message has parentheses around the message
and supplies a detailed message to support the sequence
status information. A preemptive message can also be a
lockout message. A preemptive message r~placesa
selectable message to support the sequence status
information. It also replaces a selectable message after 60
Seconds if it or a lockout message is available.
Run/Test Switch
3. In Prepurge Drive to Low Fire position, the Run/Test
Switch, when placed in the TEST position, holds the
burner sequence in PREPURGE with the firing rate
motor in the Low Fire position.
4, In PFEP, the RunlTest Switch, when placed in the TEST
position, stops the timer during the first eight seconds
when a ten second PFEP is selected or during the first
three seconds when a four second PFEP is selected,
allowing piloHurn-down test and other burner
adjustments to be made. This activates a fifteen second
flameout timer that permits pilot flame adjustm!'nt
wit,hout nuisance safety shutdowns. The RunlTe.st
Switch is ignored during PFEP for the RM7a001'
RM7840E,L if Terminals 8 and 9 or 9 and 21 are
jumpered. • .' i '; /.'"
5. During Run, the RunlTest Switch, 'whim'placed in'fhe '
TEST position, drives the firing rate motbr to the Low
Fire. position. ,.; '.
NOTE: When RM7600/RM7640 is swiiched to ihe Test
mode, it stops and holds at the next RunlTest Switch
point in the operating sequence, Make sure that the
RunlTest Switch is in the RUN position before
leaving the installation.
SETTINGS AND ADJUSTMENTS
Selectable Site-Configurable Jumpers
The RM7800/RM7640 has three site-configurable jumper
options, see Fig. 6 and Table 7. If necessary, clip the
site-cbnfigurable jumpers with side cutters and remove the
resistors from the Relay Module.

AWARNING \ ",,'''C 'A"'" CONFIGURATJON JUMPERS

Explosion Hazard.
Can cause serious injury or death.
Do not use the RunlTest switch during the Pilot Flame
Establishing Period for the RM7800/RM7840G,M
when using Direct Spark Function, because it turns on
the main gas valve, causing an accumulation of fuel in
the burner.

The Run/Test Switch is located on the top side of the

RM7800/RM7840, see Fig. 6. The RunlTest Switch allows the
burner sequence to be altered as follows:

1. In Prepurge Drive To High Fire Position, the RunlTest

Switch, when placed in the TEST position, holds in
PREPURGE with the firing rate motor·in the High Fire
position. . '
2. In the measured PREPURGE sequence, the RunlTest
Switch, when placed in the TEST position, causes the
PREPURGE timing to stop. The firing rate motor is in
the High Fire position. NOTE: CONFIGURATION JUMPERS SHOWN FOR RM7800G/RM7840G.
M12301

Fig. 6. Selectable site-configurable jumpers.

13 66-1085-3
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 7 Site Configurable Jumper Options.

Jumper Number Description Intact Clipped RM7800/RM7840 Type
(
JR1 Pilot Flame Establishing 10 seconds 4 seconds All
Period (PFEP)
JR2 Pilot Valvea/Main Flame 10 seconds 15 or 30 seconds Interrupted b RM7800G/RM7840G
Establishing Period (MFEP) Intermittent
JR3 Start-up Interlock Check Disabled Enabled All
a Pilot Valve IFirst Stage Oil Valve (Valve/Start) Terminal 21.
b A 30 second MFEP can be accomplished by adding a jumper wire between Terminals 1'9 and 5.
SERVICE NOTE:Clipping and removing a site-configurable jumper enhances the level of safety. Removal after 200 hours of
main valve operation will result in a hard lockout, Code 110.

STATIC CHECKOUT Equi~ment R\lS9mmen~~d >:.

After checking all wiring, perform this checkout before
installing the RM7800/RM7840 on the subbase. These tests
verify the Q7800 Wiring Subbase is wired correctly, and the
external controllers, limits, interlocks, actuators, valves,
transformers, motors and other devices are operating
properly,
AWARNING
Explosion and Electrical Shock Hazard.
Can cause serious injury, death or equipment
damage.
1. Close all manual fuel shutoffvalve(s) before starting
these tests.
2. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
3. Open the master switch before installing or
removing a jumper on the subbase.
4. Before continuing to the next test, be sure to
remove testjumper(s) used in the previous test.
5. Replace all limits and interlocks that are not
operating properly. Do not bypass limits and
interlocks.
LLCAUTION
Equipment Damage Hazard.
Improper testing can damage equipment.
Internal surge protectors can break down and conduct
a current, causing the RM7800/RM7840 to fail the
dielectric test or possibly destroy the internal'lightning
and high current protection. Do not perform a dielectric
test with the RM7800/RM7840 installed.
.1, Vo!tmej~r HM·ohrn/yolt.minill)um s",nsitivity)·set.clO!!1!3
0"3QO·\{9cs~al,,, . .i.. .',,'.
2, Two jumper'.,'!'ires; ,no. ·14 wire, insul')te,d" 12)nches
(304.8 mm) long with insulated alligator clips at both
ends.
General Instructions
1. Perform all applicable tests listed in Static Checkout,
2.
Table 8, in the order listed.
Make sure all manual fuel shutoff valve(s) are closed.
3. Perform only those tests designated for the specific
RM7800/RM7840 model being tested.
4. Raise the setpoint of the operating controller to simulate
a call for heat.
5. For each test, open the master switch and install the
jumper wire(s) between the subbase wiring terminals
listed 'in the Test Jumpers column.
6. Close the master switch before observing operation.
7. Read the voltage between the subbase wiring terminals
listed in the Voltmeter column.
,8. If there is no voltage or the operation is abnormal, check
the circuits and external devices as described in the last
column.
9. Check all wiring for correct connections, tight terminal
screws, correct wire, and proper-wiring techniques.
Replace all damaged or incorrectly sized wires.
10. Replace faulty controllers, limits, interlocks, actuators,
valves, transformers, motors and other devices as
required.
11. Make. sure normal operation is obtained for each
required test before Continuing the checkout.
12. After completing each test, be sure to remove the test
jumper(s).
AWARNING
Explosion Hazard.
Can cause ~~rious injury or death.
Make sure all manual fuel shutoff valves are closed
before performing static checkout.

66-1085-3 14
 RM7800E,G,L,M,' RM7840E,G,L,M 78bO SERIES RELAY MODULES

\ Table 8. Static Checkout.

RM78001
Test RM7840 Test If Operation is Abnormal,
No. Models Jumpers Voltmeter Normal Operation Check the Items Listed Below
1 All None 4-L2 Line voltage at Terminal 4. 1. Master Switch.
2. Power connected to the Master Switch.
3. Overload protection (fuse, circuit breaker,
etc.) has not opened the power line.
2 6-L2 Line voltage at Terminal 6. 1. Limiis.
2. Burner Controller.
3 ~

20-L2 Line voltage at Terminal 20. 1. Preignition interlocks.

4 4-5
..
7-L2 1. Burner motor (fan or 1. Burner mo~or s:)rcuih . n ','
blower) starts. a. Manual switch of tiiirner:motor.
2. Line voltage at Terminal b., BlJrner-motQI:.powediupp(y;-dverloag.,
7 within 10 seconds. protection, ~nd starter. " "',','
"
. yi'
;'
" ".,',",' '''!.
!

t·, ;s,tl?,~I.~er rJ:!c)tor.

2. Running or Lockout Interlocks (including
Airf)qw Switch).
5 4-10 - Ignition spark (if ignition 1. Watoh for spark or listen for buzz.
transformer is connected to a. Ignition electrodes are clean.
Terminal 10) b. Ignition transformer is okay.
6 All 4-8 - 1. Ignition spark (if ignition 1. Watch for spark or listen for buzz.
transformer is connected to a. Ignition electrodes are clean.
Terminal 8). b. Ignition transformer is okay.
2. Automatic pilot valve opens (if 2. Listen for click or feel head of valve for
connected to Terminal 8). activation.
a. Actuator if used.
NOTE: Refer to wiring diagram of h. Pilot valve.
system being tested.
7 4-21 - Same as test no. 6 for cbnnections Same as test no. 6. If using direct spark
to Terminal 8. If using direct spark ignition, check the first stage fuel valve(s)
ignition, check the first stage fuel instead of the pilot valve.
valve(s) instead of the pilot valve.
8 4-9 - Automatic main fuel valve(s) open. 1. Listen for and observe operation of the
If using direct spark ignition on a main
model with intermittent pilot on fuel valve(s) and actuator(s).
Terminal 21, check Ihe optional 2. Valve(s) and actuator(s).
second stage fuel valve, if used.
9 4-3 - Alarm (if used) turns on. 1. Alarm.
10 RM7800E,G,L; 4-5 18-L2 Firing rate motor drives open; Zero 1. Low Fire Start Switch.
RM7840E,G,L and volts at Terminal 18 after motor 2. Firing rate motor and transformer.
12-13 starts driving open.
11 RM7800E,G,L; 4-5 18-L2 Firing rate motor drives closed; line 1. Low Fire Start Switch.
RM7840E,G,L and voltage at Terminal 18 after motor 2. Firing rate motor and transformer.
14-13 is in Low Fire position.
12 RM7800E,L; 4-5 19-L2 Firing rate motor drives open; line 1. High Fire Purge Switch.
RM7840E,L and voltage at Terminal 19 after motor 2. Firing rate motor and transformer.
12-13 is in High Fire position.
13 RM7800E,L; 4-5 19-L2 Firing rate motor drives closed; 1. Low Fire Start Switch.
RM7840E,L and zero valls at Terminal 19 after 2. Firing rate motor and transformer.
14-13 motor starts driving closed.
14 RM7800E,G,L; 15-13 - 1. Raise selpoinl of Series 90 1. Series 90 Controller.
RM7840E,G,L controller-firing rate motor 2. Firing rate motor and transformer.
should drive toward open.
2. Lower selpoint of Series 90
controller-firing rate motor
should drive toward closed.

15 66-1085-3
RM7800E,G,L,M; RM7840E,G,L,M 7800 SERIES RELAY MODULES

Table 8. Static Checkout. (Continued)

RM78001
Test RM7840 Test If Operation is Abnormal,
No. Models Jumpers Voltme,ter Normal Operation Check the Ite",s Listed Below
15 RM7800M; 14-13 - If damper motor is used, motor Damper motor.
RM7840M with drives damper open.
open damper
contacts ..
16 RM7800M; 4-5 18-L2 If damper motor is used, motor 1. Low Fire Start Switch.
RM7840M with drives open; line voltage at 2. Damper motor.
open damper Terminal 18 after motor is in Low
contacts .. Fire position.
17 RM7800M; 4-5 18-L2 If damper motor is used, motor 1. Low Fire Start Switch.
RM7840M with and drives open; zero volts at 2. Damper motor.
open damper 4-13 Terminal 18.
contacts ..
Final All
& CAUTION Equipment. Damage Hazard.
I Improper wiring can damage equipment.
On completing these tests, open the master switch and remove all test jumpers from the
subbase terminal. Also remove bypass jumpers from the low fuel pressure limits (if used) to
prevent equipment damage.

Honeywell
Automation .and Control Solutions
Honeywell Honeywell Limited-Honeywell Limitee
1985 Douglas Drive North 35 Dynamic Drive
Golden VaUey, MN 55422 Scarborough, Ontario
M1V 4Z9

66-1085-3 G.R. Rev. 02-02 Printed in Mexico www.honeywell.com

 Honeywell

7800 SERIES
Relay Modules

This publication provides general checkout and troubleshooting procedures for the 7800 SERIES Relay Modules.

SYSTEM CHECKOUT it. CAUTION

IMPORTANT
Perform all Static Checkout Procedures in the
applicable relay module installation instructions
before starting these procedures.
Equipment Malfunction or Damage Hazard.
Each relay module type is unique. Using existing
wiring on a relay module change can cause
equipment damage.
Make wiring changes when a relay module is replaced

A WARNING
Explosion Hazard.
with a different 7800 SERIES Relay Module to
sequence burner.

Can cause serious injury or death. IMPORTANT

Do not allow fuel to accumulate in the combustion
chamber for longer than a few seconds wiihout
igniting to prevent danger of forming explosive mixture
Close manual fuel shutoff valve(s) if flame is not
burning at end of specified time.
A WARNING
1. If the system fails to perform properly, note the
fault code, fault message, equipment status, and
sequence time on the display. Then refer to the
Troubleshooting section.
2. Repeat all required Checkout tests after all
adjustments are made. All tests must be satisfied
with the flame detector(s) in their final position.

Electric Shock Hazard.

Can cause serious injury or death.
Equipment Recommended
1. Use extreme care while testing system. Line S7800A Keyboard Display Module
voltage is present on most terminal connections Volt-ohmmeter (1 M ohm/volt minimum sensitivity) with:
when power is on. 0-300 Vac capability.
2. Open master switch before removing or installing 0-6000 ohm capability.
7800 SERIES Relay Module or Keyboard Display 0-10 Vdc capability.
Module connector.
Checkout Summary
Make sure all manual fuel shutoff valve(s) are closed before
starting initiallightoff check and Pilot Turndown tests. Table 1 provides an overview of checkout steps performed for
each applicable system.
Do not put the system in service until you have satisfactorily
completed all applicable tests in this section and any others See Installation Instructions for location of component parts
recommended by the original equipment manufacturer.. andlor Q7800 Specifications for terminal locations.

Limit trial for pilot to ten seconds. Limit the attempt to light
main burner to two seconds after fuel reaches burner nozzle.
Do not exceed manufacturer nominallightoff tim~.

® U.S. Registered Trademark

Copyright© 1998 Honeywell Inc. • All Rights Reserved
IIIIII111
65-0229-1
7800 SERIES RELAY MODULES

Table 1 Checkout Steps and Applicable 7800 Series Systems

Piloted Infrared Flame Flame Rod Ultraviolet Flame
Checkout Step Systems DSI Systems Detectors Systems Detectors
Preliminary Inspection X X X X X
Flat(1e Signal Measurement X X X X X
Initial Lightoff Check for X
Proved Pilot
Initial Lightoff Check for X
Direct Spark !,gnition
Pilot Turndown Test X
Ignition Interference Test X
Hot Refractory Saturation X
Test
Hot Refractory Hold-in X X X X X
Test
Ignition Spark Pickup X
Response to Other X
Ultraviolet Sources
Flame Sign'al with Hot X X X X . )(c
Combustion Chamber
Safety Shutdown Tests X X X X X

Preliminary Inspection INITIAL LlGHTQFF CHECKS

Perform the following inspections to avoid common problems,
Make certain that:
1. Wiring connections are correct and all terminal screws
are tight
2, Flame detector(s) is clean, installed and positioned
properly, Consult the applicable Instructions,
3, Combination of amplifier and flame detector(s) is
correctly used, See the amplifier specifications,
4, Plug-in amplifier and purge card (if required) are
securely in place,
6, Burner is completely installed and ready to fire; consult
equipment manufacturer instructions, Fuel lines are
purRed of air,
6, Cor'nbustio,f'chamber and flues are clear of fuel and
fuel vapor,
7, Power is connected to the system disconnect switch
(master switch).
8, Lockout is reset (reset button) only if the Relay Module
is powered.
9. RunlTest Switch (if present) is in RUN position.
16., System is in STANDBY condition, STANDBY message
is displayed in the S7800 Keyboard Display Module,
11. All limits and interlocks are reset
'Flame Signal Measurement
See instructions provided with the amplifer,
Proved Pilot Systems
Perform this check on all installations that use a pilot It
should immediately follow the preliminary inspection.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this check.
1. Open the master switch.
2, Make sure that the mahual' main fueishutoff valve(s) is
closed. Open the manual pilot shutoff valve. If the pilot
takeoff is downstream from the m\>nual main fuel ,,
shutoff valve(s), slightly open the manual main valve'td
supply pilotgas flow.' Make sure the main fuel is slilitoff
just upstream from the burner inlet, or disconnect power
from the automatic main fuel valve(s).
3. Close th'e master switch imd'start the system withe. call
for heat by raising the'setpoint of the operating ,--'
controller, see the relay module sequence. The 7800
Series'Fl'elay Mddtile Should start the 'INITIATE
sequence.
4. Let the sequence advance to PILOT IGt'J (status is
displayed on the Keyboard Display Module, if used),
PILOT LED turns on, ignition spark should occur and
the pilot should light. If the pilot ignites, the FLAME LED
is energized. Go to step 7.
5. If the pilot flame is not established in ten seconds (four
seconds if configuration jumper JRl is clipped), safety
shutdown occurs. Let the sequence complete its cycle.
6. Push the reset pushbutton, and let the system recycle
once. If the pilot still does not ignite, make the following
ignition/pilot adjustments:
a. Open the master switch and remove the 7800
Series Relay Module from the subbase.

65-0229-1 2

b. On the subbase, jumper L1 to the ignition
terminal; refer to the appropriate wiring diagram
to determine the proper terminal. Disconnect the
leadwire to the pilot valve if it is connected to the
same terminal.
c. Close the master switch to energize only the
ignition transformer.
d. If the ignition spark is not strong and continuous,
open the master switch and adjust the ignition
electrode spark gap setting to the manufacturer
recommendation.
e. Make sure the ignition electrodes are clean.
f. Close the master switch and observe the spark.
g. After a continuous spark is obtained, open the
master switch and add a jumper on the subbase
from terminal L1 power to the pilot terminal 8 or
21. Reconnect the leadwire from the pilot valve if
it was disconnected in step b.
h. Close the master switch to energize both the
ignition transformer and the pilot valve.
i. If the pilot does not ignite and if the ignition spark
is still continuous, adjust the pressure regulator
until a pilot is established.
j. When the pilot ignites properly and stays ignited,
open the master switch and remove the jumper(s)
from the terminals of the subbase.
k. Check for adequate bleeding of the fuelline.
I. Reinstall the 7800 Series Relay Module on the
subbase, close the master switch, and then return
to step 4.
7. When pilot ignites, measure the flame signal. If the pilot
flame signal is unsteady or approaching the 1.25 Vdc
minimum value, adjust the pilot flame size or detector
sighting to provide a maximum and steady flame signal.
8. Recycle the system to recheck lightoff and pilot flame
signal.
9. When the MAIN LED turns on, make sure the automatic
main fuel valve is open; then smoothly open the manual
main fuel shutoff valve(s) and watch for main burner
flame ignition. When the main burner flame is
established, go to step 16.
10. If themain buirier flame is not established within five
seconds or the normallightoff time as specified by the
equipment manufacturer, close the manual main fuel
shutoff valve(s).
11. Recycle the system to recheck the lightoff and pilot
flame signal.
12. SmoothlY open the manual fuel shutoff valve(s) and try
lightoff·again. (The first re-attempt may·have been
required to purge the lines and bring sufficient fuel to
the burner:)
13. If the main burner flame is not established within five
seconds or the normal lightoff time specified by the
eqUipment manufacturer, close the manual main fuel
. shutoff valves(s). Check all burner adjustments.
14. If the· main burner flame is not established after two
attempts:
A. Check for improper pilot size.
S. Check for excess combustion air at low fire.
C. Check for adequate low fire fuel flow.
D. Check for proper gas supply pressure.
E. Check for proper valve operation.
F. Check for proper pilot flame positioning.
15. Repeat steps 8 and 9 to establish the main'llurner
flame; then go to step 16.
16. With the sequence in RUN, make burner adjustments
for flame stability and Btu input rating.
3 65-0229-1
7800 SERIES RELAY MODULES
17. Shut down the system by opening the burner switch or
by lowering the setpoint of the operating controller.
Make sure the main flame goes out. There may be a
delay due to gas trapped between the valve(s) and
burner. Make sure all automatic fuel valve(s) close.
18. Restart the system by clOSing the burner switch andlor
raising the setpoint of the operating controller. Observe
that the pilot is established during PILOT IGN and the
main burner flame is established during MAIN IGN
within the normallightoff time.
19. Measure the flame signal. Continue to check for the
proper signal through the RUN period. Check the signal
at both High and Low Firing Rate positions and while
modulating, if applicable.
20. Run the burner through another sequence, obServing
the flame signal for:
a. Pilot flame alone.
b. Pilot and main flame together.
c. Main flame alone (unless monitoring an
intermittent pilot). Also observe the time it takes
to light the main flame. Ignition of main flame
should be smooth.
21. Make sure all readings are in the required ranges
before proceeding.
22. Return the system to normal operation.
NOTE: Afler completing these tests, open the master switch
and remove all test jumpers from the subbase
terminals, limits/controls or switches.
Direct Spark Ignition Systems
This check applies to gas and oil burners not using a pilot. It
should immediately follow the preliminary inspection. Refer to
the appropriate sample block diagram of field wiring for the
ignition transformer and fuel valve(s) hookup.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this check.
1. Open the master switch.
2. Complete the nonmal ready-to-fire checkout of the fuel
supply and equipment as recommended by the
equipment manufacturer.
3. Close all manual main fuel shutoff valve(s). Check that
the automatic fuel valve(s) is closed. Make sure fuel is
not entering the combustion chamber.
4. Close the master switch and start the system with a call
for heat by raising the setpoint of the operating
controller; see the relay module sequencing. The
program sequence should start the INITIATE sequence.
5. Let the sequence advance through PREPURGE (if
applicable), Ignition spark should ocCUr when the PILOT
LED turns on. listen for the click of the first stage fuel
solenoid valve(s). The relay module locks out and the
ALARM LED turns on.
6. Let the 7800 Series Relay Module complete its cycle.
7. Open the manual fuel shutoff valve(s).
8. Push the reset button and the relay module recycles the
program sequence through PREPURGE (if applicable).
9. When the PILOT LED turns on, make sure that the first
stage burner flame is established. If it is, go to step 15.
10. If the first stage burner flame is not established within
four seconds, or within the normallightoff time specified
bY the eqUipment manufacturer, close the manual fuel
shutoff valve(s), and open the master switch.
11. Check all burner adjustments.
7800 SERIES RELAY MODULES
12. Wait about three minutes. Close the master switch,
open the manual fuel shutoff valve(s), and try to light off
the burner again. The first attempt may be required to
purge the lines and bring sufficient fuel to the burner.
13. If the first stage burner flame is not established within
four seconds, or within the normallightoff time specified
by the equipment manufacturer, close the manual fuel
shutoff valve(s), and open the master switch.
14. If necessary, repeat steps 11 through 13 to establish
the first stage burner flame. Then go to step 15.
15. When the first stage burner flame is established, the
sequence advances to RUN. Make burner adjustments
for flame stability and input rating. If a second stage is
used, go to step 18.
16. Shut down the system by opening the burner switch or
by lowering the setpoint of the operating controller.
Make sure the burner flame goes out and all automatic
fuel valves close.
17. If used, remove the bypass jumpers from the low fuel
pressure limit and subbase.
18. If a second stage is used, make sure the automatic
second stage fuel valve(s) opened. Check the lightoff as
follOWS (or go to step 19):
a. Open the manual second stage fuel valve(s).
b. Restart the system by raising the setpoint of the
operating controller.
c. When the first stage burner flame is established,
watch for the automatic second stage fuel
valve(s) to open. Observe that the second stage
lights off properly.
d. Make burner adjustments for flame stability and
input rating.
e. Shut down the system by lowering the setpoint of
the operating controller. Make sure the burner
flame goes out and all automatic fuel valves
close.
f. Go to step 19.
19. Restart the system by closing the burner switch andlor
raising thesetpoint of the operating controller. Observe
that the burner flame is established during PILOT IGN,
within the normallightoff time specified by the
equipment manufacturer.
20. Measure the flame signal. Continue to check for the
proper signal through the RUN period. Check the signal
at both high and low firing rate positions and while
modulating. Any pulsating or unsteady readings require
further attention.
21. Make sure all readings are in the required ranges
before proceeding.
NOTE: On completing these tests, open the master
switch and remove all test jumpers from the
subbase terminals, limits/controls or switches.
22. Return the system to normal operation.
PILOT TURNDOWN TI=ST (ALL
INSTALLATIONS USING A PILOT)
Perform this check on all installations that use. a pilot. The
purpose of this test is to verify that the main burner can be lit
by the smallest pilot flame that can hold in the flame amplifier
and energize the FLAME LED. Clean the flame detector(s) to
make sure that it detects the smallest acceptable pilot flame.
65-0~~9-1
If using AMPLI-CHECKTM or self-checking amplifier and 1M
ohm/volt meter, the flame Signal fluctuates every time the
amplifier does a self-check or a shutter check.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this test.
1. Open the master switch.
2. Close the manual main fuel shutoff valve(s).
3. Connect a manometer (or pressure gauge) to measure
pilot gas pressure during the turndown test.
4. Open the manual pilot shutoff valve(s).
5. Close the master SWitch' and start the system with a call
for heat. Raise the setpoint of the operating controller.
The 7800 Series sequence should start, and
PREPURGE (if applicable) should begin.
6. After the PILOT LED turns on in interrupted pilot
applications, set the Run/Test Switch to the TEST
position to stop the sequence. The FLAME LED .comes .
on when the pilot ignites.
NOTE: If the sequence does not stop, reset the .
system and make sure you set the Runrrest
Switch to TEST within the first eight seconds
of the PILOT IGN sequence.
IMPORTANT
You have 0.8 second or three seconds, depending
on PFEP selected, to position the RunlTest Switch to
the TEST position 10 stop the sequence after the
statt of the PILOT IGN period.
7. Turn down the pilot pressure very slowly, reading the
manometer (or pressure gauge) as it drops. Stop
instantly when the FLAME LED goes out. Notelhe
pressure. The pilot is at the minimum turndown position.
Immediately turn up the pilot pressure until the FLAME
LED comes on again or.the flame sigl1al increases to
1.25Vdc.
. '
NOTE: If there is no flame for fifteen second.s, with the
RtJNrrE9T s)'litch In the TEST pOSition, the
relay module locks OUt.
8. Repeat step 7 to verify the pilot gas pressure-reading at
the exact paint the FLAME LED light goes out. .
9. Increase the pilot pressure immediately until the
FLAME LED comes on, and then turn it down slowly to
obtain a pressure reading just above the dropout point
or until the flame signal increases to 1.25 Vdc. .
10. Set the Runrrest Switch in the RUN position (if used)
and let the sequence proceep. When the MAIN'LI;D
turns on, make sure the automatic. main fuel valve(s)
opens; then smoothly open the man~al main fuel,
shutoff valve(s) (or any other manually·openei:j,safety
shutoff valve(s), if used) and watch for main purner
ignition. If the main burner flame is established"go to
step 18.
NOTE: This.step re~Yires two people, one to open the
manual valve(s) anq one to "!!ltch for ignition.
11. If the main burner flame is'n01 establishid within five
seconds,or within the norm.allightoff time,sp~Rjfied by.
the equipment manufacturer, close the manual inain
fuel shutoff valve(s).and open: the m~ste,-switc". If the.
lightoff is rough, the pilot flame size is.loo small.
4

12. Close the master switch to recycle the burner and stop
the sequence in the PILOT period by using the Runl
Test Switch.
13. Increase the pilot flame size by increasing its fuel flow
until a smooth main flame is accomplished.
14. Reposition the flame scanner sight tube or use orifices
until the pilot flame signal voltage is in the range of 1.25
to 1.50 Vdc.
15. When the main burner lights reliably with the pilot at
turndown, disconnect the manometer (or pressure
gauge) and turn up the pilot gas flow to that
recommended by the equipment manufacturer.
16. If used, remove the bypass jumpers from the subbase
terminals, limits/controls, or switches.
17. Run the system through another cycle to check for
normal operation.
18. Rellirn the system to normal operation.
IGNITION INTERFERENCE rEST
(ALL FLAME RODS)
Ignition interference can subtract from (decrease) or add to
(increase) thellame signal. If it decreases the flame signal
enough, it causes a safely shutdown. If it increases the flame
signal, it could cause the FLAME LED to come on when the
true flame signal is below the minimum acceptable value.
Start the burner and measure the flame signal with both
ignition and pilot (or main burner) on, and then with only the
pilot (or main burner) on. Any significant difference (greater
than .5 Vdc) indicates ignition interference.
To Eliminate Ignition Interference
1. Make sure there is enough ground area.
2. Be sure the ignitionelectiode and the flame rod are on
opposite sides of the ground area.
3. Check for correct spacing on the igriition electrode:
a. 6000V systems-1/16 to 3/32 in. (1.6 to 2.4 mm).
b. 10,00DV systems-1/B in. (3.2 mm).
4. Make sure the leadwires from the flame rod and ignition
electrode are not too close together.
5. Replace any deteriorated leadwires.
6. If the problem cannot be eliminated, consider changing
the system to an ultraviolet flame detection system.
Hot Refractory Saturation Test
(All Infrared Detectors)
Start the burner and monitor the flame signal during the
warmup period. Adecrease in signal strength as the
refractory heats up indicates hot. refractory saturation. If
saturation is extreme, the flame signal drops below 1.25 Vdc
and the system shuts down as though a flame failure
occurred.
If hot refractory saturation occurs, the condition must be
corrected. Add an orifice pl",te in front of the cell to restrict the
viewing area, lengthen the sight pipe or decrease the pipe
size (diameter). Continue adjustments until hot refractory
saturation is eliminated.
5 65·0229-1
7800 SERIES RELAY MODULES
Hot Refractory Hold-in Test
(Rectifying Photocell, Infrared Detectors,
Ultraviolet Detectors)
This condition can delay response to flame failure and also
can prevent a system restart if hot refractory is detected.
Infrared (lead sulfide) detectors can respond to infrared rays
emitted by a hot refractory, even when the refractory has
visibly ceased to glow. Infrared radiation from a hot refractory
is steady, but radiation from a flame has a flickering
characteristic. The infrared detection system responds only to
flickering infrared radiation; it can reject a steady signal from
hot refractory. The refractory steady signal can be made to
fluctuate if it is reflected, bent or blocked by smoke or fuel
mist within the combustion chamber. Be careful when
applying an infrared system t6 verify its response to flame
only.
The ultraviolet detector can respond to hot refractory above
2300°F (1371°C).
1. Operate the burner until the refractory reaches ils
maximum temperature (Infrared Only).
If the installation has a multi-fuel burner, burn the
heavier fuel that is most likely to reflect, bend or
obscure the hot refractory steady infrared radiation
2. When the maximum refractory temperature is reached,
close all manual fuel shutoff valves, or open the
electrical circuits of all automatic fuel valves.
3. Visually obServe when the burner flame or FLAME LED
goes out. If this takes more than three seconds, the
infrared detector is sensing hot refractory.
4. Immediately terminate the firing cycle. Lower the
selpoint to the operating controller, or set the Fuel
Selector Switch to OFF. Do not open the master switch.
NOTE: Some burners continue to purge oil lines
between the valves and nozzles even though
the fuel valves are closed. Terminating the
firing cycle (instead of opening the master
switch) allows purging the combustion
chamber: This reduces a buildup of fuel vapors
in the combustion Chamber caused by oil line
purging.
5. If the detector is senSing hot refractory, correct the
condilion by one or more of the following procedures:
a. Add an orifice plate in front of the cell to restrict
Ihe viewing area of the detector.
b. Resight the detector .at a cooler, more distant part
of the combustion chamber. Make sure the
detector properly sights the flame.
c. Try lengthening the sight pipe or decreasing the
pipe size (diameter).
For details, refer to the detector Instructions and the
equipment Operating Manual. Continue adjustments until hot
refractory hold-in is eliminated.
7800 SERIES RELAY MODULES
IGNITION SPARK RESPONSE TEST
(ALL,ULTRAVIQLJfT DETECTORS)
Test to make certain that the ignition spark is not actuating
the FLAME LED:
1. Close the pilot and main burner manual fuel shut·off
valve(s).
2. Start the burner and use the RunfTest Switch (if
available) to stop the sequence in the PILOT IGN
period. Ignition spark should occur, but the flame signal
should not be more than 0.5 Vdc.
3. If the flame signal is higher than 0.5 Vdc and the
FLAME LED does come on, consult the equipment
operating manual and resight the detector farther out
from the spark; or away from possible reflection. It may
be necessary to construct a barrier to block the ignition
spark from the detector view. Continue adjustments
until the flame signal due to ignition spark is less than
0.5 Vdc.
NOTE: The Honeywell Q624A and Q652A,B Solid State
Spark Generators prevent detection' of ignition spark
when properly applied with C7027, C7035, C7044 or
C7061 Ultraviolet Flame Detectors. The Q624A and
Q652B are only for use with gas pilots; the Q652A Is
only for oil applications.
Response To Other Ultraviolet Sources
Some sources of artificial light (such as Incandescent or
fluorescent bulbs, mercury sodium vapor lamps and daylight)
produce small amounts of ultraviolet radiation. Under certain
conditions, an ultraviolet detector responds to these sources
as If It Is sensing a flame, To check for proper detector
operation, check the Flame Failure Response 11me (FFRT)
and conduct Safety Shutdown Tests under all operating
conditions.
Flame Signal With Hot Combustion Chamber
(All Installations)
1. With all Initial start-up tests and burner adjustments
completed, operate the burner until the combustion
,chamber is at the maximum expected temperature.
2. Observe the equipment manufacturer warm-up
Instructions.
3. Recycle the burner under these hot conditions and
measure the flame signal. Check the pilot alone, the
main burner flame alone, and both together (unless
monitoring only the pilot flame When, using an
intermittent pilot, or only the main burner flame when
using DSI). Check the signal at both High and Low
Firing Rate positions and while modulating, if
applicable.
4. Check the FFRT of the flame amplifier and relay
module.
5. Lower the setpoint of the operating controller and
observe the time it takes for the burner flame to go out.
This should be within the maximum FFRT.
6. If the flame signal is too low or unsteady, check the
flame detector temperature. Relocate the detector if the
temperature is too high.
7. If necessary, realign the sighting to obtain the proper
signal and response time.
S. If the response time is still too slow, replace the Plug-in
Flame Signal Amplifier.
65-0229-1
9. If the detector is relocated or resighted, or the amplifier
is replaced, repeat all required Checkout tests.
SAFETY SHUTDOWN TESTS
(ALL INSTALLATIONS)
Perform these tests at the end of Checkout, after all other
tests are completed. If used, the external alarm should turn
on. Press the .RESET pushbutton on the relay module to
restart the system.
1. Opening a Preignition Interlock during the STANDBY or
PREPURGE period (only for RM7800, EC/RM7840,
RM7838B, EC7810, EC7820, EC/RM7830, ECI
RM7850).
a. "Preignition ILK" fault is displayed on the
Keyboard Display Module. Fault code 10 or 33 is
displayed to denote the fault.
b. Safety shutdown occurs. .'
2. Opening a Lockout Interlock during PREPURGE,
PILOT IGN, MAIN IGN or RUN period «)nly for
RM7800, EC/RM7840, RM7838B, EC7810, EC7820,
EC/RM7830, EC/RM7850).
a. "Lockout ILK" fault is displayed on :the Keyboard
Display Module, Fault code 11 or 12 or 21 or 29 Is
displayed to denote the fault.
b. Safety shutdown occurs.
3. Detection of flame 40 seconds after entry to STANDBY
from RUN, fault code 9. Detection of flame from ten
seconds up to 30 seconds Into PREP URGE time.
a. Simulate a flame to cause the flame signal
voltage,level to be at least 1.25 Vdc for 40
seconds after entry to STANDBY from RUN and
also slmul.ate a flame signal for 10 seconds to
30 seconds for PREPURGE.
b. "Flame Detected" fault Is displayed on the
Keyboard Display Module, Fault code 9 or 15 or
181s displayed to denote·the fault.
c. Safety shutdown opcu·rs.
4. Failure to Ignite pilot. ,
a. Close pilot and main fuel manual shutoff valve(s).
b. Cycle burner on,
c. Automatic pilot valve(s) should,be energizlld but
the pilot cannot ignite.
d. "Pilot Flame Fail" fault Is displayed on the
Keyboard Display Module. Fault code 28 Is
displayed four or ten seconds, depending on the
jumper configurati.on selection for Rilo! flame
Establishing Period (PFEP) after the pilot valve(s)
is energized to denote the fault. •
e. Safety shutdown occurs.
5. Failure to ignite main (only interrupted pilot application).
a. Open the manual pilotvalve(s); leave'the main
fuel manual shutoff valve(s) biased.
b. Depress the RESET button.
c. Start the system.
d. The pilot should ignite and the flame slgnill
should be at least 1.25 Vdc but the main burner
cannot light.
e. The flame signal should drop below 1.25Vdc
within the FFRT of the amplifier and the r~lay
module aiter the interrupted pilot goes out.
f. "Main Flame Ign: fault is displayecf on the
Keyboard Display Module. Fault code 19 is
displayed to denote the fault.
g. Safety shutdown occurs.
6

6. Loss of flame during RUN.
a. Open the main fuel manual shutoff valve(s) and
open manual pilot shutoff valve(s).
b. Depress the RESET button.
c. Start the system. Start-up should be normal and
the main burner should light normally.
d. After the sequence is in the normal RUN period
for at least ten seconds with the main burner
firing, close the manual main fuel shutoff valve(s)
to extinguish the main burner flame. (On
intermittent pilot applications, also, close the pilot
manual shutoff valve.)
e. The flame signal should drop below 1.25 Vdc
within the FFRT of the amplifier and the relay
module after the main flame andlor pilot goes out.
f. <Main Flame Fail< fault is displayed on the
Keyboard Display Module. Fault code 17 is
displayed to denote the fault.
g. Safety shutdown occurs. (ECIRM7890, ECI
RM7895, RM7896 relay modules will recycle if
jumper JR2 is intact, then lock out on failure to
light the pilot.)
7. Opening a Preignition Interlock after the first five
seconds of POSTPURGE.
a. Open the main fuel manual shutoff valve(s) and
open manual pilot shutoff valve(s).
b. Depress the RESET button.
c. <Preignition ILK< fault is displayed on the
Keyboard Display Module. Fault code 33 is
displayed to denote the fault.
d. Safety shutdown occurs.
IMPORTANT
1. If the relay module fails to shut down on any of
these tests, take corrective acf;on; refer"to
Troubleshooting and the relay module diagnostics
and return to the beginning of all Checkout tests.
2. When all Checkout tests are completed, reset all
switches to the original status.
TROUBLESHOOTING
System Diagnostics
Troubleshooting control system eqUipment failures is easier
with the refay module self-diagnostics and first-out
annunciation. In addition to an isolated spst alarm relay
(audible annunciation), the relay module provides visual
annunciation by displaying a fault code and fault or hold
message at the S7800 Keyboard Display Module (standard
on RM7800 and RM7838A,B devices; optional on all others).
The relay module provides 127 diagnostic messages for
troubleshooting the system (see Table 3).
Self-diagnostics of the relay module enables it to detect and
annunciate both external and internal system problems. Fault
messages, such as interlock failures, flame failures and false
flame' signals are displayed at the KDM, and annunciated at
the 7800 SERIES Relay Module by the ALARM LED.
7 65-0229-1
7800 SERIES RELAY MODULES
The KDM displays a sequence status message indicating:
STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN and
POSTPURGE. The selectable messages also provide visual
indication of current status and historical status of the
equipment such as: Flame Signal, Total Cycles, Total Hours,
Fault History, Diagnostic Information and Expanded
Annunciator terminal status (if used). With this information,
most problems can be diagnosed without extensive trial and
error testing.
Table 2 provides the sequence and status hold messages.
Table 3 is a summary of all relay module fault messages, fault
codes, and troubleshooting suggestions. In addition,
Diagnostic Information and History Data are available to
assist in troubleshooting the relay module.
The relay module provides diagnostic information to aid the
service mechanic in obtaining information when
troubleshooting the system. Information available in the
Diagnostic Information includes Device Type, Device Suffix,
Software ReVision, Manufacturing Code, Flame Amplifier
Type, Flame Failure Response Time, Selectable Jumper
Configuration Status, RunlTest Switch Status and Terminal
Status.
Diagnostic Information Index
The relay module monitors input/output terminals and can
display the status of the terminal at the KDM (see Table 2)
(example: Pilot Valve T81). See the applicable relay module
installation instructions for a complete terminal description
and number. The display shows the actual status of the
terminal. If voltage is detected at the terminal, 1 is displayed,
but if no voltage is detected at the terminal, 0 is displayed.
Historical Information Index
The relay module has nonvolatile memory that allows the
Relay Module to retain historical information· for the six most
recent lockouts. Each of the six lockout files retains the cycle
when the fault occurred, the hour of operation when the fault
occurred, a fault code, a fault message and burner status
when the fault occurred.
IMPORTANT
Some older relay modules can not operate without a
KDM, extension cable assembly with KDM or a Data
ControlBus Module™ installed.
SERVICE NOTES:
1. If the KDM is scrambled, remove and reinstall the
KDM, and reset the 7800 Relay Module.
2. Reset the 7800 Series Relay Module by pressing the
RESET pushbutton on the 7800 Series Relay
Module, or pressing a remote reset pushbutton wired
through the KDM, Data ControlBus Module™ or
Remote Reset Module. A power-up reset causes an
electrical reset of the relay module but does not
reset a lockout condition.
3. Use the access slots on the sides of the Q7800A,B
to check terminal voltage.
4. Maximum ambient operating temperature of a
C7012E,F; Series 1 through 6, is reduced to
125°F because of the duty cycle operation of the
relay module.
7800 SERIES RELAY MODULES

Table 2. Keyboard Display Module Sequence and Status Hold Messages.

Sequence Status
INITIATE mm:ss The Keyboard Display Module (KDM) indicates the burner status, INITIATE, a stabilization period
for the relay module to check for any fluctuations in ac line voltage inputs or control inputs on
power up or during normal operation. The timing of the INITIATE period is either two seconds or
ten seconds, depending on the model, before entering STANDBY.
If the relay module is in an INITIATE HOLD status, the following conditions could exist:
INITIATE HOLD: The KDM indicates the burner status and that it is Waiting for excess line noise to ciear up, which
(AG Frequency/Noise) prevents sufficient reading of the line voltage inputs. The burner sequence does not advance into
STANDBY until the excess line noise ceases or a line frequency error occurs; this is caused by
using a 60 Hz device on a 50 Hz line, or vice versa on devices with a date code earlier than 9804,
is corrected.
INITIATE HOLD: The KDM indicates the burner status and that ac line power has momentarily dropped out. The
(AG Line Dropout) burner sequence does not advance into STANDBY until the ac line voltage has stabilized
throughout the INITIATE sequence.
INITIATE HOLD: The KDM indicates the burner status and that line frequency is faster than the expected value.
(AG Frequency) The burner sequence does not advance into STANDBY until the line frequency returns to the
proper value; this is perhaps caused by using a 60 Hz device on a 50 Hz line for devices: with a
date code earlier than 9804.
INITIATE HOLD: The KDM indicates the burner status and that low line voltage (10% lower than rated voltage) has
(Low Line Voltage) occurred. The burner sequence does not advance into STANDBY until the line voltage is at a
sufficient level for proper operating parameters.
STANDBY The KDM indicates the burner status, STANDBY. The burner can be placed in STANDBY by
opening the burner switch or if the operating controller indicates its setpoint 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 an Expanded Annunciator is connnected, the display
messages are enhanced.
If the relay module is in a STANDBY HOLD status, the following conditions could exist:
STANDBY HOLD: The KDM indicates the burner status and that a flame is detected. A demand is present for burner
F/G (Flame Detected) operation. The sequence does not advance to PREPURGE until the flame signal clears. If the
flame Signal does not clear within 40 seconds, the relay module locks out.
STANDBY HOLD: T20 The KDM indicates the burner status and that the Preignition Interlock is not closed. A demand is
(Preignition Interlock) present for burner operation, but the burner sequence does not advance to PREPURGE until the
Preignition Interlock proves closed. If this time exceeds a 30 second hold, the relay module locks
out.
STANDBY HOLD: T7 The KDM indicates the burner status and that the Lockout Interlock is closed. A demand is
(Lockout Interlock) present for burner operation, but the burner sequence does not advance to PREPURGE until the
Lockout Interlock proves open. If this time exceeds the 120 second hold, the relay module locks
out.
STANDBY HOLD: T7 The KDM indicates the burner status and that the Running Interlock is closed. A demand is
(Running Interlock) present for burner operation, but the burner sequence does not advance to PREPURGE until the
T17 for EG/RM7810, Running Interlock proves open. If this time exceeds the 120 second hold, the relay module locks
7820, 7830, 7850 out.
devices
PURGE The KDM indicates the burner status, PURGE, Which is the period of time the blower motor is
running before the Ignition period. The timing of the PURGE period is selectable.
If the relay module is in a PURGE HOLD status, the following conditions could exist:
PURGE HOLD: T19 The KDM indicates the burner status and that the High Fire Switch is not closed. The firing rate
(High Fire Switch) motor is driving to its PURGE rate position. If this time exceeds four minutes and fifteen seconds,
the relay module locks out.
PURGE DELAY: T19 The KDM indicates the burner status and that the High Fire Switch is jumpered. The High Fire
(High Fire Switch Switch is bypassed, welded or otherwise prematurely closed. The system automatically adds 30
Jumpered) seconds to allow the firing rate motor additional drive time to reach or near the open damper
position before starting the PURGE sequence.
PURGE HOLD: TEST The KDM indicates the burner status and that the RunlTest Switch is in the TEST position. The
(Runrtest Switch) sequence does not continue until the RunlTest Switch is placed in the RUN position.
NOTE: Normal sequences are in bold type, while abnormal sequences are in regular type. This table is for all 7800 SERIES
Relay Modules so all listed steps may not apply to the unit installed.

65-0229-1 8
 7800 SERIES RELAY MODULES

Table 2. Keyboard Display Module Sequence and Status Hold Messages (continued).

Sequence Status
If the relay module is in a PURGE HOLD status, the following conditions could exist (continued)
PURGE HOLD: Ti8 The KDM indicates the burner status and that the Low Fire Switch is jumpered. The Low Fire
(Low Fire Switch Switch is bypassed, welded or otherwise prematurely closed. The system automatically adds 30
Jumpered) seconds to allow the firing rate motor additional drive time to reach or near the closed damper
position before starting the ignition sequence.
PURGE HOLD: FIG The KDM indicates the burner status and that a flame is detected. The burner sequence does not
(Flame Detected) advance through PREPURGEbecause a flame is detected as being present. The sequence holds
waiting for the flame signal to clear. If the time exceeds 30 seconds, the relay module locks out.
PURGE HOLD:Ti8 The KDM indicates the burner status and that the Low Fire Switch is not closed. The firing rate
(Low Fire Switch) motor is driving to its Low Fire position in preparation for Ignition Trials. If this time exceeds four
minutes and fifteen seconds, the relay module locks out.
PURGE HOLD: T7 The KDM indicates the burner status and that the Running Interlock is not closed. The sequence
(Running Interlock) does not advance to ignition until the Running Interlock proves closed. If this time exceeds 30
seconds, the relay module locks out.
PILOT IGN mni:ss The KDM indicates the burner status, PILOT IGN, and the timing of the PILOT IGN trial begins, in
seconds. During this period, the relay module permits the pilot valve to open and the pilot flame
to establish.
tf the relay module is in a PILOT HOLD status, the following condition could exist:
PILOT HOLD: TEST The KDM indicates the burner st<iius:'PILOT IGN, and that the RunfTest Switch is in the TEST
(RunfTest Switch) position. The sequence does not continue until the RunfTest Switch is placed in the RUN
position.
MAIN IGN mm:ss The KDM indicates the burner status, MAIN IGN, and the timing of the MAIN IGN trial begins, in
seconds. During this period, the relay module permits the main valve to open and the main flame
to establish.
,
RUN The KDM indicates the burner status, RUN, which is the period of time after the Ignition Trials and
) before the operating controller setpoint is reached. During this time, the burner is firing under
control of the firing rate control.
If the relay modul~ is in a RUN HOLD status, the following cpndition could exist:
RUN LOWFIRE: TEST The KDM indicates the burner status and that the RunfTest Switch is in the TEST position.
(RunfTest Switch) Normal modulation or operation does not continue until the RunfTest Switch is placed in the RUN
position.
POSTPURGE mm:ss The KDM indicates the burner status, POSTPURGE, which is the period of time after the RUN
period when the blower motor continues to run. The timing of the POSTf'URGE period is fifteen
seconds.
Waiting for The KDM has power but is waiting to receive a signal from the relay module to continue
connection ... operation.
RESET/ALARM TEST The KDM indicates the burner status, RESET/ALARM TEST. This condition indicates that the
reset button is pressed. If it is held for more than four seconds, the alarm output is energized. The
I
alarm output is de-energized when the reset button is released.
Additional Sequence Status Information When An Expanded Annunciator Is Connected To The Relay Module:
BuFiNER OFF: T6 The KDM indicates the'Burner Switch is not closed. The burner sequence does not advance to
(Burner Switch) PF\EPURGE until the Burner Switch clpses.
STANDBY The KQM indicates the tiumer st"ius, STANDBY, and that the Operating COntrol is nOlclosed.
The bumer sequence does not advance to PREPURGE until the Operating Control closes.
STANDBY HOLD: T6 The KDM indicates the burner status'; STANDBY, and that a limit is not closed. The burner
(EA Hold Message) sequence does not advance to PREPURGE until one or all limits close downstream from the
Operating Control.
STANDBY HOLD: T6 The KDM indicates the burner status, STANDBY, and that the control input is not closed. The
(Circuit Fault) burner sequence does noladvance to PREPURGE until the control input closes.

NOTE: Normal sequences are in bold type, while abnormal sequences are in regular type. This table is for all 7800 SERIES
Relay Modules so all listed steps may not apply to the unit installed.

9 65·0229-1
7800 SERIES RELAY MODULES

Table 3 Hold and Fault Message Summary

Fault Code System Failure
Fault 1 No card is plugged into the
"No Purge Card" purge card slot.
Fault 2 Excess noise or device
"AC Frequen/Noise" running on slow ae.
Fault 3 Ac line dropout detected.
"AC line Dropout"
Fault 4 Device running on fast ae.
"AC Frequency"
Fault 5 Low ac line detected.
"Low line Voltage"
Fault 6 Purge card timing changed
"Purge Card Error" since card was initially read.
Fault 7 Flame sensed when flame
"Flame Amplifier" not present.
Fault 8 Flame sensed when no
"Flame Amp/Shutr" signal expected during
shuUer-check or Ampli-
Check™ versions.
Fault 9 Flame sensed when shuUer
"Flame Detected" open and no flame is
expected during STANDBY.
Fault 10 Preignition Interlock fault
"Preignition ILK" during STANDBY
"EC/RM7800, 7840, 7838B
only).
Recommended Troubleshooting
1. Make sure the purge card is seated properly.
2. Inspect the purge card and connector on the relay module for
damage or contaminants.
3. Reset and sequence the relay module.
4. If the fault code reappears, replace the purge card.
5. Reset and sequence the relay module.
6. If the fault persists, replace the relay module.
1. Check the relay module and display module connections.
2. Reset and sequence the relay module.
3. Check the relay module power supply and make sure that both
frequency and voltage meet the specifications.
4. Check the backup power supply, as appropriate.
1. Make sure the purge card is seated properly.
2. Inspect the purge card and connector on the relay module for
damage or contaminants.
3. Reset and sequence the relay module.
4. If the fault code reappears, replace the purge card.
5. Reset and sequence the relay module.
6. If the fault persists, replace the rel<).y module.
1. Check wiring and correct any errors. Make sure that flame
. sensor wires are in separate conduits. Check for noise
coupling·lnto the flame detector leadwires.
2. Make sure that flame detector and flame amplifier are
compatible.
3. Remove the flame "mplifier and inspect connections. Reseat
the amplifier.
4. Reset and sequence the relay module.
5. If the code reappears, replace the amplifier. and/or the flame
detector.
6. If the fault persists, replace the relay module.
1. Check that flame is not present in· the combustion chamber;
correct any errors.
2. Check wiring and correct any errors. Make sure that flame
sensor wires are in separate conduits, Check for noise
coupling into flame detectoi leadwires.
3. Remove the flame amplifier and inspect its connections.
Reseat the amplifier.
4. Reset and sequence the relay module.
5. If the code reappears, replace the amplifier andlor the flame
detector.
6. Ifthe fault persists, replace the relay mod'!'e.
1. Check wiring and correct any errors.
2. Check Preignition Interlock switches to assure proper
functioning.
3. Check fuel valve operation.
4. Reset and sequence the relay module; monitor the Preignition
Interlock status.
5. If·the code persists, replace the relay module.
(continued)

65-0229-1 10

Table 3. Hold and Fault Message Summary (continued)
Fault Code System Failure
Fault 11 Running Interlock powered at
'Running ILK On' improper sequence point.
Fault 12 Lockout Interlock powered at
'Lockout ILK On' improper point in sequence.
Fault 13 Combustion airflow interlock
'Airflow Sw. On' fault during STANDBY.
Fault 14 High Fire Interlock Switch
'High Fire Sw.' failure to close during
PREPURGE.
Fault 15 Flame sensed when no flame
'Flame Detected' is expected during
STANDBY.
Fault 16 No-flame detected during
'Flame-Out Timer' Pilot Flame Establishing
Period.
Fault 17 Main flame failure during RUN
'Main Flame Fail' after flame is established and
on for at least 10 seconds.
7800 SERIES RELAY MODULES
Recommended Troubleshooting
1. Check wiring to make sure that interlocks are connected
properly between terminals 6 and 7. Correct any errors.
2. Reset and sequence the relay module.
3. If the fault perSists, measure the voltage between terminals 6
and G (ground), then terminals 7 and G. If there is line supply
VOltage present at terminal 6 when the controller is off, the
controller switch may be bad or is jumpered.
4. If steps 1 through 3 are correct and there is line supply
voltage present at terminal 7 when the controller is closed
and the fault persists, check for a welded or jumpered
Running Interlock, Lockout Interlock, or Airflow Switch.
Correct any errors.
5. If steps 1 through 4 are correct and the fault perSists, replace
the relay module.
1. Check wiring and correct any errors.
2. Reset and sequence the relay module.
3. Use either the manual motor potentiometer to drive the motor
to the High Fire position or use the RuniTest Switch option,
if available. Sequence to Prepurge drive to High Fire and
place in the Test pOSition. Adjust the High Fire Switch while
in this state to make sure that it closes properly.
4. Measure the voltage between terminal 19 and G (ground)
while in the Prepurge drive to High Fire state. Line supply
voltage should be present. If not, the switch adjustment is
incorrect andlor the switch is defective and needs replacing.
5. Reset and sequence the relay module. II line supply voltage
was present between the High Fire Switch and terminal 19,
and the fault still perSists, replace the relay module.
1. Check that the flame is not present in the combustion
chamber; correct any errors.
2. Make sure that the flame amplifier and flame detector are
compatible.
3. Check wiring and correct any errors.
4. Remove the flame amplifier and inspect the connections.
Reseat the amplifier.
5. Reset and sequence the relay module.
6. If the code reappears, replace the amplifier andlor the flame
detector.
7. If the fault persists, replace the relay module.
1. Measure the flame signal. II one eXists, make sure it meet
specifications. Make any necessary burner adjustments using
manufacturer instructions.
2. Make sure that the flame amplifier and flame detector are
co.mpatible.
3. II the code reappears, replace the amplifier andlor the flame
detector.
4. If the fault persists, replace the relay module.
1. Inspect the main fuel valve(s) and connection(s).
2. Make sure that the fuel pressure is high enough io supply
fuel to the combustion chamber.
3. Check the flame detector sighting 'for adequate flame Signal
throughout the burner firing rate.
(continued)
11 65-0229-1
7800 SERIES RELAY MODULES

Table 3. Hold and Fault M'essage Summary (continued).

Fault Code System Failure Recommended Troubleshooting

Fault 18 Flame sensed when shutter is 1. Check Ihat flame is not present in the combustion chamber.
'Flame Detected' open and no flame is expected Correct any errors.
during PREPURGE. 2. Make sure that the flame amplifier and flame detector are
compatible.
3. Check the wiring and correct any errors. Make sure F and G
wires are in individual conduits and protected from stray
noise pickup.
4. Remove the flame amplifier and inspect the connectors.
Reseat the flame amplifier.
5. Reset and sequence the relay module.
6. If the code reappears, replace the flame amplifier and/or the
flame detector.
7. If the fault persists, replace the relay module.
Fault 19 Flame was lost during MFEP or 1. Inspect the main fuel valve(s) and connection(s).
'Main Flame Ign: the first 10 seconds of the RUN 2. Make sure that the fuel pressure is high enough to supply
state. fuel to the combustion chamber.
3. Make sure the flame detector is positioned to obtain the
required flame signal strength; reset and recycle.
Fault 20 Low Fire Interlock switch failure 1. Check wiring and correct any errors.
'Low Fire Sw. OW to close during PREPURGE. 2. Reset and sequence the relay module.
3. Use either the manual motor potentiometer to drive the
motor to the Low Fire position or use the RunfTest Switch
option, if available. Sequence to Prepurge drive to Low Fire
and place in the Test position. Adjust the Low Fire Switch
to make sure that it closes properly.
4. Measure the voltage between terminal 18 and G (ground)
while in the Prepurge drive to Low Fire state. Line supply
voltage should be present. If not, the switch adjustment is
incorrect andlor the switch is defective and needs
replacing.
5. Reset and sequence the relay module. If line supply voltage
was present between the Low Fire Switch and terminal 18,
and the fault still persists, replace the relay module.
Fault 21 Running Interlock fault during 1. Check wiring; correct any errors.
'Running ILK' PREPURGE. 2. Inspect the fan; make sure there is no blockage of the air
intake and that it is supplying air.
3. Make sure the Interlock Switches are working property and
that all switch contacts are free of contaminants.
Fault 22 Lockout Interlock fault during 4. Reset and sequence the relay module to PREPURGE (place
'Lockout ILK' PREPURGE. the RunlTest Switch in the Test position, if available).
Measure the voltage between terminals 7 and G (ground).
Line voltage should be present.
F<'!ult 23 Combustion airllow interlock 5. If. steps 1 through 4 are correct and the fault persists,
• Airllow Switch* fault during PREPURGE. replace the relay module.

Fault 24 The flame interlock (relay 1. Check for F leadwire routing. Make sure routing is in its
'Call Service' module) was on when it should conduit and isolated from noise·producing circuits.
be off.
Fault 25 The flame interlock (relay
'Call Service' module) was off when it should
be,on.
Fault 26 The Manual Open Valve Switch 1. Check wiring and correct any errors.
·M<'!n·Open Sw. OW was off when it should be on 2. Make sure that the Manual Open Valve Switch is fully open.
(RM7838B only). 3. Make sure that the Manual Open Valve Switch is
functioning properly and that the switch contacts are free
from contaminants.
4. Reset and sequence the relay module.
5. Make sure that the Manual Open Valve Switch provides an
electrical path when closed. Verify that the relay module is
receiving power at terminal I?
6. If steps 1 through 5 are correct and the fault persists,
replace the relay module.
(continued)

65·0229-1 12
 7800 SERIES RELAY MODULES

Table 3. Hold and Fault Message Summary (continued).

Fault Code System Failure Recommended Troubleshooting

Fault 27 Start Switch was on during 1. Start Switch held on too long.
'Start Switch On' PREPURGE (RM7838A, 2. Check wiring; verify that Start Switch is correctly connected.
RM7838B only). 3. Make sure that the Start Switch is functioning properly and that
the switch contacts are free of contaminants.
4. Reset and sequence the relay module to PREPURGE; set the
Runrrest Switch to Test. Make sure there is no power at
terminal 6 during PREPURGE.
5. If steps 1 through 3 are correct and the fault persists, replace
the relay module.
Fault 28 Pilot flame failure. 1. Check pilot valve wiring and operation. Correct any errors.
'Pilot Flame Fail' 2. Check fuel supply.
3. Check pilot pressure and repeat pilot turndown test.
4. Check ignition transformer electrode, flame detector, flame
detector sighting and flame amplifier.
5. If steps 1 through 4 are correct and the fault persists, replace
the relay module.
Fault 29 Lockout Interlock fallit. 1- Check wiring; correct any errors.
'Lockout ILK' 2. Inspect the fan; make sure that there is no blockage of the air
intake and that it is supplying air.
3. Make sure that the Lockout Interlock Switches are working
properly and that all switch contacts are free of contaminants.
4. Reset and sequence the relay module to PREPURGE (place the
RUnrrest Switch in the Test position, if available). Measure the
voltage between terminals 7 and G (ground). Line voitage
should be present.
5. It steps 1 through 4 are correct and the fault persists, replace
the relay module.
Fault 30 Running Interlock fault. 1- Inspect the Running Interlocks, including the Airflow Switch,
'Running ILK' and the connections.
2. Make sure that the Running Interlocks, including the Airflow
Switch, are functioning properly and that switch contacts are
free of contaminants.
3. Reset and sequence the relay module to PREPURGE. Set the
Ruorrest Switch, if available, to Test. Measure the voltage
between terminal 7 and G (ground). Lin,r voltage should be
present.
4. If steps 1 through 3 are correct and the fault persists, replace
the relay module.
Fault 31 Low Fire Interlock Switch 1. Check wiri~g; correct any errors.
'Low Fire Sw. OW failure to close during RUN 2. Reset and sequence the relay module.
(RM7838B only). 3. Use either the manual motor position to drive the motor to the
Low Fire position, or use the Runffest Switch option, if
available. Sequence to Run drive to Low Fire and place in the
Test position. Adjust the Low Fire Switch'while in this stale to
make sure it is closing properly.
4. While in Run, drive to Low Fire state, measure the voltage
,between terminal 18 and G (ground). Line voltage should be
present. If not, the switch adjustment is incorrect andlor the
SWitch is defective and needs replacement.
5. Reset and sequence the relay module. It line voltage was
present between the Low Fire Switch and terminal 18 and the
, fault persists, replace the relay module.
(continued)

13
7800 SERIES RELAY MODULES

Table 3. Hold and Fault Message Summary (continued).

Fault Code System Failure Recommended Troubleshooting

Fault 32 Combustion Airflow 1. Check wiring; correct any errors.
'Airflow Switch' Interlock fault. 2. Inspect the fan; make sure there is no blockage of the air intake
and it is supplying air.
3. Make sure the Airflow Interlock Switches are working properly
and all switch contacts are free of contaminants.
4. Reset and sequence the relay module to PREPURGE. Place the
RunlTest Switch in the Test position, if available. Measure the
voltage between terminals 7 and G (ground). Line voltage
should be present.
5. If steps 1 through 4 are correct and the fault persists, replace
the relay module.
Fault 33 Preignition interlock fault. 1. Check wiring; correct any errors.
'Preignition ILK' 2. Inspect the Preignition Interlock switches and make sure they
function properly.
3. Check fuel valve operation. Valve must close within five
seconds.
4. Reset and sequence the relay module.
5. During STANDBY or PREPURGE, measure the voltage between
terminal 20 and G (ground). For EC/RM7810, 7820, 7830, 7850,
check voltage between terminal 17 and G. Line voltage should
be present. If not, the Preignition Interlock switches can be
def"ctive and need replacing.
6. If the fault persists, replace the relay module.
Fault 34 CTL input was energized at 1. Check wiring; correct any errors.
'Control On' the wrong time for the relay 2. Reset and sequence the relay module.
module. This fault implies a 3. If fault persists, replace the relay module.
field wiring error.
Fault 35 Safety relay was off when it 1. Reset and sequence the relay module. If fault repeats, replace
"'Call 'Service'" should be on or a fuse has relay module, but be sure to test for excessive loads on
blown. appropriate terminals described by fault code.
Faul!36 Main valve terminal was off 2. If fault does not repeat on next cycle check for electrical noise
*CaU Servige* when it should be on. being coupled into the relay module through the loads on
appropriate terminals described by the fault code.
Fault 37 Pilot (ignition) valve terminal 3. If fault persists, replace the relay module.
'Call Service' was off when it should be
on.
Fault 38 Ignition terminal was off
'Call Service' when it should be on.
Fault 39 V2S valve terminal (usually
"'Call Service'" terminal 21) was off when it
should be on.
. Fault 40 Safety relay was on when it
"'Call Service'" should be off.
Fault 41
*Main Valve On'"
Main valve terminal was on
when it should be off. A WARNING
Explosion Hazard.
Fault 42 Pilot (ignition) valve terminal
'Pilot Valve On' wason when it should be Can cause explosion, serious injury or death.
off. 1. Remove system power, turn off fuel supply.
Fault 43 Ignition terminal was on 2. Check for wiring errors that could provide power to
'IQnition On' when it should be off. terminals described by the fault. Correct any errors.
Fault"44 V2S valve terminal, used as 3. Re-power system; reset and sequence the relay module.
'Pilot Valve 2 On' a pilot, is on when it should 4. If fault persists, replace the relay module.
be off. 5. When fault is corrected, turn on fuel suoolv.
(continued)

65-0229-1 14

Table 3. Hold and Fault Message Summary (continued).
Fault Code System Failure
Fault 45 Low Fire Interlock switch failure
'Low Fire Sw. Off' to close or stay closed.
Fault 46 This fault indicates:
'Flame Amp Type' a. The Flame Failure Response
lime (FFRD orTYPE input
from the amplifier changed
while the device was
powered; or
b. A standard amplifier was
used In a pilot valve
application; or
c. A three-second FFRT
Amplifier was used with the
relight option on the
RM7890 Relay Module.
Fault 47 The configuration jumpers differ
'Jumpers Changed' from the sample taken at startup.
Fault 48 V2S valve terminal, used as a
'Delayed MV On' delayed main valve, was on when
It should be off.
Fault 49 The manual open switch was on
'Man-Open Sw. On.' when it should be off.
Fault 50 The sequence logic detected a
'Jumpers Wrong' combination of jumpers that is
illegal for the sequence eg, if it is
correct to clip Jumper JR1 or
Jumper JR2, but not both, this
fault would be used when both
are clipped (RM7888 only).
7800 SERIES RELAY MODULES
Recommended Troubleshootin\!
1. Check wiring; correct any errors.
2. Reset and sequence the relay module.
3. Use either the manual motor position to drive the motor to
the Low Fire position, or use the Runrrest Switch option, if
available. Sequence to Run, drive to Low Fire and place in
the Test position. Adjust the Low Fire Switch while in this
state to make sure it is closing properly.
4. While in Run, drive to Low Fire state, measure the voltage
between terminal 18 and G (ground). Line voltage should
be present. If not, the switch adjustment is incorrect
andlor the switch is defective and needs replacement.
5. If steps 1 through 4 are correct and the fault still persists,
replace the relay module.
1. Remove power to the device.
2. Reseat the flame amplifier and reset and sequence the relay
module.
3. For EC/RM7890 only; make sure that Jumper JR2 is
completely clipped if a three-second FFRT amplifier is
being used. If Jumper JR2 Is intact (relight option is
selected), use 0.8 second FFRT amplifier.
4. For RM7838B only; make sure that a Shutter Check Flame
Amplifier Is being used with the Pilot Valve Hold option
selected.
1. Inspect the jumper connections. Make sure that clipped
jumpers are completely removed.
2. Reset and sequence the relay module.
3. If fault perSists, replace the relay module.
AWARNING
Explosion Hazard.
Can cause explosion, serious Injury or death.
1. Remove system power, turn off fuel supply.
2. Check wiring; correct any errors.
3. Inspect the V2S Fuel Valve and its connections.
Make sure the switch is working correctly and Is not
jumpered or welded.
4. Reset and sequence the relay module.
5. If fault persists, replace the relay module.
AWARNING
Explosion Hazard.
Can cause explosion, serious injury or death.
1. Remove system power, turn off fuel supply.
2. Check wiring; correct any errors.
3. Inspect the Manual-Open Switch and its
connections. Make sure the switch is working
correctly and is not jumpered or welded.
4. Reset and sequence the relay module.
5. If fault perSists, replace the relay module.
1. Inspect the jumpers and refer to the installation instructions
for compatible jumper configurations.
2. Make sure that clipped jumpers are completely removed.
3. Reset and sequence the relay module.
4. If fault perSists, replace the relay module.
(continued)
15 65-0229-1
7800 SERIES RELAY MODULES

Table 3. Hold and Fault Message Summary (continued).

Fault Code System Failure Recommended Troubleshooting
Fault 51 Flame signal value is too high 1. Make sure Ihat flame detector and flame amplifier are
'Flame Too Strong' to be valid. compatible.
2. Remove the flame amplifier and inspect the connections. Reset
the flame amplifier.
3. Reset and sequence the relay module.
4. Check the flame detector sighting position, reset and cycle.
5. Verify that no ignition noise is present in the F lead due to wire
routing.
6. Measure the flame strength. Verify it meets specifications. If
not, refer to the flame amplifier andlor flame detector checkout
procedures.
7. If the code reappears, replace the flame amplifier andlor the
flame detector.
8. If the fault persists, replace the relay module.
Fault 52 Pilot Valve 2 (terminal 21) was 1. Inspect terminal 21 and connections. Make sure that the valve
'Call Service' off when it should be on. is operating properly.
2. Reset and sequence the relay module.
3. If the fault persists, replace the relay module.
Fault 53 Lockout Input fault 1. Check wiring; correct any errors.
'Lockout Switch' (EC/RM7810, 7820, 7830, 2. Inspect the Lockout Switch to make sure it is working
7850 only). properly.
3. Reset and sequence the relay module. During STANDBY or
PREPURGE, measure the voltage between terminal 20 and G
(ground). Supply voltage should be present. If not, the
lockout switch is defective and needs replacing.
4. If the fault persists, replace the relay module.
Fault 54 Combustion pressure switch 1. Check wiring; correct any errors.
*Comb. Pressure* fault (Fulton pulse only). 2. Inspect the Combustion Pressure Switch to make sure it is
working correctly.
3. Reset and sequence the relay module.
4. During STANDBY or PREPURGE, measure the voltage
between terminal 20 and G (ground). Supply voltage should
be present. If not, the Combustion Pressure Switch is
defective and needs replacing.
5. If the fault persists, replace the relay module.
Fault 55 Purge fan switch is on when it 1. Check wiring; correct any errors.
'Purge Fan Sw. On' should be off (Fulton pulse 2. Inspect the Purge Fan Switch terminal 18 and its connections.
only). Make sure the switch is working correctly and is not jumpered
or welded.
3. Reset and sequence the relay module.
4. If the fault persists, replace the relay module.
Fault 56 Block intake fault 1. Check wiring; correct any errors.
'Block Intake' (Fulton pulse only). 2. Inspect the Block Intake Switch and make sure it is working
properly.
3. Reset and sequence the relay module.
4. During PREPURGE, measure the voltage between terminal 7
and G (ground). Supply VOltage should be present. If not, the
Block Intake Switch is defective and needs replacing.
5. If the fault persists, replace the relay module.
Fault 57 Purge Fan Switch is off when 1. Inspect the Prepurge Fan Switch terminal 18 and the
'Purge Fan Sw. OW it should be on (Fulton pulse connections. Make sure the switch is working properly.
only). 2. Reset and sequence the relay module.
3. If the fault perSists, replace the relay module.
Faults 58 - 66 Unused faults -
·Call Service*
Fault 67 L1 and L2 1. Check L1 and L2 for proper line phasing.
'AC Phase' miswiredlexchanged
(EC/RM7810, 7820, 7830,
7850 only).
(continued)

65·0229--1 16
 7800 SEFIIES RELAY MODULES

Table 3. Hold and Fault Message Summary (continued).

Fault Code System Failure Recommended Troubleshooting

Fault 68 Preignition Interlock fault. 1. Check wiring; correct any errors.
'Preignition ILK' 2. Inspect the Preignition Interlock switches and make sure
they work properly.
3. Check fuel valve operation. Valve must close within five
seconds.
4. Reset and sequence the relay module.
5. During STANDBY or PREPURGE, measure the voltage
between terminal 17 and G (ground). Supply voltage should
be present. If not, the Preignition Interlock switches are
defective and need replacing.
6. If the fault persists, replace the relay module.
Fault 69 - 70 Unused faults. -
~CallService'
Fault 71 Low Fire Switch closed, High 1. Check firing rate position switches (usually in Modutrol®
'Dynamic LFS' Fire Switch must be open Motor) for proper operation.
(EC/RM78S0 only). 2. Check wiring, correct any errors.
3. Reset and sequence the relay module.
4. If the fault persists, replace the relay module.
Fault 71 Limit input (terminal 7) is off 1. Check limits to make sure they are satisfied after resetting.
*Limits Complete* when it should be on (RM7888 2. Check electrical connections to terminal 7 of wiring
only). subbase.
3. Reset relay module.
4. If the fault persists, replace the relay module.
Fault 72 High Fire Switch closed; Low 1. Check firing rate position switches (usually in'Modutrol®
'Dynamic HFS' Fire Switch must be open Motor) for proper operation.
(EC/RM78S0 only). 2. Check wiring, correct any errors.
3. Reset and sequence the relay module.
\ 4. If the fault persists, replace the relay module.
.'
Fault 72 Special Function 2 Input 1. Check operation of Special Function 2 of PLC.
'Spec.Func.2' (terminal 17) is off when it should 2. Check electrical connection to terminal 17 of wiring
be on. subbase and confirm presence of supply power when
Special
Function 2 is activated.
3. Reset relay module.
4. If the fault persists, replace the relay module.
Fault 73 Special Function 3 Input 1. Check operation of Special Function 3 of PLC.
'Spec.Func.3' (terminal 19) is off when it should 2. Check electrical connection to terminal 19 of wiring
be on. subbase and confirm presence of supply power when
Special
Function 3 is activated.
3. Resetrelay module.
4. If the fault persists, replace the relay module.
Fault 75 Flame Indication Feedback 1. Remove wire to terminal 21 and reset relay module.
'Flame Proven (terminal 21) either on when it 2. If the fault persists, replace relay module.
Feedback' should be off or off when it 3. Reconnect wire to terminal 21. If the fault returns, verify
should be on. wiring.
Fault 76 - 93 - -
'Accessory Fault'
Fault 94 - 104 - -
'Call Service'
Fault 105 Relay Module self-test failure. 1. Reset and sequence the relay module.
'Call Service' 2. If the fault reappears, remove power from the relay module
Fault 106 Relay Module self-test failure. and reapply the power; reset and sequence the relay
'Call' Service' module.
3. If the fault persists, replace the relay module.
Fault 107 Relay Module flame signal
'Call Service' crosscheck failure.

(continued)

17 65-0229-1
 7800 SERIES RELAY MODULES

Table 3. Hold and Fault Message Summary (continued).

Fault Code System Failure Recommended Troubleshooting

Fault 109 Negative cycle test failed, 1. Make sure a good earth ground connection exists at the
'Call Service' earth ground absent or line installation site and all earth ground connections are complete
voltage phasing improper. and correct.
2. Make sure the relay module and all loads operate at the same
line voltage phase.
3. Reset and sequence the relay module.
4. If the fault persists, replace the relay module.
Fault 110 The configuration jumpers 1. Inspect the jumper connections. Make sure they match the
'Call Service' differ from stored values. original selection and clipped jumpers are completely
removed.
2. Reset and sequence the relay module.
3. If the fault persists, replace the relay module.
4. Configuration jumpers must be selected prior to 200 hours of
operation. If configuration jumpers are changed after 200
hours of operation, lockout 110 occurs. Relay module cannot
be reset and tilUstbe replaced.
Fault 111 Relay Module configuration 1. Inspect the jumper connections. Make sure they match the
'Call Service' jumper test failure. original selection and clipped jumpers are completely
removed.
2. Reset and sequence the relay module.
3. If the fault persists, replace the relay module.
Fault 112 - 126 Relay Module self-test 1. Reset and sequence the relay module.
'Call Service' failure. 2. If the fault persists, replace the relay module.
Fault 127 Safety relay feedback circuit 1. Reset and sequence the relay module.
'Call Service' was in an improper state. 2. If the fault persists, replace the relay module.

65-0229-1 18
 MUX2700-G @ 'H'h 2000
.I. UJ' Series
20050 Sulbiatc (MI) ITALY
Ph ++39 - 039 6292 1
32 channel MULTIPLEXER Fax ++39 - 039 6292240

For morc comprehensive information and specification, Power-up and LED indications
SAFE AREA or please refer to the User Instruction Manual: PN. 475137 The information provided by the Mux 2700 LED (mounted
HAZARDOUS AREA zone 2
at the panel front) is summarised in the following table:
Model MUX2700 Application
The Mux2700 HART@ Multiplexer provides 32 sigllal Colour Name Function
channels for connection to "smart" transmitters or control If."=""-I-'-=~I-'-=="'---------j
devices supporting digital comm~nication according to the Yellow HART Tx Ongoing HART communication with
field devices
Ch.l
HART standard. It acts as an interface between a II-:,--I-:c-c=-=~~~:='--c-cc--c---c--I

= fl/:l:JI'
:£C'!i::. M"
1==\1==: 0,.,,,
","os
workstation (typically a PC) and the HART field devices.
The workstation connects, in a ~ulti-drop configuration,
II-'G::.re:.:'"n+p-,W"R,-O"N+S:.:u"pp",rY,-i"nd:.:ica=to::.r"(b:::!in,,k=-s::atc:p.:.ow::.,::.r-.::u",p}'---j
Internal fault indication (power-up
• with up to 31 Mux2700 using an RS485 serial line. Red FAULT ~~~~I~O~o~~~)[it during normal operation
IL__L-_ _===========::::l
HART
.lode The Mux2700 interrogates eacb field device, under the
supervision of the workstation, retrieving information for
storage in its internal database. In t.he following, the Mux 2700 power-up sequence is
descfibed. ----
• After power-up. the 3 LEOs stay On for around 3s.
Warning • An internal self-test is then perfonned and, if any problem
o is detected, the Red LED goes f(Xed On (during the self-test,
The Mux2700 module is not certified for intrinsically safe
applications and must not be used to directly interface with which last around 8 s, the Green LED blinks).
hazardous-area located field devices. However, SOffie • The Yellow LED then start blinking, indicating that the
solutions do allow the mounting of the Mux2700 on the Mux 2700 is performing the locale activity, that can last up
Rl _______________/ same board where intrinsically safe isolators are located. to around one minute.
In this case, the safety-related application areas must be • The Yellow LED should then go Off, unless the scali
addressed by trained pcrspnnel who are fully acquainted operation is enabled or the Maintenance Workstation is
with the principles of intrinsically safe systems. directly communicating with a field device.

Address Setting Specification

The Mux 2700 module operates as a slave device on a DC Supply
mUlti-point RS-4SS serial line. A unique address is Current cOllSumplion:
therefore to be specified for eal:h Mux connected to the 30 rnA at 24 V, typical, RS485 quiescent.
same serial line. To set the reqUITed address, use the first Signal channels
five switches (located at the top of the unit) according to Number ofchannels: 32.
the following table. Please note that the address 0 is Dc isolalion:
reserved and is never to be used (sec Fig. 2). dual capacitor each channel.
Baud-rate setting: SW6 a'nd SW7 permit to set the desired Receive signal rallge:
serial line baud~rate. Please' note that the s-ome 0.12 Vpp< signal < 1..5 Vpp.
configurations arc reserved and never to h,e used Receive impedance:
!ill 5000n typo
IJ[i Carrier detect level:
11U Installation and Connections 0.1 Vpp, typo I
The Mux2700 HSM module is ~ plug-in unit intended for 1}allsmit amplitude: i
insertion in a suitable H.LS. TenWnation Board. Therefore, 200 mV (200n load, typ.)
the primary electrical conqections (supply, field 500 mV (500n load, typ.)
connection, serial lines) ar~ mad~ at the Tennination Board
level. Please refer to the relevant H.I.S. series board Serial Port
instruction manual for details. Line type:
The Mux2700 l;lox - unlike other HiD-type enclosures - is RS-485.
not mechanically polarised hecause its different connectors Line topology:
mtEJ avoid the possibility of wrongly inserting it in an I.S multi"point, mastcNlave connection.
• - - - - - - - - - - - - - - - / isolator slot No polarisation prong-is therefore to be found
on the hottQm oftbe enclosure.
To mount a new Mux2700 module on the board, proceeds
Module tag as follow:
• identify the Mux2700 slot.
, carefully align the unit connectors with the board ones,
then gently press down module.
• push down the yellow tabs on each side ofthe module to
flIntlysecureittotbepanel. ***ATTENTION AMS USERS***
To remove an installed Mux2700, simply lift the red tabs
and gently unplug it from the panel.
The Mux2700 is an hot plug-in capable module THIS PRODUCT REQUIRES THAT THE
At plug~in time, no relevant disturbance is to be expected LATEST DEVICE DESCRIPTION AND
on 4/20 rnA field signals. Before powering up the unit for RESOURCES FILES BE IMPLEMENTED IN
the first time, please remember to carefully check supply ORDER TO ENSURE PROPER OPERATION
voltage level and polarity. OF THE MUX2700G WITH AMS SUITE:
INTELLIGENT DEVICE MANAGER 6.0 OR
THE NEWEST REVISIONS.
THESE FILES CAN BE FOUND AT THE
FOLLOWING ADDRESS:

http://www.elconhis.comIHARTmux.html

FOR MORE INFORMATIONS, VISIT THE DEDICATED HiS WEB SITE: www.,leonhis.eom
 20050 Sulbiate (MI) ITALY
NlUX Z7UU-lJ UJ ~ 2000 Ph ++39 - 039 6292 I
MULTIPLEXER HART, 32 canali .Il~ Series Fax ++39 - 039 6292 240

Per informazioni pill esauricnti e specifichc tecnichc, SI II Mux2700 c un dispositivo plug-in che si puo rimuovere
SAFE AREA Of prega rjferirsi al manuale di istruzione: PN. 475137 anche satta tensione, per cui durante Ie fasi di inserzione e
) HAZARDOUS AREA zone 2 rimozione, i segnali 4120ma in campo non subiscono
Modell\.fUX2700 influenze significative. Si presti attenzione alia polarita cd a!
Applicazioni valore dclla tensione prima di alimentare il dispositivo per la
II multiplexer HART Mux2700 ha 32 canali C SI collega a prima volta.
o trasmettitori "smart" 0 analogni dispositivi di controHo
che supportino Ia comunicazione digitale secondo 10
CIl.l
standard HART. Avviamento ed indicazioni dei LED
'1-::=::\!l:=:::RS48S Esso e un'interfaccia fra la postazionc di lavoro Sui pannello frontale del dispositivo sono situati 3 LED che
= J!lj ,
"1_ Dala
Bu~
9";;:·1:' Mux (tipicamentc un Personal Computer) cd i dispositivi HART fomiscono Ie seguenti indicazioni:
HART
", installati in campo.
Ogoi stazione di lavore) puo connettere fino a 31 Colore Nome FUnzione
dispositivi "Mux2700" in configurazione "multi-drop"
utilizzando una linea seriale RS485. Gial10 HARTTx Comunicazi.one HART verso i dispositivi
in campo attiva
II Mux2700 intcrroga ago! dispositivo in campo ad esso
collegato sotto la supervisione d~Ua stazione di lavoro, la Verde PWRON (IampeggiaPresenza alimentazione
all'accensione)
o o quale utilizza Ie infonnazioni memorizzandole ne! suo
AII'accensione verffica eventuali guasti
database interno. Rosso FAULT del modulo. In condizioni d·1 normale
funzlonamento deve rimanere spento.

Avvertenze
1mIl_______________-" II modulo Mux2700 non ecertificato per applicazioni a Oi seguito viene descritta la sequenza di' accensione del
Mux2700:
sicurezza intrinseca e non deve essere usato per
• Subito dopo I'accensione, i 3 LED rimangono accesi per
interfacciarsi direttamente a dispositivi installati in area
circa 3 secondi.
pericoiosa.
• Viene quindi eseguito un test diaglloslico intemo (durante
Tuttavia alcune soluzioni permettono il montaggio del
il quale il LED verde lampeggia).
Mux2700 direltamente sulla stessa piastra di tenninazione
dove sono installati gJi isolatori a sicurezza intrinseca.
II LED rosso si accendern solo in presenza di un eventuale
guasto 0 malfunzionamento. La fase di test dura circa 8
In questa specifico caso, Ie aree a sicurezza intrinseca secondi.
relative, devono essere specificate e sotto il controUo di un
• II LED giallo inizia quindi a iampeggiare per circa un
operatore che sia adeguatamente addestrato e che conosca
minuto indicando che I'attivita di ricerca dei dispositivi di
tutti i principi de)1a sicurezza intrinseca. campo ein corso.
• Fatte queste verifiche, il LED giallo si spegncra salvo che
il PC stia direttamente comunicando con i disposilivi in
Impostazioni - Indirizzi campo oppure ehe la funzione "scan" sia abilitata.
Ogni linea seriale RS485 puo collegare
)5 contemporaneamente fmo a 31 dispositivi Mux2700,
05
ognuno dei quali si comporta come "slavel \ deve percio Specifiche Tecniche
essere definito da un indirizzo preciso ed univoco. Per
impostare I'indirizzo desiderato oecorre agire sui cinque Alirnentazionc CC
micro-intenuttori (SWI.-;.SW5) situati sulla parte fronlale COllSumo di correllle:
del Mux, facendo riferimenlo alia tabella in figura 2. 30 rnA a 24 V tipici, can linea RS485 inattiva.
Si noli che I'indirizzo "0" e riservato e non dovra mai Segn:.1i
essere usato. Numero di canali: 32.
Impostazione del Baud-rate: Per. selezionare il baud-rate lsolamento in CC:
desiderato occorre agire sui due miero-interruttori SW6- due condensatori pcr ogni canale.
SW7 situati sulla parte frontale del Mux (vedere la fig. 2). Campo di ricezione del segnale:
Si noti che eonfigurazioni diverse da queUe indicate nclla 0.12 Vpp, tipici.
tabeUa di fig. 2 soon risclVate e non devono mai essere usate.lmpedenzo i1l riceziolle:
5000 n lipici.
Livello di rilevamento portollte:
1mEJ1 _____________J Installazione e Connessioni 0.1 Vpp, {ipici.
II Mux2700 e un modulo plug-in che si installa su Ampiezza di trasmissione:
opportune piastre di terminazione della famiglia 200 mY (carico lipico di 200 n)
Module tag denominata "Hart Interface Solutions" (HIS). Tutti i 500 mY (carico tipico di 500 n)
coJlegamenti necessari (segnali dal campo, alimentazione;
linea seriale) sono realizzabili sui rnorsetti e/o connetton Porta seria1e
disponibili aU'operatore sulle piastre stesse. Fare aUresi Jipo di linea:
riferimento ai manuali di istruzione delle singole piastre RS-485.
per maggiori dettagli applicativi. Carallerisliche di linea:
II modulo Mux2700 ha connettori diversi rispetto ai connessione multi point, master-slave.
moduli della famiglia HiD peqan.to, pur non essendo
meccanicamente polarizzato. ne viene comunque impedita
J'accidentale ioserzione in posizioni dedicate ad isolaton ***N.B.: UTENTI AMS***
IS.
Procedura di instalrazione del Mux2700: PER UTILIZZARE L'UNITA' MUX2700G IN
• Centrare il modulo alIa propria sede ed innestarlo can AMBIENTE AMS (VERSIONI 6.0 E
cura (rno ache i suoi connettori non siano completamente SUCCESSIVE) E' NECESSARIA LA
ingaggiati con quelli presenti sulla piastra. VERSIONE Plu' RECENTE DEI RELATIVI
• Abbassare Ie linguette rosse sui fiancbi del modulo per
assicurame it bloccaggio meccanico.
FILE DI DESCRIZIONE E DI RISORSE.
• Per rimuovere it modulo procedere semplicemente in SE TALI FILE NON SONO DISPONIBILI,
modo inverso. E' POSSIBILE SCARlCARLI DA:

http://www.elconhis.comIHARTmux.html

~' _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _J
PER ULTERIDRIINFORMAZIDNI, VISITATE IL SITO WEB HiS DEDICATD: www.elconhls.com
(

HPSM/32!fB-02
.Includes:
HPSMl32/TB-02IFUSE
HPSMl32/TB-021HF -16
HPSMl32/TB-021HF -16IFUSE
HPSMl32/TB-021HF -32

Installation Manual

IMSM003
129-0039A

Released EDM c:hockout2006-FEB-1S

 Table of Cont ents
1. General Description ...... ...... ...... ...... ...... ...... ...... ...... ......
1.1 Introduction ....... ....... ....... ....... ....... ....... .......
.... 5
....... ....... ... 5
l.l.l Purpose ...... ...... ...... ...... ...... ...... ...... ...... ......
.... 5
1.1.2 Functions...... ...... ...... ...... ...... .1 •....• ..•.... .•..•.
.•••.• . 5
1.1.3 HART Overview....... .... " '" ..... " ...... ...... ...... .....
' ..... 6
1.l.4 Specifications....... : ...... ...... ...... ...... ...... ...... ......
... 6
1.1.4.1 2700 MUX Specifications...... ...... ...... .... , ......
...... .. 6
1.1.4.2 HPSM Termination Board Specifications...... ...... ......
...... .6
1.1.4.3 RS-485 Line Specifications ....... ....... . ' ..... ' ......
.... , .. 7
1.2 Asset Management Solutions Software...... ...... ...... ......
...... ...... ...... .. 8
1.3 Associated Tools and Test Equipm enl ...... ...... ...... ......
...... ...... ...... .. 8
1.4 Quali ty Assurance ...... ...... ...... ...... ...... ...... ......
...... .... , ....... . 8
1.5 Certifications and Compliance ....... ... , ...... ...... ......
...... ...... ...... .. " 8
1.6 Unpacking and Inspection...... ...... ...... ...... ...... ......
...... ...... ...... . 8
1.7 Stom ge... ....... ....... ....... ....... ....... ....... .......
....... ....... ... 9
2. Installation ...... ...... ...... ...... ...... ...... ...... ...... ...... ......
...... . 9
2.1 Environmental Conditions ...... ...... ...... ...... ...... ......
.... :, ...... ...... 9
2.2 Intrinsic Safety ....... ....... ....... .... '...... ...... ......
...... ...... ...... .. 9
2.3 MoiInting...... ...... ...... ...... ...... ...... ...... ......
...... ...... ...... .. 9
2.4 Cables...... ...... ...... ...... ...... ...... ...... ......
...... ...... ...... .... 10
2.4.1 Universal Cable...... ...... ...... ...... ...... ...... ...... ......
2.5 Wiring ...... ...... ...... ...... ...... ...... ...... ...... .... 10
...... ...... ...... .... 10
2.5,1 Power...... ...... ...... ...... ...... ... '....... . : ...... ......
...... Il
2.5.2 RS-485 ...... ...... ...... ...... ...... .... , .. , ...... ......
...... ... 1 i
2.5.3 Field Corniections....... ....... ....... ....... . , ...... ...... ......
.... 12
2.5.4 Control Connections ...... ...... ...... ...... ...... ...... ......
...... 12
2.5.5 HART Communicator....... ....... ....... ....... ....... .......
...... 13
2.6 Grounding ....... ....... ....... ....... ....... ....... .......
....... ....... ...... 13
3. Operation ...... ...... ...... ...... ...... ...... ...... ...... ...... ......
3.1 Initial Setup....... ....... ... " ....... ..... , ...... ......
...... ... 13
...... ...... ...... .... 13
.3.1.1 2700 Settings...... ...... ...... ...... ...... ...... ...... .....
'....... 13
3.1.1.1 Address ...... ...... ...... ...... ...... ...... ...... ......
... 14
'3.1.1.2 Baud Rate ...... ...... ...... " ....... .... ' ...... ......
..... 14
3.1.2 RS·485/RS-232 Converter....... . , ...... ...... ...... ...... . "
3.2 Start-up Sequence...... ...... ...... ...... ...... ...... ...... .... '" .15
...... ...... ...... '. 15
3.3 Controls: ...... ...... ...... ...... ...... ...... ...... ......
...... ...... ...... .. 15
3.4 Indicators ...... ...... ...... ...... ...... ...... ...... ......
...... ...... ...... .. 15
3.5 Modes ofOpem tion, ...... ...... ...... ...... ...... ......
...... ...... ...... .... 15
4. Theor y of Opera tion (principles of Opera tion) ....... ....... ... " ......
4.1 HART Filters....... ....... ....... ..... : .. , ...... ......
..... , 15
...... ...... ...... ..... 16
4.2 Multiple Multiplexers ... , ....... ....... ....... ....... .......
....... ....... ...... 16
5. Troubleshooting...... ...... ...... ...... ...... ...... ...... . , .... " ...
: .. '" .. , 17
5.1 2700 MUX...... ...... ...... ...... ...... ...... ...... ......
...... ...... ...... . 17
6. Maiut euanc e....... ....... ....... . , ....... ....... .. " ....... . " . " ......
...... 18
7. Parts List. ...... ...... ...... ...... ...... ...... ...... ...... ...... ......
...... .. , 18
8. Glossary....... ....... ....... ..... , ...... ...... ...... ...... ...... ......
.. : ... 18
9. Conta ct Iuform ation ...... ...... ...... ...... ...... .. '.' ...... ...... ......
.... '.. 19

3 129-0039A
 Figur es
Figure 1. HPSMJ32/TB-02 Layou t. ....... " ...... ...... ...... ...... ..... ' .....
' ..... 7
Figure 2. RS-485 Wirin g...... ...... ...... ...... ...... ...... ...... ...... ......
...... . 12
Figure 3. 2700 MUX Label s .. , ...... ...... ...... ...... . " " ..... " .......
'" ....... . i4
Figure 4. 2700 MUX Bloclc Diagra m ....... ....... ...... r .................
" ........ 16

Table s
Table L PI & P2 Pinou t Codes ....... ....... ... '" ....... .... " ...... ...... ......
... 10
Table 2. Maximum Wirin g Lengt hs...... ...... ...... ...... ...... ...... .....
'" ..... II
Table 3. RS-485 Baud Rate...... ...... ...... ...... ...... ...... ...... ...... ......
.... 14
Table 4. RS-485 Addre ss ...... ...... ...... ...... ...... ....•. '" ...... ' .......
..... " 14
Table.5. 2700 MUX LED Indica tions ...... ...... ...... ...... ...... ..•...
...... ...... 17
Table 6. Replaceable Parts...... ...... ...... ...... ...... ...... ...... ...... ......
.... 18

Appe ndix A - Wirin g Diag rams

Analog Input Series Wirin g Diagr am ...... ...... ...... ...... ...... ......
...... ...... 21
Analog Input Parall el Wirin g Diagr am ... , ..... , ...... ...... ... ' .......
....... ..... '. 22
) Analog Ontpu t Wirin g Diagr am ...... ...... ...... ...... ...... ......
..... ' ....... .. ,. 23

·4 I 29,0039 A
 1. General Description
1.1 Introdu ction

This manual provides guidance for the inst,allation, operation, ,and mainten
ance of y~ur P+F 2700 Multiplexer, and
tennination board model number, HPSMl32/TB-02. TIlis includes model
numbers: HPSMl 32ffB-0 2IFtJSE ,
HPSM/32/TB-02!HFI6, HPSMl32ffB-02IHF-16!PUSE, and HPSM/3
2ffBi-021HF32.
TI,e P+P 2700 MUltiplexer will be referred to in this manual as the 2700
MUX. All further references to the
HPSMl32/TB-02, HPSMl 32ffB-0 2IFUSE ;HPSM l32/TB- 02fHFI 6, HPSMl
32/TB-02IHF-16IFUSE, and
HPSMl32ffB-02fHF32 will be simply I-lPSM. Please note that any referenc
es to HART filters wiU only apply to
the HPSMl 32ffB-0 2fHFI6 , HPSM!32ffB-02/HF-16IFUSE or HPSMl
32ffB-02fHF:J2. When referring to the two
I units as a whole, they will be called the HART Interface Solution, or
simply HIS.
To avoid damage, failure, or improper operation, read this manual carefull
y before ins14l.ling and operating the
equipment.

1.1.1 Purpos e

The 2700 MUX is a HART signal multiplexer unit, which allows access
to HART communioation on existing
4-20mA wiring.

1.1.2 Functions

Your HART Interface Solution interfaces up to 32 field located HART

devices, 'Jhe 2700 MUX is the:il,ar t Dfthe
system. It acts as a gateway device, routing communications between the
inainten~m::;e work,statfon PC" and, ill(}
HART devices. The 2700 MUX uses the HART protocol ,on ,both the
RS-485 lirikto the maintenance wcirkStation
PC and on the Bell 20:2 Frequency Shift Keying (FSKj link (base ~T
proto~ol) to each ofthe HART devices. 'It
interrogates each HART device, retrieves device infonnation, and stores
it in an ·interp.al database. This information
is available to the maintenance workstation software.
. :
Furthennore, the 2700 MUX a.cts as a message coordinator for 9OrtlIJ1u
nicattOh '~etween the maintenance
workstation PC and the HART devices: In this way, 'the 2700 MiJX
is transparimt to the user. In fact,' tile user has
access to eaCh HART device as if'connectea'dlrectly at the devi~e itself.
Additionally, tIle 2700 MUX may be
connected in a HART RS-485 multidrop network. A maintenance worksta
tion PC can ~se this multidrop network
for configuration, maintenance, calibration, diagnostics, and da~ a<?cess.
. ..
HART Interface Solutions are supplied by,P+F with several models in
order'to allow simple and reliable corirt'<idtion
with Smart devices. .
" , ' .
The HPSM/ 32ffB-0 2 is the foundation of this product line. It is simplx.
a passive module that gives the 2700 MUX
accesst o the HART data. The different variations are functionally'siri
illar with'the following optional features:
IIl.'SM!32fTB-02rFUSE: Adds ~,OmA 'fuse in series with tfie't6mninal blocks on li1l32 channels
HPSNV3~-02fHFI6: Adds HART'filters in series with chanNels 1-16
HPSMl32/TB-02IHF-16fFUSE: Adds HART filters inseri"s with 'cha~els l-l6:and 50niA fuse in series
with'
channels 17-32
HPSMl 32ffB-0 2fHF32 : Adds HART filters to all 32 channels

5 129-0039A
 1.1.3 HART Overvie w

HART is an acronym for "Highway Addressable Remote Transducer".

111e HART protocol makes use of the Bell
202 FSK standard to superimpose digital signals at a low level on top
of the 4-20mA signal. This enables two-way
communication and makes it possible for additional infonnation beyond
just the normal process variable,to be.
communicated to/from a smart field instrument. TIle HART protocol commu
nicates without interrupting the 4-
20mA signal and allows a: host application (master) to get two or more
digital updates per second from a field
device. As the digital FSK signal is phase continuous, time is no interfer
ehce with the 4-20mA signal.
1.1.4 Specifications

1.1.4.1 2700 MU'x Specifications

POWER SUPPLY: 24 YDC (-15%, +25%)

SUPPLY CURRENT: 20YDC, 32mA (typical, R$485 quiescent)
24'\1DC, 28mA (typical, RS485 quiescent)
30YDC, 23mA (typical, RS485 quiescent)
MODULE CONNECTION: 2, plug-in, 40-poles miniature connectors
EMC: EN50081-2, EN50082-2
ISOLATION: 1500Vrms for I minute
ENVIRONMENTAL CONDITION LlMlTS :
Operating temperalure: 0 to 55"C (32 to 131"F)
Storage Temperature: -20 to 70"C (-4 to 167"F)
Relative Humidity: 5 to 90% non-condensing
SIGNAL CHANNELS:. Up to 32 signal pairs unbalanced
DC-ISOLATION:' DnaI' capacitorisolation in eacli loop'
ALLOWED COMMON MODE YOLTAGE: Up to 30Y
DIFFERENTIAL MODE CLAMPING: +1- 5.2Y (for transient or AC
signals)
RECEI VESfG NAL RANGE: O.l2Vpp < signal < I.5Vpp
RECEIVE IMPEDANCE: >50000
CARRIER DEmC T LEVELS: Signal> 0.12Vpp - Cj) asserted
Signal < 0.080Vpp - CD not asserted
TRANS MIT SIGNAL AMPL rtutiE: 200n load - O·.43Vpp < sigmil< 0.49Vpp
5000 ioad -'1.1 Vpp < signal < 1.2Vpp
CARRIER STOP TIME: <10 bit time
.
DEViC E CONNECTION TYPE: Secondary DeviCe (DC-isolated bus
device)
IMPEDANCE LEVEL TYPE: High impedance device
DATA..LINK TYPE: Primary or Secondary master (configurable)
FffiLD MULTI-DROP SUPPORT: Available on request
1
i.lA.2 HPSM Termin ation Board specific ations

MOUNTING: Mounts to standard T-type (EN500 22 (D)N46277,3»

CONNECTIONS: Phoenix Contact 5.0&mm screw lenninals for power,
or G-type (EN50035 (DIN46277-1) DIN rail.
I
RS-485, and flO; 4-40 Screw (Crmina.ls for
shie.!d conn~ctions; Two 37-pin S'ub-D tYpe ""nnect ors.for universa.! cable
POWER FUSE: 125mA, 5x20mm
DIMENSIONS: (See Figure I)
... .
.
I
Length = 11.8" (300mm)
Width = 5.0" (127mm)
Height = 2.84" (72mm) .£7.3" (186mm) wlMUX installed]

l
6 129-0039A
I
.J .,
.'
• HPSM/32/TB-02 Layout

• r'-----RS~~-6S~-------
TO FIELD DEVICES
11""'~W.~
G.,r(l:\(!~J

• .
r= ""
Ile~r

• ~ OC
PTI N L.H TILT R OM ON Nl

~ °i!.~II!1°I·!0110!01!0100!0i011011111·1·101!0~'~'~:M~I~11£11
~~~io~j
'-"- ;;. k

•I ~
aa
... +~ .....

,~,.". ,~ ..."
v;:;J
~ ~
03

'"
000000

0 '1000

, " ' , . , ....

0
0000

00 0
G

0
0 0

0
'"

0
'" B1-3Z(1

Cl~(SIq e
''''''''''''''''''~''''"'' • • '''' • • " . C>~N'"
TO PLC/DCS CONTROL SYSTEM
1:
l" 11-t----'----,-~.-jl---1~
-~~-""

I ELeON
..... "....,'"
~

INSTRUMEt(f~.IfIC.

r 1.1A.3 RS-485 Une Specifications

Figure 1

I
~.
COMMUNICATION PORT: RS-485 differential pair (isolated). An
connect the PC host station to the board Terminal block (see Figure 3).
RS-232 to RS-485 converter is needed to
DIGITAL COMMUNICATION SPEED: 9600 bps or 19200 bps (user
selectable)
I MULTI-DROP ADDRESSING: up to 31 2700 MUX modules (32 channel
MULTI-NETWORK OPERATION: Available within software options
MAXIMUM NUMB ER OF 2700 MULTIPLEXERS IN NETWO RK:
s each)

31
NETWORK TOTAL: 992 per Serial Line
MULTI·NET WORK OPERATION: 4 Serial Lines; Available witlJin.
maintenance software packag e
SMART PROTO COL 'PRESENTLY SUPPORTED: HART .
OUTPu T NETwO RK: RS-485 (use an RS-232 to RS-485 converter
Keithley type MiOOO to connec t the PC
( main(enance station).
BAUD RATE: 9600 bps or 19200 bps (user selectable)
TOTAL NUMB ER OF BITS: II bits
NUMBER OF DATA BITS: 8 bits
PARITY: ODD
NUMBER OF STOP BITS: I bit
TRANS MISSrO NTYPE : 2-wire

7 129-0039A
 I
1.2 Asset Management Solutions (AMS) Software

AMS software provides an easy-ta-use means for integrating various device management software packages into a
I
unified system. AMS operates under the Microsoft® Win~ows® format. It combines the various device (or asset)
management tasks into an application with a common look-and-feel and centralized data storage.
I
AMS provides access to functionality available via the HART communications protocol for any HART device
I
whose Device Description (DD) is registered with the HART Comrnunicatio~ Foundation.

For more infonnation on instaHation of AMS software, consult the AMS Installation Guide.

L3 Associated Tools and Test Equipment

No special tools or test equipment are required.

1.4 Quality Assurance

All Pepperl+Fuchs production is performed under a Quality Assurance program following written procedures, which
are specific for each line of instruments, during the manufacturing, intermediate testing and inspection, and finat
inspection phases.

Each 2700 MUXunit undergoes accelerated thermic aging (bum-in) for a minimum.200 hours at 50°C (122°F) with
at least f cooting thermic cycle at O°C (32°F) and back to 50°C (122°F). The purpose is to identify weak
components" that may develop initial- fault mechanisms que to uInfant Mortality!!, Only after a positive bum~in test.
instniments undergo a complete final inspection performed with computerized automatic testing equipment
specifically devel()ped by P+F for this purpose.

1.5 Certifications and Compliance

HART interface Solutions are CE compliant

This Equipment is suitable for use in Class I, Division 2, Gro~ps A, B, C, and D or non-h~rdous lopations only,
Eqnipment must be mounted in an enclosure that meets the requirements of ANSIII8A S82.0 1& 882.03 and the
National Electrical Code.

1.6 Unpacking and Inspection

Upon receipt of the materials, you should 'check the integrity of the packing and the contents. in case of damage due
to shipping, you should promptly and properly report to the shipper, supplying all necessary information.

If instruments are not for inunediate use, we reconunend that youeheck that all characteristics shown on the
instruments jabet meet order specifications (model, snpply voltage and frequency, input/output range, certification,
tag etc.) as well as the actual application.requirements.

If not installed, equipment should be stored following recommendations ofthe next section.

8 129-0039A
 1.7 Storage

• [n case of storage of instruments and accessories, proper care should be

damage. Always store instruments in their sealed original packaging

Provide adequate protection to prevent damages that may be caused by

• Rain, excessive humidity and/or temperature excursions (inadequate
• Dust (build~up of a corrosive patina that may cause oxidations and
taken to· protect them from any possible
until they are installed.

exposure to:
lihcJtcring).

•
reduce isolation).
• Aggressive and polluting atmospheres with consequent corrosion
.
• Access by insects/rodents (damage of packing or content).
• Mechanical shocks or unauthorized packing opening.

•I
• "Intense' vibrations (loosening of fastened parts, fatigue failures, etc.),
• Any other possible risk.

Make sure the storage tempera ture does not exceed the limits of -20.
to +55°C (-4 to 131°F) for mediurn!long term
storage (days/m onths) and -25 to +75°C (-13 to 167°F) for short term
storage (a few hours) transportation/shipment.
If inspection is completed, pack instruments in their original packing
. List-the contents on the packaging to avoid
unnecessary further insp'ections.

2. Installation
I 2.1 Environmental Conditions

HIS products, like most modem electronic equipment, can operate in wide
temperature and humidity ranges.
However, practical consideration suggests a guideline on operating environ
ment for best results.
• Keep operatin g tempera ture below 35°C (95° F), ideally between 2Q o
C and 25°C (68-and 77°F), avoidin g wide

I •
•
and rapid temperature ex~ursions.
Control relative humidit y within 40 to 60.% to avoid risks of static charges
Limit the presence of corrosive atmosphere, fumes an,d dust" sealing and
or condensation.
.

purifying the control room area and

using air filters in the cabinet air intakes (clean cable entry patli);'if
necessary.
I •

2.2
Reduce vibratio ns (if any) to safe levels.

Intrinsi c Safety

I The HIS system can interfac e HART devices located in Hazardo us

areas by interposition at suitable galvani cally
isolated Intrinsically Safe Barriers. The barriers must allow biditect
ional HART signal commu nication in addition
to the normal 4-20. lIlA loop current processing.

I 2.3 Mounti ng

The 270.0. MUX is a plug-in unit that must be inserted in the appropr
iate teI'mination board position. Exerds e c;u:e in
1 the insertion to mate the connector's phis, then firmly press the module
"Quick- Lock" mechan isms on each end of the module to secure it to
to engage ille connector. Use Pi-F's simple
the tennina tion board.
The HPSM is designe d to be mounte d on T-type or G-type DIN rail.
The board should be mounte d near the
marshalling panels or termina tion panels.

9 129-QQ39A
 2.4 Cables

HART signals are brought to tl,e 2700 MUX either by use of the screw-t
ype tennina l blocks or by use of the
universal cables on the HPSM panel.

2.4.1 Univers al Cable (Sec Table l)

The universal cable allows you to connect the HPSM in series or parallel I
to any DCS flO tennina tion panel. Each
cable has a DB-37 pin connector for connect ion to the HPSM. On the
opposit e end, 16 labeled pairs of color-coded
wire provide connection to your tennination paneL See Table 1 for pin
"assignments.

Table I
PI & P2Pi nout Code s
Male 37 Pin Signal # Chann el Male 37 Pin Signal # Chann el
D-sub Pin # D-sub Pin #
1 NC Unused 20 NC Unused
2 I- I-I 17- 21 2- 2- 118"
3 1+ 1+/17+ 22 2+ 2+ 118+
4 3- 3-/19- 23 4- 4- 120-
5 3+ 3+ 119+ 24 4+ 4+/20+
6 5- 5- 121- 25 6- 6-/22-
7 5+ 5+121+ 26 6+ 6+/22+
8 7- 7- 123- 27 8-
) 8- 124-
9 7+ 7+/23+ 28 8+ 8+/24+
10 9- 9-/25- ·29 10- iO-/26-
11 9+ 9+125+ 30 10+ 10+ 126+
12 ll- ll-/27 - 31 12- 12- 128-
13 11+ ll+ 127+ 32 12+ 12+ 128+
14 13- 13-/29- 33 14- 14- 130-
15 13+ '1:3+ 129+ 34 14+, 14+/30+
16 . 15- 15-/31- 35 16- 16-132-
17 15+ 15+ 131+ 36 16+ 1M 132+
18 NC Unuse d 37 NC Unused
19 NC Unuse
.. d
,

2.5 Wiring

The 2700 MUX is a plug in unit and is connect ed to the HPSM by a

multipo le connect or. TIlerefore, all electrical
connections (supply, field connection, serial lines, etc.) are made at
>
the tennina tion board unit.
."

\.

10 129-003 9A
 2.5.1 Power

Connec t 24 VDC to the 3-pin removable terminal at the end of the liPSM.
The connector is polarized, so you
cannot insert it incorrectly. The polarity is marked on the board and the
terminals.
WARNING! Improper supply connections can seriously damage the instrum
ent
and result in risk of fire or explosion in hazardoustlocations!

DC SUPPL Y REQUIREMENTS: Check correct polarity of supply

line, making sure that voltage excursions never
go lower thall 21.5 V (including ripple effect) or higher than 28 V.

WARNING! Note that a crude, poody filtered or unregulated supply.

can
produce destructive (hundre ds of volts) voltage spikes during supply
transformer
switch-offttat1Sient; this could cause minor problems.tO electro-mechan
ical
components like relays or solenoid s but will surely degrade or destroy
electron ic
equipments. In case of doubt, provide over-voltage limiting by adequat
ely
dimensioned surge arresters on primary winding and voltage limiters (power
zeners, zenamic, etc.) on the DC supply line to limit transients within
30-35V
peak.

SUPPL Y CONDU CTORS SIZING:

A single unit requiring 100 niA will have a conductor sizing based on mechan
ical strength rather than current
carrying capacity_ A reverse polarity shunt diode and series fuse protecti
on are provided to avoid damaging the
module in case of accidentally reversed polarity connection.. In this case,
the reverse voltage is clampec;l at -0.6 V
and the T.B. slow blow fuse blows. Restore correct supply polarity
and replace the blown fuse with the spare o1)e .
supplied in the T.B. spare fuse holder (take care to reinstall a good,
properly sized, new spare fuse!).

2.5.2 RS-485 (See Table 2)

RS-485 wiring is connected as shown in Figure 2. These wires carry

data from the HIS to the PC via an
RS-485IRS-232 converter. Connect the convert er to a serial port on the
PC as indicated ·in the convert er's
documentation.

Table J-.
M axun um·W··
lrmg Lengll
. tI s
Communication Protocol Maximum Cable 'tehgt li ' .

Feet M~ter~,
. RS-232 50
.. 15
RS-485 4000 1200
HART 900 to 6500 275 to 2000
. /.
RS-485 cable length can be mcreased 'fh,gh perform ance cables are
used.
HART cable length depends on the capacitance of tile cable and device,
and the load resistor. The general rule is:
R x C < 65ms. Consult "HART - A TeChnical Descrip tion" for more
details. This is a free docume nt published by
the HART Commu nication Foundation.

11 129-0039A
 RS-485 Wiring

Figure 2
2.5.3 Field Connections (See Appendix A)

Field wiring can have many variations, depending on the type offield device. The wiring will either be in parallel or
series. this reference is made to" the flO loop whether the wiring already exists or not. Most wiring scenarios are
shown in Appendix A. If your application does not match thbse shown, pl""$e contact your nearest P+F
representative (See Chapter 10). ""

.2.5.4 Corltro!" Connections

If your unit is wired in parallel, no connectioM should be made to the control "side terminais. When wiring in series,
refer t6 the appropriate series wiring diagram in Appendix A.

"12 129-0039A
•
•
2.5.5 HART Communicator

[n HART communications, there is one slave (field device) and up

,. ~. to two masters (e.g. Multipl exer, HART
Communicator, VO module), The HART Communicator can be cormect
ed to the field side tenninals ~ a secondary
master. In your software settings, the 2700 MUX must to be the primary
master in order to use the HART
Communicator.

There cannot be more than two masters. [fthree or more masters are conn~ct
ed, a primary/ secondary co!)tlict will
occur and communications will cease with all devices on that loop.
When the 2700 MUX is used with a HART
I compatible VO system, the 2700 MUX must be configu red as the seconda
MUX as the primary master. The HHT is asecondary master by default, and
ry master. Otherw
ise, configu re the270 0
can be connect ed to the loop when no

•
other device on that loop is configured as a secondary master.

WARNING! Do not connect the HART Commu nicator to any Intrinsic

ally Safe
field wiring unless the terminal is approve d as Intrinsically Safe and
suitable for
the actual haiardous location classifi.cation of the specific hazardous location
.
Also consider HART Communi~at9r safety parame~ers and eqlliyafent
capacitance and inductance before concludif!,g that you can safely connect
it to
the I. S. side ofthe circuit.

I 2.6 Grounding,

•
TI,e HPSM provides two separate shield terminals. TI,e field side termina
is are connect ed to .SBD 1, which provides
a single point to properly ground field wiring shields. SBD2 is connect
ed to the control side shield termina ls and the
power supply shield tenninal. This terminal may not be necessary to use,
but is available for different applications.

3. Operation
3.1 I~itial Setup

I The default settings for each· 2700 MUX areas fonows:

Address = 1
Baud Rate = 19200
I 3.1.1 2700 Setting s (See Figure 3)

I The User Switches buffer has eight inputs from a low profile DIL switch
The functions of the switche s are as follows:·
Switch -; . (T) ReserVed for lEST putpose s
reachab le through the front lab~i.

Switct, 6 (RI) B.AUD~TE 1

I Switch 5
Switch 4
(RO)
(B4)
BAUD RATE 0
ADPRE SS 4
Switch 3 (B3) ADDRE SS 3

I Switch 2
Switch I
Swiid; 0
(B2)
(B 1)
(BO)
ADDRE sS 2
ADDRE SS 1
ADDRESS 0

I Further information is given on the front and side labels (Figure 3).
setting of every DIP switch combin ation .
In partiCUlar, the side label gives the correct

...;

13 129-003 9A
 3.1.1.1 Addres s

The address of the 2700 MUX is'determined by th~ DIP switches as

noted below (Table 4). Each MUX on the same
RS-485 network must have a differen t address, but they do not have
to be sequent ial and do not necessarily need to
start at address I. Possible addresses are 1-31. Address 0 is invalid'
and cannot be used. Note that network
properties of the software setup refers tq "multi-dropping." ll1is refers
to multipl e 2700!vf UXs on the same
network, not mUltiple devices on the same [/0 loop (also referred to
as '}nulti-d ropping "). Multi-dropping should be
enabled in the network setup.

3.1:1.2 Baud Rate

RS-485 BAU D RAT E

SWi) SW7
9600
19200 . I ON
OFf·
OFF
OFF
Table 3
The baud rate of the 2700 MUX must match the baud rate of the PC
Com-Po rt and the RS-2321RS-485 converter.
All three units must have the same baud rate to function properly. TIiebau
d rate can be either 9600 or 19200 and is
sei"ected as shown in T~ble 3.

2700 MUX Labe ls RS-485 ADD RESS

SWI SW2 SW3 SW4 'SW5 SWI SW2 SW3 SW4 SW5
0 OFF OFF OFF OFF OFF 16 OFF OFF OFF OFF ON
(3 1 ON OFF OFF OFF OFF ; 17 'ON OPF· OFF: ·OFF· ON
2 OFF ON OFF OFF OFF 18 . OFF ON OFF OFF ON
'15 ()" 3 ON' ON' OFF OFF OFF 19 ON' ON OFF 'OFF ON
4 OFF OFF ON OFF OFF 20 OFF OFF ON OFF ON
MUX 5 ON OFF ON OFF OFF Zl 'ON OFF' ON OFF ,:ON
2700 6 OFF ON ON OFF OFF 22 OFF ON ON OFF ON
32ChIMOi 7 ON ON ' ON OFF' OFF 23 .'ON' ON OW '. OFF ON
HAAT

""""'- 8
9
OFF
ON
OFF
OFF'
OPF
OFF
ON .
ON
,OFF 24,
OFF 25
OFF 'OFF' OFF ON ON

......
ON OFF ON OFF OFF ON ON
10

i
OFF ON OFF ON OFF 2'/j OFF ON OFF' ON ,ON

-... 11 ON ON OFF ON OFF 27

WfI ADDRESS
ON ON OFF ON ON
"'" 12 OFF OFF ON ON OFF 28 'Ol'F OFF ON ON ON
: : BAUQRATE 13 ON OFF ON ON OFF 29 ON OFF ON' ON ON
14 OFF ON ON ON 'QFF 30 OFF ON ON ON ON
15 ON ON ON ON OFF 31 ON ON ON ON ON
bJ
~

Figur e 3 Table 4
)

14 129-0039A
•
•
I
3.1.2 RS-232 IRS-485 Couver ter

An RS-232 to RS-485 convert er must be placed between the HIS and the
reconun ends the Keithley M I 000 for non-CE applications.
comput er's RS-232 port. P+F

•
I
[fonly one RS-232 to RS-485 convert er is used in setting up the system,
1200 meters (4000 feet). [ftile network surpasse s 4000 feet, an RS-232
Keithley MHioO can fulfill this function. The repeater amplifie s tlie
over' long distances.

3.2 Start-u p Sequen ce

then the RS-485 network must be less than
to RS-485 repeater can be used. 11le
origin~ RS-485 signal when it is transmi tted

Proper start· up sequenc e for the 2700 MUX is as follows:

I I. Make all signal connect ions to the HPSM
2, Connec t RS-485 wires and adjust network settings
3. Apply field power or source 4·20mA

I 4. Tum on power to or plug in the 2700 MUX

5. After the 2700 MUX has complet ed the start-up sequenc e, then start AMS

3.3 Control s
I The only controls on the P+F equipm ent are the DIP switche s noted
above. All other settings are a function ofdle
software. Please refer to your software instruction manual for further details.

I 3.4 Indicat ors (See Figure 3)

r
Three LEOs on the front of the 2700 MUX inaicate status. Nonnal
operatio n is as follows:

• PWR ON: Green LED lit when power is applied to the 2700 MUX. Power is
automat ically applied when the
2700 MUX is plugged into tile HP'SM.
• HART TX: Shows 2700 MUX commun ication with field devices
I • FAULT : Fault LED should not be lit during nonnal operatio n.
.

One LED on the termina tion board is a power indicati on showing

24 VDE: available.
I 3.5 Modeso C Operat ion

• SCAN MODE: Comma nd to the 2700M UX from the softwar e telling

I device automat ically. Otherw ise, the 2700 MUX will only commun
the softwar e. '
the 2700 MUX to periodic ally, scan each
icate with a device when told to do so by

• BURST MODE: When a fiela device is in burst mode, it automat

ically sends informa tion without being
I comman ded to do so. This is a break from the master-s lave· nature
MUX will support it when burst mode is selected in the softwar e.
"fHAR T conm.un iclition, but the 2700

I 4. Theory of Operation (principles of Operation)

Referrin g to Figure 4, the heart of the .2700 MUX is the microproceSsor

I modem 'generates the physica l layer ofibe HART protOCOl, while

multiple xer links one specific channel (deviCe) at a time. An RS-485
. One serial port togethe r with the HART
th~ ch"'l\lel,~e!ect,circuit togethe r with the cha!illel
circuit complet es the gatewa y betWeen the
maintenanCe worksta tion PC and the devices . The user'sw itches circuit
provides informa tion required by the 2700
MUX for initializ ation and configu ration. Specific ally, the baud rate for
commun ications to the mainten ance
worksta tion PC and the 2700 MliX address are selected .
'

1\
15 129-003 9A
 2700 MUX Block Diagram

RS-485
Interface RS-485 Line
Power
Supply
SectIon
HART Channel 1
+24 V +}-+-- -1
G NO < 1--+..,.-1
'--,.- -' L-.{-'- +-i H+-(.+ i-) .
r--H '-0 HART Channel 32

Figure 4
4.1 HART Filters

IiART filters may be necessary for certain systems for the followin
g tcasons:

• To increase low output impedance ofDCS so the HART signals have

sufficient amplitude
• To remove fa,st transients from step changes in DeS output
• To prevent disruption ofDCS circuitry by HART signals

Note that when a HART filter is used, the HART simal will:not be availabl
e to any monitoring equipment on the
control side of the HPSM, including the DCS or HHT. P+F recommends
HART filters for any HART output signal
(valves). DCS systems from Bailey, Fischer and Porter, Honeyw~
ll, Foxboro, and Fisher-Rosemount may require
HART filters. Consult with the valve or lIP supplier to know if filters
are required for a specitk control system or
field device.

HPSM/32fTB-021HF16: Channels 1-16 have HART filters. Channels

17-32 do not.
HPSM/32ffB.-021HF32: Channels 1-32 have HART filters.

CAUTION: HART filters ar~.only for use with output signals. Transm
itters will .
not function when connected to a channel with a hart filter

4.2 Multipl e Multipl exers'

Up to 31 2700 MUXs can be connected on a single RS'485

are COllliecied'in daisy-chain form, and redundant terminals network to suppbrt 992 devices, Multiple'2700 MUXs
are provided for thIs on e~ch board.

16 129-0039A
•II 5. Trou blesh ootin g
Due to the modular nature of the HIS system, a commu nication failure
may occur anywhe re in the data tr;msfer link
from the softwar e to the field device. fll order to identify where the

I important to understand which compon ents arc working correctly.

troubleshooting. Some afthe most commo n mistakes are: imprope
improper network settings, and improp~r address ing of the 2700 MUX.
loss of commu nication has occurred, it is
Often, some simple checks wiH save hours of
r wiringjconnections, baud rate mismatches,

I 5.1 2700M UX

•I
The LEDs at the front of the 2700 MUX provide a convenient indicati
on to the user that the 2700 MUX i.s
operational. During nonnal operation, the "Power On" light should
be on. The "Fault" light should be off. The
"Tx" light may either be off or flashing steadily.

When power to the 2700 MUX is cycled or a "Reset" comman d is issued,

~II the lights will come on. TIlen, the
"Power On" light only will come on. For the next 60 to 120 seconds
, the "Tx" light will flash three times then
pause. During this time, the 2700 MUX is scannin g each of the 32
channels. When it is finished, the "Tx" light will
either flash steadily or tum off altogeth er. If you see all ofthe above
occur, the 2700 MUX is operatin g properly.
In addition, the TEST setting on the optiqn switche s can be used to gain
cOnfidenc;~ that the module is functioning.
Follow the procedu re below td use this fe~ture:
.
1. With the power off, set the end' switch to the TEST position (ON).
The module should not. be connect ed to
I the RS-48S network, the RS-48S address switches have"no effect. Ifan
module, the BAUD. rate switche s should be set
RS-48S "tennina l is connected to the
2. Switch power on."The LEDs should light for about 1 second each
in sequenc e (RED, YELLO W,
GREEN ... ).
3. If the LEDs do not flash, there is a fitult with the module and it
should be rt;tumed for replace ment
4. To retum to normal operation, remove"power to the 2700 MUX
and set the TEST switch to the off position.
Ensure that the correct BAUD rate is selected and that an RS-48S address
is set. TIlen, re-apply power.
If you suspect the 2700 MUX is not function ing properly, use Table
I 5 below.

Table 5
I Svmnt om
2700 MUX LED Indic ation s
Cause Soiuti o!l
Lights flash sequentially TEST switch is ON SwitCh o.ffthe power
I Put TEST switch OFF
Restart the system
No LEDs lit Power fail or fuse open
. 24 VDC supply LED
Check
( Only yellow LED lit Scanning is disabled.
and fuse
" "

Check wiring continuity

If sca!ll1ing is enabled, then no
HART devices were detected
bv the 2700 MUX
Red LED lit Self-test fault Contact Pepper1+Fuchs for
further instructions

17 129-003 9A

~""""'_" __ '._ ..'A __ ," __ ..

6. Maintenance
Pepperl+Fuchs apparatus do not require any particular maintenance under normal operating conditions. They are
designed to operate trouble-free and with high stability for long periods.

WARNING! Any repair made by unauthorized personnel may completely

invalidate the safety characteristics of the unit and could 'foid all warranties.
Repair not made by Pepperl+Fuchs is fully at user's risk and responsibility. In
addition, the warranty terms of the unit will be null and void to all effect.

7. Parts List
Table 4 is a representation of the parts on the HPSM that can be replaced by the USet. There are no parts in or on the
2700 MUX itself that can be replaced in the field. If any other parts need to be replaced, please contact your nearest
Pepperl+Fuchs representative for instructions.

Table 6
R epJacea
I ble Parts
PattNumber Descripti6ti
501.300 Supply ~Dliibd
~02401 Terminal blocks MVSTBW 2.5i'ji'ST~$.<iS
508100 Fuse 5x20 time-lag, 125mA FSI, FS2
508200 Vertical fuse holder for 125mAFSf, FS2'
508300 50mA TRS Microfuse U;,32

8. Glossary
DCS Distributed Control System
FSK Frequency Shift Keying
HART®Highway Addressabie Remote Transducer
HHf Hand Held Terminal
IS' Intrinsic Safety
MW Ml).itltenance Workstation
PC Petpona\ Co[llPllter
PLC Prograriunable Logic Controller
TB . T~rInin~tio~ Board

18 129-0039A
I
9. Contact Information
I Intern ationa l Headq uarter s

Europe
Pepperl+Fuchs GmbH
Konigsberger Allee 87
Mannheim
68307 Germany
I Phone: + 49 621 776-0
Fax: + 49 621 776- 10 00
Email: info@de.pepperl-fuchs.com

I Website: www.pepperl-fuchs.com

Regional Headq uarter s

Italy and Medite rranean
Pepperl+Fuchs Blcon - Head Office
Via delle Ind ustrie, 4
Mezzago (Mi)
20050 Italy
Phone: ++39 039 6292 I
Fax: ++39 039 6292 290
Email: info@it.pepperl-fuchs.com
Website: www.elconinstruments.com

North Americ a & South Amerie a

Pepperl+Fuchs loc. - USA Headquarters
1600 Enterprise Parkway
Twinsb urg,OH 44087
USA
Phone: +I -330 425 3555
Fax: +I -330 425 4607
Email: sales@us.pepperl-fuchs.com
Website: www.am.pepper[-fuchs.com

Asia Pacific
Pepperl+Fuchs Pte Ltd - Asia Pacific
P+F'Bui[ding .
[8 Ayer Rajah Crescent
139942 Singapore
Phone: +65·779 90 9 [
Fax: +65 873 1637
Emai[: sales@sg.pepperl-fuchs.com
Website: www.e[coninstruments.com

19 129-0039A
 Appendix A

I/O
Wiring Diagrams

20 129-0039A
•
•
Analog Input Series Wirin g Diagr am

Self-Powered Transmitters

•I
XMTR Power

"Ah Po~.(-tJ

H 0250 ohms
~+-~N~~-~(-~J~_____ ___~iB
Bl----- ---""Neg.
"-=
4-20 rnA
,q
FIELD SIDE CONTROL SIDE

I Self Powered
Transmitter
TERMINALS

_ _ _ _ OR-'----_ __
TERMINALS

I XMTRPo wer

('J~,+,P:'::OO::.->.:.('J' ----r'r- ------!A

•I (-J .-,'--'-' =-'--\d -------- ----ij

Self Powered
FIELD SIDE
TERMINALS
Transmitter 37-PIN SUB-D
CONNECTOR P 1 (P2)

Loop Powered Transmitters

I ~+:..;POc::'--,,(':...JA--- ----- -\ A AI--_ ___ __PC>oec'-""'-,
Neg.(-)
T 24 Vdc
4-20mA BI---- --="-" 'J. v
250 ohms

FIELD SIDE CONTR OLSIDE

Loop Powered TERMINALS TERMINALS
Transmitter
_ _ _ _ OR>-_ _,-

FIELD SIDE
Loop Powered TERMINALS
Transmitter
37-PIN SU6-D
CONNECTOR P1 (P2)

21 129-0039A
 Analog Inpnt Parallel Wiring Diagram

Loop or Self-Powered
Transmitters

,,-;:) ~I 4-20 rnA Pes. (+)

Ncg.(-) ~ 24 Vdc
~ 250 ohms

I I
""
A
~ -,
Transmitter
BB\
CONTROL SlOE
TERMINALS

OR

4-20 rnA Pos. (+)

Nog. (_) ~ 24 Vdc
~r---------~,,----~--~==~~~
250 ohms

Transmitter

37-PIN SUB-O
CONNECTOR P1 (P2)

22 129-0039A
 Analog Output Wiring Diagr am

Smart Valves (AO Signals)

~

1'0 o'I:~:
r'"
Pas. (+)
A Ah Pos. (+) 4-20 rnA
Nog. (-) ( l ~

Ncg.H
8 8
I 'c ~.
Smart Valve ShIeld
~I'

FIELD SIDE CONTR OL SIDE

TERMIN ALS TERMIN ALS

-- 08
)

, ~
.'0 0'
Smart Valve
Pos.(+},,- ...

:~:.-~N"':O!.:'""-(-)-I(c-JI'--_ _~r;:,.B
4-20 mAY
• IL.~J2to'hilill·'M<L-·--J,C
~

A Po,-<+) 4-20 rnA

He . ~

FIELD SIDE
TERMIN ALS

t 37-PIN SUB-D
CONNECTOR P1 (P2)

I
,.

23 129-0039A

Released EOM o:h<lcl<01l1 2Ra .....FEB.1!

ACM STEP DOWN

TRANSFORMER

INSTALLATION, OPERATION AND MAINTENANCE OF
GENERAL PURPOSE DRY TYPE TRANSFORMERS
600 VOLTS AND BELOW
1. GENERAL
The installation, operation and maintenance of dry type
transformers should be performed by an electrician or other
qualified personnel who are familiar with international,
national, andlor local electrical codes and with the potential
shock hazards associated with electrical equipment.
These instructions cover two types of enclosure construction:
ventilated and encapsulated.
A) Ventilated units are NEMA type 2 enclosures suitable for
indoor use. They are UL-3R listed and CSA certified for
outdoor use with the addition of an optional weather shield
kit. The proper weather shield part number is listed on the
nameplate.
B) Encapsulated units are NEMA 3R enclosures suitable for
either indoor use in harsh environments or for outdoor use.
CE marked units have a protection index of IP23.
This transformer is ready for installation and operation. It must
be installed per the National Electrical Code® and local code
requirements. It is recommended that these instructions be
l-· ··read carefully-prior to installation and kept·for. future
reference.
I CE marked transformers must be installed per EN 60742.
2. INSPECTION AND HANDLING
The transformer should be inspected carefully upon receipt to
check for any visible or concealed damage that may have
occurred during shipment. If damage is found, a claim should
be filed immediately with the carrier.
Single and three phase transformers, in smaller KVA sizes,
are provided with lifting ears. Larger KVA sizes are palletized
and can be lifted with appropriately sized fork lifts or hoisted
by the lifting lug bolts provided on the core frame after
removal of the top cover. Incorrect handling can bend the
enclosure or cause other damage or result in personal injury.
3. INSTALLATION
1V1"i11."'N~
Hazardous Voltage.
~
Will cause severe
personal injury
or death.
Turn Rower off
supp ying device
before installing.
WARNING: There is a potential danger of electrical shock
when working on electrical equipment! Make sure power is
off before installation. Replace all covers before energizing
transformer.
INSTRUCTION SHEET I
A) Ventilated Dry Type Transformers
Ventilated units can be installed indoors or outdoors. Outdoor
installation requires the addition of a weather shield to be
UL-3R listed. For outdoor installation, check electrical codes
for the proper protection of transformer against adverse
weather conditions.
Ventilated units should be installed in a upright position on
walls (optional wall mounting brackets are available for certain
KVA sizes), beams, platforms, floors or other structures
capable of supporting their weight.
The ambient air should be dry and free from dust, dirt,
corrosive fumes, heat or other adverse conditions. The unit
should be installed a minimum of 6" from the wall or other
obstructions that might prevent proper air flow through the
vents.
Ventilated transformers are designed for operation in an
average ambient temperature of 30 degrees C (86" F) and a
maximum of 40 degrees C (104" F) not to be exceeded.
Large KVA sizes contain "shipping bolts" to prevent damage
. during.shippiog_"1:lwse.sl1ould be,removedjust.prior. to
installation of the unit.
B) Encapsulated Dry Type Transformers
Encapsulated units can be installed. indoors or outdoors.
When installed outdoors, these units should be installed with
the wiring compartment down to prevent the entrance of
moisture. Some encapsulated units have a top entry wiring
compartment and can be installed vertically (wiring
compartment up).
For indoor floor mounting of an encapsulated unit that has a
bottom entry wiring compartment, the unit can be installed
horizontally (on its back side) for ease of making wire
connections.
4. ELECTRICAL CONNECTIONS
WARNING: Danger of electrical shock! Do not remove parts
or make connections while the transformer is energized.
Refer to the transformer nameplate label or enclosed wiring
diagram for primary and secondary voltage combinations,
frequency and number of phases. Tap connections and
voltage combinations are also listed on the diagram or
nameplate.
CAUTION: Do not make connections other than those
shown. The transformer must be as large (KVA) as the load
it must operate. Never exceed the nameplate rating as this
could result in overheating, reduced life expectancy, or in
worst cases, fire.
PART NO. A-701953-A
 INSTRUCTION SHEET A1

A) Ventilated Dry Type Transformers 5. GROUNDING

Proper assembly of the connector (lug) to the transformer
terminal is extremely important. Make certain that the
connector is sized for the cable and is of the correct type to
match cable and terminal metals. Always follow
recommendations of the connector (lug) manufacturer. Space
and insulate connectors per the NEC®'
All dry type transformers have a ground stud in the enclosure.
The transformer enclosure should be solidly grounded to
protect personnel. The customer supplied grounding
conductor should have a current-carrying capacity to meet
international, national, andlor local requirements.

6. MAINTENANCE
INSTRUCTIONS FOR ALUMINUM BUS BAR CONNECTIONS
Non-ventilated encapsulated styles only require periodic
The following steps should be followed when making wiping of dust and dirt from the outside of the case under
connections to transformers with ALUMINUM BUS BAR normal conditions and environments. Adverse conditions may
TERMINALS. require more frequent inspections.

1) Remove oxide form joint area of transformer bus terminal. Ventilated units should be inspected within one to three
This may be done with a wire brush or emery cloth. Other months after initial installation. Air ducts should be kept clear
tools may be used but care should be taken to avoid at all times. Vacuum cleaners or low pressure compressed dry
I scratching or gouging terminal. air can be used to remove dirt or dust. A regular inspection
schedule for cleaning and maintenance will help ensure
\ 2) Coat terminal area with joint compound, following added safety and longer transformer life.
I manufacturer s instructions.
If a dry type transformer accidentally gets wet, it must be
3) Make connections using one of the bolting methods shown. cleaned and thoroughly dried before energizing. Otherwise,
\, complete failure could result!
I
ALUMINUM BOLTS STEEL BOLTS CAUTION: Never pertorm internal maintenance while the unit
STEEL BOLT, ASTM-A325 is energized!
ALUMINUM BOLT - - (HIGH STRENGTH)
ALUMINUM FLAT
WASHER
r
/ .
HEAVY GAUGE STEEL
FLAT WASHER
r---~==i=====!::i.--, 7. STORAGE
Both ventilated and encapsulated transformers should be
BUS BAR stored in a clean, dry area. Care should be taken to prevent
TERMINAL
TERMINAL LUG moisture or condensation from entering the transformer, and
ALUMINUM FLAT vent openings should be covered on ventilated units. If stored
WASHER 'BELLEVILLE SPRING
WASHER outside, the transformer must be covered and protected from
ALUMINUM NUT
water, dust and other airborne contaminants.
STEEL NUT, ASTM·A325
(HIGH STRENGTH)

8. LIMITED PRODUCT WARRANTY

CAUTION: Care should be taken to avoid shearing aluminum
bolts. Follow manufacturer s maximum torque rating.
All dry type transformers are warranted against defects in
materials and workmanship. This is a limited product warranty
and certain conditions apply. Please contact the manufacturer
for further information on warranty claims.

Place cup in washer toward bus bar. Draw washer to flat
position for proper torque.
B) Encapsulated Dry Type Transformers
Proper assembly of the field wiring to the transformer leads is
extremely important. Make certain that the connector or
terminal is sized for the cable. Space and insulate connectors
NOTICE: These instructions are general in nature and may
not cover all variations in transformer design or conditions
of installation, operation and maintenance in enough detail
to meet customer needs. Additional instructions may be
included with this transformer. If you need further
information or should a problem arise, please contact the
manufacturer.

j or terminals per the NEC®.

CE marked transformers must be connected per EN 60742.
I

PART NO. A-701953·A

PRIMARY FUSE SIZING CHART FOR SINGLE PHASE TRANSFORMERS'
120 190 200 208 220 240 277 380 400 416 440 480 ; 600
50 2 - - - - 1 - - - - - 1 1
100 4 - - - - 2 - - - - - 1 1
'1150 4 - - - - 2 - - - - - 1 1
250 4 - - - - 4 - - - - - 2 2
500 8 - - - - 4 - - - - - 4 4
750 12 - - - - 6 - - - - - 6 4
1000 16 10 10 10 8 8 8 6 6 6 4 4 6
1500 20 16 16 16 12 12 10 8 8 8 6 6 6
2000 25 16 16 16 12 16 16 101 10 10 8 8 6
3000 32 20 20 20 20 16 16 16 16 16 12 12 10
5000 63 40 32 32 32 32 25 20 16 16 16 16 16
7500 80 50 50 50 50 40 40 25 25 25 25 20 16
10000 125 80 63 63 63 63 50 40 32 32 32 32 25
15000 160 100 100 100 100 80 80 50 50 50 50 40 32
25000 315 200 200 160 160 160 125 100 80 80 80 80 63

PRIMARY FUSE SIZING CHART FOR THREE PHASE TRANSFORMERS'

208 240 416 480 600
3000 16 16 8 8 6
6000 25 20 16 16 10
9000 32 32 16 16 16
15000 63 50 32 25 20
30000 - - - 50 40

* Recommended Rating for International Fuses.

A·70214B
 Operator's 'Asmf Series 300
( Automatic Transfer Switches
Manual O-design, 30 through 230 amp. sizes
Refer to the outline and wiring drawings provided with
your ASCO Series 300 ATS for all installation details.

ASCO Series 300 Automatic Transfer Switches CATSs) are

CAUTION Is used in this manual to warn
of possible equipment damage.
. An experienced licensed electrician m1)St install the ATS.
Listed under Underwriters Laboratories UL 1008 Standard
for'Safety for Automatic 'Itansfer Switches. ASCO Series
300s are alBo Listed under CSA C22.2 No. 178 Standard for
Automatic 'Itansfer Switches.. All control features are UL
Component Recognized, which assures that ASCO auto-
matic transfer switches meet OSHA Safety Requirements
and will be acceptable to electrical inspectors.
ASCO Series 300 Automatic'Itansfer Switches are suitable
for emergency and standby system' applications. They meet
emergency·system rating requirements as defined in Na-
tional Electrical Code (NBC) Article 700 and UL 1008.
Also, they are suitable for the requirements of NEC Article
517 - Health Care Facilities; NEC Article 701 - Legally
Required Standby Systems, NEC Article 702 - Optional
Standby Systems, NFPA 99 Health Care Facilities, and
NFPA 110 Emergency and Standby Power Systems.

Rating Label
Each automatic transfer switch contains a rating label to
define the loads and fault circuit withStand I closing ratings.
Refer to· the label on the .transfer switch for specilic values.

Do not exceed the values on the. rating label.

Exceeding the rating can cause personal
injury or serious equipment.damage.

TA~LE OF CONTENTS
. : ", . '. ':. ::
... " . : ','

. :··i:··;...·· .

INSTALLATION ...................••....• 1

SEQUENCE OF OPERATION .... ; .......• 2

TESTING & SERVICE •...............•.... 3

ADJUSTMENTS ......................... 4

CONTROL FEATURES ................... 5

( ) INDEX. .. . .. . .. . .. . .. . .. . ... . . . back cover

\.. . .
,',

liSCO Technologies·
:..
Power Hanover Road, Florham Park, New Jers"y
50
For sales or service call 1
USA
07932_1'591
(ASCO) . www.ascopower.com
800 80G-2726
381333-228 F
•

ASCO POWER TECHNOLfOGIES'CANADA' PO Box 1238, 17 Airport Road, B( rasnctfoo)rd, Ontario, Canada N3T5T3 . 'EMERSON.
telephone 519 75B-849Q, ax 519 .75fHJ876, for service calI 1 888.234-.2726 A . www.a~co ..ca "~..w.rkPoV("
. _ • • • _ _ nO ,., • • __ '"" ; , • • • •: _ " ' • • • _ _ '•• , . " _ " , ,," " " '. . , • • • '. _ •• "_
.', "",:' .. , ...•...;

Catalog Number Identification

(
A typical Catalog Number is shown below with its elements explained. The example is for a Series 300 ATS with
switched neutral, 3 pole, 230 amp, 480 V; in a lYpe 1 enclosure:
0300 B 3 230 N 1 c

B -switched 2 -single 0 230 •• A 115 H380 1 - standard C -type 1

C - oven~pping 3 - three 0 B 120 J 400 1X -if F -type 3R
blank-solid C 208 K 415 accessories G-type4
orderoo
D 220 L440 . L -type 12
E 230 M blank - open type
*It' 230 amp. limited F24<i N 480
to 480 volts

terminals for switch' membrane

position contacts controls

load p'ower
connecti.ons

Controlier
emergency power
connections

Transfer Switch

. '. >11.1!\intf'l~~~q~,'hqn~le '. .

'(s.eEl·WAI'I!'lINGunder .' .
"Mlmual 'operation)

terminals for
. engine start contacts
'.
,l'

. normal power
connections

.cable spacers
( s e e INSTALLATION)

230 amp. size in typical enclosure with location of customer connections

 SECTION 1
·Series 300 Automatic Transfer Switches are factory
wired and tested. Installation requires skid removal
then securing the enclosure to the supporting
foundation.
Mounting
Refer to the applicable enclosure outline drawing
furnished with this switch and mount the Series 300
according to· details and instructions shown on diagram.
Protect the automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the ATS.
Mount the ASCO ATS vertically to a rigid supporting
structure. Level all mounting points by using flat
washers behind the holes to avoid distortion of the
switch.
INSTALLATION
Connecting Power Conductors
After the power cables have been tested, connect them
to the appropriate terruinallugs on the transfer switch
as shown on the wiring diagram provided with this
Series 300. Make sure the lugs provided are suitable
for use with the cables being installed. Standard
terruinallugs are soideriess screw type and will accept
the wire sizes listed on the drawings provided with the
Series 300. Be careful.when stripping insulation from
the cables; avoid nicking or ringing the conductor.
Remove surface oxides from cables by cleaning with a
wire brush. When aluminmn cable is used, apply joint
compound to conductors. Tighten cable lugs to the
torque specified on rating label.
Three cable spacers are included with 150, 200, and 230
ampere transfer switches. When installing power
cables, run the cables through the cable spacers as
shown in Figure 1-1. Position cable spacers within 1 Yz
inches from lugs.

The cable spacers must be located as shown

Line Connections for 150, 200, and 230 ampere transfer swItches.
Refer to the Wiring Diagram provided with your Series
300 ATS. Ail wiring must be made in accordance with
the National Electrical Code and local codes. cable spacers

De-energize the conductors before making o

any line or auxiliary circuitry connections.
Be sure that Normal and Emergency line 1 !h Inch approximate
connections are in proper phase rotation.
Place engine generator starting c!)ntrol in the
OFF position. Make sure engine generator is
. not in operation.

", ().

Figure 1-1. Cable spacers for 150, 200, & 230 amp.
Testing Power Conductors
transfer switches.
:Do not connect the'power conductors to the ASCO
.Series 300 transfer switch. until they are tested.
:Iristalling power cables in conduit, cable troughs and
.ceiling,suspended hangers often requires considerable
force. The pulling of cables can damage ·insulation and
stretch or break the conductor's strands. For this
reason, after the cables are pulled into position, and
·before they are connected, they should be tested to
( verifY that they are not defective or have been
damaged duri,ng installation.
U
r"
-.1
!
\.
L
1-1
 INSTALLATION
Engine Starting Contacts
Customer co!U1ections for engine control cOntact
CO!U1ections are located on the transfer switch. Refer
to wiring diagram proVided with the Series 300 ATS,
and CO!U1ect the engine start wires to the appropriate
terminals. See Figure 1-2 and Thble A
Table A. Engine start connections.
(continued)
Controller Ground
A grounding wire must be connected to the controller's
lower left mounting stud. Because, the co~troller is
mounted on the \,uclosure door; a conductive strap
must be used between the enclosure and the door.
this connection provides proper grounding which does
not rely upon the door hinges,

Harnesses
The transfer switch is connected to the left side of the
controller by a plug-in harness (two plugs).

left side Auxiliary Circuits,

ofswifx:h
Connect auxiliary circuit wires to, appropriate terminals
TOP ~ _ _ ...,
on transfer switch as' shown oli'the wiring diagram
STUD ~--I ~-1 provided with this Series 300 Automatic 'tniusfer
tIIlOOLE ~! T~L
STUD ~"':f'"r-+ Switch. Make the necessary auxiliary connections by
NR I
OOTTOM ~ -II- .-l referring to Section 5, Control Featnres.
STUO ~NR

Figure 1-2. Engine starting coritact label and

terminals located on the transfer switch.

Connections to Controller for other Control Features

)
(located on bottom of Controller)

Load Disconnect Programmable Remote Control Features Connections

Feature Engine Exerciser
Connections connection, (refer to the Wiring Diagram &
(see Wiring Diagram 'f page 5-4 for DIP switch settings)
I fr~~:;~~d Each control contact must be suitable for factory
& refer to page 5-4
for DIP switch settings) page 5-2) for a 5 V DC low energy circuit. use only

I , ~ r.----~------~I--------------_,I r~. .~A~. .~,

1','

. m tJ 0 0 uo?·;a .
," ' '. 4 ) 5 , 6 ] ',S ,,'il 10 J1 ,12J3. 14 15:16 '

1 2 3
LOAD OPTIONAL MOMErITARY MAINTAINED , INHIBIT BYPASS L:
DISCONNECT' ENGINE , TEST OPENTO' TRANSFER TRANSFER ;'".
COrITACTS EXERCISER SWITCH TRANSFER TO TO TIME DELAY
EMERGENCY EMERGENCY
, / '~ ____________~~~~~~~~ __________--J/ , /
OUTPUT INPUT CONTACTS FOR
CONTACTS 5VDC5mA FACTORY i
120VAC 5A USE
I,.
I:
Figure 1-3. Input I outputlal;lel on the C,ontroliershowing possible connections to the lower tenninal bloc;k. ; ,
'.,'
"'~
if'
. r.
I'
"

1-2
I
!<
i..
-- .. ---~- _....... --_ ......'.-... .:.............. .

INSTALLATION (continued)
Functional Test
The Functional 'Iest consists of three checks: manual Position ofthe transfer switch is indicated here'
operation, voltage checks, and electrical operation.
weight marked N (normal)
and E (emergency)
Do these checks in the order presented to
avoid damaging the automatic transfer switch.
maintenance
Read all instructions on the Wiring Diagram and labels handle
affixed to the automatic transfer switch. Note the
control features that are provided and review,their
operation before proceeding.

1 - Manual Operation Test

weight
A maintenance handle is provided on the Transfer Switch
for maintenance Purposes only. Manual operation of
floating
the transfer switch should be checked before it is
weight
,energized (operated electrically).

With ALL POWER OFF grasp

Do not manually. operate the transfer switch maintenance.handle and turn it
until both power sources are disconnected: quickly with your thumb and fingers.
open both circuit breakers.
Figure 1-4. Maintenance handle and positions.
1. After deenergizing both power sources, open the
) enclosure 'door. Locate and the maintenance
handle on the left side of the transfer switch frame.
See Figure 1-4.
2. Grasp the attached maintenance handle and tum it
with thwnb and fingers as shown to manually operate
it The maintenance handle toms the opposite
direction of the weight· Move it up or down as
shown to manually operate the transfer switch. It
should operate smoothly without any binding. If it
. d6esnot, checlrfor shipping damage or CQastJ;udiPll
."
.' . .
de1)fis. .: " ,;... .
..':, ~ '. .
.3. ~Re~ the transfer~tchto. ~e.l-!()PI1'!;l p{)s[tipn.. ':,. ' ... '

. ····Not~: if Normal and Emergency conneCtions ~re'

, . reversed this operation is also reversed.
. Now continue to ~ - Voltage Checks on next page.

. i.::
,.'
.1
,k
1-3
 ". ',-, .. : '~'-":':'."'" : .. -.'....'-

INSTALLATION (continued)

ASCO@
Power Transfer Switch

Transfer SwItch Position

Normal 0
Source Accepted
Normal 0
;::;;> observe these lights

Emergency 0 Emergency 0

~
L:..J
Pro~1 for 11S See.

Rgure 1-5. Standard controls and indicators.

2 - Voltage Checks
Close. the normal source circuit
First check nameplate on transfer switch; rated voltage breaker. The Normal Transfer Source Accepted .
must be the same as normal and emergency line voltages. 1 Switch Position and the Normal
Source Accepted lights should
come on.
Normal
Emergency 0 •
Use an accurate voltmeter to

Use extreme caution when using a meter

to measure voltages in the following
check phase to phase and
2 phase to neutral voltages pres-
ent at the transfer switch normal
source terminals.

Close the emergency source

\W
Source Accepted
. steps. Do not touch power terminals; .circuit breaker. (Start generator,
shock, burns, or death could result! 3 if necessary.) The Emergency
Sou,-ce Accepted light should
come on.
. Normal
Emergency. •
Perform steps 1 through·6 at the right. Observe the
·status lights. See Figure 1-5.
Use an accurate voltme.\er to
o
o
Black circle means light is on.
White circle means light is off.

• If necessary, adjust voltage regulator on the

·check phase to phase and
4 phase·to neutral voltages pres-
ent at the transfer switch emer-
gency source terminals.* \W
.~
.gynerator according to the mannfacturet'~ recoiDlUe)l- L!.s,E1.a. pna~~ IQt<ltion .lT1et~r to
.dation;;.':!:he.;,wtomatic n.3.itsiei-Switc:hl'{i1l tespqnc\ ..•. on~c;" PtliJ,s,E\(OtiJ,ti<?J")9f.illT)(lrc ,
'.. o~ly to .the :ra(;;dvoli~ge &P~cifi~d o~ !he Tr'!risfer •.. _..
..
.5.. ge!1cysource; it irU.lst Q~ -ttui _ . :.........:@
'.' ....:.,:
. "

. Switch nameplate. . . simle as the normal source . ~::

Also see page 4-1 for the HI-LOW voltage adjust

Shut down the engine-genEira-
setting in the controller. The LOW setting shifts all
tor. if applicable. The Emergen-
voltage settings down 42%; for example, 240 V to cy Source Accepted light should
Source Accepted
2.30V. . 6 go off. Tlien put the starting
control· selector switch (on the
generator set) in the automatic
Normal
Emergency •
0
;.-.

position. Close enclosure door.

Now continue to 3 - Electrical Operation on next page.

1-4
 , . <;,," " '.'.,""", .""" .. " .' .. ~-'- .. '.-.' .. ' '.' .'.'".'.,,'. ., ',,',',

INSTALLATION (continued)

ASCO"
Power Transfer Switch
observe these lights
Transfer Switch P051tion ource Accepted
Normal 0 Normal 0
Emergency 0 Emergency 0
press this button

Figure 1--B. Standard controls and indicators.

3 - Electrical Operation The normal source .must be
available and the generator Source Accepted
First check 'nameplate on transfer switch; .fated voltage
must be the same as normal and emergency line voltages.
1 must be ready to start.
Check that the Narmw Source
Accepted light is on,
Normal
Emergency •
0
Press and hold the Transfer Test
button until the engine starts Transfer
2 and runs. This should happen Test
wHhin 15 sec.
.Perform steps 1 through 8 at the right. Observe the
status lights. See Fignre 1--6. Source Accepted
The EmergencySource
. 0 Black circle .means light is on.
o White circle means· light is off.
3
Accepted light should come on. NQrt'Da1
Emergency. •
) The transfer switch 'should
'NOTE: If Motor Load Transfer transfer to the Emergency Transfer Switch
position. The Emergency Position
feature is activated, thel\ transfer may 4 Transfer Switch Position light
not occur immediately after the Normal 0'
should come on and the Normal Emergency.
respective time delays. lhinsfer will light should go off.
only occur when the phase relation- If the transfer to emergency
ship between sources is correct. ·delay is used the transfer
should occurs after a time delay Bypass
This completes the Functional 'lest of the ASCO 5 (Lip to 5 minutes). Time De.lay
Series 300 AutomatiC Thmsfer Switch. Leave the For immediate transfer press
e"gine:-generator startingcont;rol in the 'automatic . the.Bypass Time [)elay b\Jtton.
positiol),' :, :
;......
'. .. '> ,.:. . . .• ,,\> .
: .. ".:, '. :.(: IheJri\!1$Ji\r,$Witi;lfi~ljQ~19"'·," '.
... tr<m~I~r;qaq~~Clthe.No~a,1 .
"\:.:'
. >. .. .
.:: .... .,:'.:
'Transfer Switch
'.

.
"
.
;"
..
j".',",',.

'.,:'. '.:. ~'~.~

position. The. Normal Transfer PosUian r-~;
6
Switch Position light should
come on and the Emergency
light should go off.
Normal
Emergency •0'

If the retransff3r to normal delay

is used the retransfer .should
occur after a time delay . Bypass
7 Time Delay
(up to 30 minutes).
For immediate r.,transfer press
the Bypass Time Delay button.
The unloaded running delay
keeps the generator running for Source Accepted
\ 5 minutes (coQI-clown period).
8 Then the generator should stop
and the Emergency Source
Normal
Emergency •0'
Accepted' light should go off.

1-5
 "' ..',',. __ .. : ..... ', :. ,'. , .. t" _ .......,'..... , .. .

SECTION 2 SEQUENCE OF OPERATION

Ughts show position of transfer switch. Ughts show the sources accepted.
Transfer To Emergency Ught for built-in
engine exercise timer:
The sequence for load tral1'lfer to
emergency source begll1'l automatical- ASCO" ~
EMERSON.
,.. blinks rapidly when
Power Transfer Switch NetworX~r
button is held 5 sec.
ly when normal source voltage falls while being set
below the preset dropout point or >- blinks slowly when
Transfer Switch Position Source Accepted
when Transfer Test button is pressed. Normal Normal
button is released (set)
An under voltage condition on any and during 20 min.
Emergency Emergency
phase of the normal source is de- exercise period.
tected by the sel1'lor. >- stays on after engine
stops (exerciser is
When the normal enabled for weekly
source voltage fails or operation)
the Transfer Test See page 5-1
button is pressed, the fpr complete
Hold 15 sec. to Press to cancel the Hold 5 seg. to set instructions
BE relay de-energizes start the engine active exercise period 20 min. engine exercis's
.and relay NR begll1'l generator and to (stops engine now or period immediately (engine.
its timing cycle (lor 3 transfer the load after cooldown) See startS) and weekly thereafter.
seconds, momenfaly to emergency. page 5-1. Figure 2-1. Membrane controls and indicator lights.
nomuU SOluee ol)lage
delay). The NR relay is provided with a fune delay on Retransfer to Normal
..dropout to override momentary outages and prevent The sequence for load· retransfer to the normal source
nuisance starting of the engine~driven generator. If the automatically begins when the voltage seosor detects
normal source voltage returns above the sel1'lor dropout restoration of the normal source. The voltage level
setting before the fune delay expires, the NR relay timing must ri$e above the preset pickup point" on all phases
cycle is reset to zero and' relay SE energizes. before the sensOr will accept the normal source.
If the normal source voltage does not return above the When the normal source is ·accepted by the sensor,
sel1'lor dropout setting before the fune delay expires, the relay SE begins its timing cycle (adjustable 1 sec. to 30
NR relay de-energizes and signals the engine-driven gen- min., retransfer to nomzal delay). For immediate
erator to start. At the same time, a voltage and frequen- retransfer press Bypass Time Delay button. SE relay is
Cy sensor begil1'l monitoring the emergency source. The provided with a time delay on pickup to prevent
sensor will accept the emergency source only when both immediate load retransfer to the normal source. The
voltage and frequency reach preset pickup points. Usual- delay insures that the normal source has stabilized
ly about ten seconds elapse from dropout of the NR relay before reconnection of vital loads. If the normal
to aCceptance by the sen~or. This time span occurs be- source voltage falls below the present dropout point
cause the engine-driven generator must crank, start, and .before the time delay expires, the timing cycle is reset
run up to nominal pickup points.. For this reason, if the t() zer(). If~~ ~~.e.rgef1'iY~ollr"" fail~ for more thaJ;i4
. .' . T.,rruWer.:[est .bllttpn,ls pr~.~dit ti;ufs(ti~i1e!4fpr15sec- . secohdsquringlll¢,timiJ;igcycle,)3Rri"lay dr()psput •.
. .•.. ocids.Uth~ eUi~rg~ncjsoiiic.;. il;av,;;u~b!eiiniJ,.ediately, ' . ..... :';hdthei~;;~ii;)m1i1ediai~iy~~tf;i~sfeiTed lathe ....
the sensor may aCcept it as SOOn as NR relay drops out. normal source, if th~t so~Ce is acceptable.
When the emergency source is accepted by the sensor, SE relay energizes and ER relay is dropped out. The
relay ERbegins its.timing cycle (transfer UJ emergency TS coil is energized, the transfer switch operates, and
delay). ER relay is provided with an adjustable (0 to 5 all switch contacts (mains, controls, auxiliaries).reverse
minutes) time delay on picknp to delay transfer of the position. The transfer switch is now supplying the load
load to the emergenCy source. For inrmediate transfer from the normal source again. .
press' Bypass Time Delay button.
Upon retrallJlfer to the normal source, NR relay begins
ER relay.energizes, the 1'8 coil is energized, the transfer its timing cycle (unloaded lUJl1ling de/a); engitui eooldown).
switch operates, and aU switch contacts (mains, .controls, NR relay is provided with a 5 min. time delay on pickup
a;uxiliaries) reverse position. The transfer switch is now . to keep the engine nmning for a cool-down period.
.supplying the load from the emergency source.
NR relay energizes after the time delaY'and signals the
The transfer switch will reniain in the Emergency engine-driven generator to shut down. All circuits are
position until the normal source is restored. ·If the
reset ror ariy future normal source failure ..
Transfer Test button is used, the transfer switch will
remain on emergency until the retransferto norm,al Activation of standard control features shown inSection5 win
delay times out. . alter the ~eql:lence·of operation ·and introduce additi'onal time
delays during transfer operations .
.2-1
" - ..,.. ,:.. ....•. - ...,. ;.,:...•.,.:
,' ',. ' ".~. , .•..... -...•. , ...'--.. -.. ,.
SECTION 3
PREVENTIVE MAINTENANCE
For high reliability and long life for the ATS:
Operate the switch at least once a month. Perform this
4-step Electrical Operation Thst (test with load transfer).
S
ASCO
Power Transfer Switch
Transfer S\,!ltch Position Source Accepted
Normal '0 Normal
Emergency 0 Emergency
Pl1MIl\lnlll
ngM FLASHES
Transfer Switch Test
1.. Press and hold the door-mounted Trimsfer Test button
until the engine starts and runs. This should happen
within 15 seconds.
2. The transfer switch will operate to the Emergency
·position.. If the Transfer To Emergency Delay is used,
the transfer will occur after a time delay (up to 5
minutes). For immediate transfer press Bypass
Time DelaY button.
3. The Transfer Switch will operate back to the Normal
position after the Retransfer To Normal Delay (up to
30 niinutes). For immediate retransfer press
Bypass Time Delay button.
4. Unloaded Running (Engine' Cooldown) Delay allows
engine to run unloaded for 5 minutes.
Checklist for Yearly Inspection
Cl Clean the enclosure. De-energize all sources,
ilien brush and vacuum away any excessive dust
accumulation. Remove moisture with a clean cloth.
. .'0 Check ·the ·transfer .switch .contactS;. De-energize ,
~~s<i~he,I~l\1~,~i~,iiii.lY~;f4~~i;;~~r:~t~ii.~~ei\;
'and Check contact condItion. The non-replaceable
.main contacts· are designed to last the life of the
'transfer switch. Reinstall the· barriers carefully.
Cl Maintain transfer switch lubrication. Under
, normal operating conditions no furoher.lubricating
is required. Renew factory lubrication if the switch
is subjected to severe dust or abnormal operating
conditions or if TS coil is replaced. Order lubricant
625550-001 (Castrol EndurexR 4000 lubricant).
. 0 Check aU cable connections &. retighten them.
'Thrque to vallles shown on transfer switch labeL
.Replacement parts. When ordering parts provide the
Serial and Catalog Nos. from the transfer switch
nameplate. Contact AS!. In the US call
1-80~OO-ASCO (2726), or in Canada call
1-888-23i!-ASCO (2726). .
. ,,;-.,., ........ ".
TESTING & SERVICE
DISCONNECTING THE CONTROLLER
The harness disconnect plugs are furnished for repair
purposes only and should not have to be unplugged. If
the controller must be isolated, follow these steps
carefully. .
Disconnecting the Plugs
0
0 1. Observe the position of the transfer switch.
a. If the transfer switch is in the Nonnal position,
place standby engine starting oontrol in the off
position. Then open the emergency 'source cirCuit
breaker.
b. If the transfer switch is in the Emergency position,
open the normal source cirCuit breaker. PIace the
engine starting oontrol in the test or /Un .position.
2. Separate the quick disoonnect plugs by squeezing
the latches. Do not pull on the harness wires.
3. Label, remove, and tape the signal wires connected
to the' engine start terminais on the transfer switch:
TB1 and TB3, or TBl and TB2.
Reconnecting the Plugs
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Nonnal position, be
sure that the standby engine starting control is
still in the off position. The emergency source
circuit breaker still should be open.
b, If the transfer switch is in·the'Emergenry position, ;'.:
'. '. !lO!lllal.s0l!!"",cit:"\Iit9r~a.k~f Etjl). sho"'4 be oPen.
. •'2;. ·~i~R;Wist'~e.·s.i~lli:fur~~~~,~~~p.~i;!1\Q,th~ •. .,. .
·appropriate. el).gine start terminals .on· tpe transfer
switch. See Seciion 1, Eng;ne Starting Contacts .
3. The harness plugs and sockets are keyed.
Carefully align the.plugs with the sockets
and press straight in until both latches 'click.
4.. Restore the opposite source as follows:
a. If the transfer switch is in the Nonnal position,
place the standby engine starting control in the
automatic position. Then close the emergency
source 'Circuit breaker.
b. If the transfer switch is in the Emergenry position,
close the normal source circuit'breaker. The load
will be automatically retransferred to the normal
source afterthe RetraJisfer to Nannal Delay. For
immediate retransfer, press Bypass Tii1ie Delay
button. Place the engine starting control in ·the.
auto117{l!ic l?ositiol).
3-1
 ••• -•••••':•• 0; •••• : .,:' ••. :, ••.•••
·.......... - .. ,. _. .,_ .... "-... ::.-.:-":.,,~:.~:<:: .. .

SECTION 4 ADJUSTMENTS
Time Delay Adjustment To change a setting, follow procedure on page 4-2. Use
Standard time delays are set to customer specifications Table 4-1 as a guide to time delay values and their cor-
(if.none specified, standard factory settings are used). responding adjustment DIP switch or potentiometer.

Table 4-1. lime Delay Settings

5 minutes non-adjustable

Sensor Adjustments
Voltage and frequency sensor pickup and dropout points
are set to customer specifications (if none specified, Any change In these settings may affect the
standard factory settings are used). To change a setting, normal operation of the automatic transfer switch.
This change could allow the load circuits to
follow procedure on page 4-2. Use Tables 4-2 and 4-3 remain connected to a low voltage source.
for settings and corresponding DIP switch actuators.

"Y'""""Y Settings. (1iiiI Shaded DIP switches are standard fort"",

PUIN Pickup 90%

90%

90%*
Normal Source Voltage
85%
DO/N Dropout 85%
80%

...... '70.%'
'. ' , .

Emergency Source
Frequency 60Hz Actuator 4 off
/ 60/50
60/.50 Hz .60 Hz
Hz 50Hz Actuator 4 on
3 phase
Voltage Pha:;es 3,1 3/1 3
1 phase Actuator 6
*. If dropout voltage is set to 90%, the pickup voltage must be set to 95%.

Table 4'3. Transformer Voltage Adjust.

(Low setting
. Shifts all voltage settings down
. 4.2%; for example, 240 V to 230 V, or 480 V to 460 V)

LOW/
Voltage Adjust (4.2%) HI
HI HI 20n
,.
j ..
4-1 I::
 Nameplate Catalog Number Identification
The Transfer Switch nameplate includes data for each A typical Catalog Number is shown below with its
specific ASCO.Series 300 ATS. Use the ATS only elements explained. The example is for a Series 300
within the limits shown on this nameplate. ATS with switched neutral, 3 pole, 200 amp, 480 V, in
a Type 1 enclosure:
D300 B 3 200 N 1 C

B - SWitched 2 -single 0 30 A 115 K415 1 -standard C -type 1

C - overlapping 3 -!h,ee0 70 B 120 L440 1X-if F -type3R
blank-solid 104 C208 M46C accessories G -type 4
150 D 220 N480 ordered
L-type12
200 * E230 P550 blank
1< 200 amp. limited F240 Q 575
to 480 volts
H 380 R.600
J400
Controlier

load power
connections

. Transfer
'Switch

maintenance
handle .

.. . . . :·':.(~~~l~~iM~r '" .

. terminals for
eflgine start
contacts

normal power
connections

cable spacers
(see INSTALlATION)

200 amp. size in typical enclosure with locatiOn of cu.stomer connections

.... ' ..~- ...... : " .. ...... _... -.".
' ' .............. : .:.,.:.-'... :.

TESTING & SERVICE (continued)

MANUAL LOAD TRANSFER 1. Open normal and emergency source circuit breakers,
This procedure will manually transfer the load if the
controller is disconnected, 2. Use the maintenance handle to manually operate
transfer switch to the opposite source. See page
1-3, Manual Operation Test.
Do not manually operate the transfer switch 3. If the transfer switch is in the Emergency position
until both 'power sources are disconnected:
manually start the engine generator and then close
both circuit breakers.
the emergency source circuit breaker.

TROUBLE-SHOOTING
Note the control features that are activated or
furnished on the switch and review their operation.
Refer to Section 5, Control Features.
Table 3-1. Trouble-Shooting Checks.

not start when Hold the Transfer Test button
Test button Is 15 sec. or the outage must be
and held for 15 long enough to allow for the 1
or when the normal or 3 sec. Momentary Normal
source fails, Source Outage Delay plus
engine cranking and starting
time.
I
I'""n.t,p, the load to cy Delay (0 to 5 min.) to
emergency source after the out For immediate transfer,
gen-set starts: press the Bypass Time Delay
button. If Motor Load Transfer
is active, wait for Inphase con-
,dition (see below):
I;:~~;~~tj6 must be In
I' ' position. Batteries
must be charged and
connected. Check wiring to
engine starting contacts.
breaker closed, 90% of phase to
Generator frequency must be phase voltage between
least5? Hz. transfer switch terminals EA
and EC (or EL1 -and EL2 for 2
pole switches).'
* These,are factory settings.

Delay (1 sec. to 30 min.) to 90% of nominal phase to

time out For immediate re- phase voltage between
transfer, press Bypass Time trimsler SWitch terminals NB
Delay button. If Motor Load and NC, NC and NA, and NA '
Transfer is active, wait for·jn~ and NB (ot NL1 and NL2 for 2
phase condition (see below). pole switches).

\.' Tr9,1,I,~I~~.-§.Jt\,~illll£L;)t~,~';M,e~$~L~~(J.~Ic;l·,Tr"~sf~~,,,e"ture(~efertopage 54) ., ',. ""

, '3. Press and hold Transfer T~ button. The load
should transfer to emergency source when meter
Use extreme'cauiion'whe,n using a'meter needle is near (j 1Iolts. If transfer does not ocCur,
to measure voltages in the following steps. Motor Load Transfer feature is not operatllg,
Do not touch power terminals; shock,
4, Release the Transfer 'Jest button. The load should !
,burns, or death cou.ld result! i':
retransfer back to the normal source after the
1. Connect a voltmeter (set for twice system
,i
Retransfer to Normal Delay, if used. The ~etransfer
phase-:-to-phase voltage) between Transfer Switch should occur when the needle is near 0 volts. If
terminals NA and EA. retransfer dpesnot pccur after the time delay, the
- 2, Manually start generator. Voltmeter needle should Motor Load Transfer feature is not operating.
( sweep back and forth at a regular rate'between 0 5, For immediateretransfer, press the Bypass Time
and about twice system 1Ioltage. Delay button. Then disconnect the 1Ioltmeter.

If the problem is isolated t,o circuits on the controller or the transfer switch, call your lo~al ASCO Power Technologies , '
, sales office, representative, or ASI. ' In the United States, call1:-800-800'':2726. In Canada, calI 1-888-234,-2726.
Furnish th,e S,erial Np., Bi,l1 of Material,(BOM) No., and ,Catalog I'!o. from transfer switch nameplate.
3.,.2
Ii .
i
.! .
....• - .. ........... ...
' ' ... '-~ .'.. ' ;..... ~.:.; .' -'~""
' , '.'-_." ' .... ':.. ..
~ ;

AQJUSTMENTS (continued)

cover thumb
Do not make any setting latch
while the controller is .=-:t-
: :-.:-
-_...=---
-==.,-

~-~::-
How to Change a Setting
1. Prevent the transfer switch from operating by discon- hook on
·necting one source first, then the other, as follows: left side
a. If the tran~fer switch is in the .Nonnal position,
open the emergency source circuit breaker.
Thrn the engine startiug control to off. Then
open the normal source circuit breaker. Figure 4-1. Controlier cover latch.
b. If the transfer switch is in the Emergency
position,· open the normal source circuit breaker.
Thrn engine starting control to test or run. Then
o
open the emergency source circuit breaker.

2. Disconnect both harness plugs from controller by

squeezing the latches. Do not pull on the wires .

.3. Remove cover from the oontroller by releasing latch J5 battery

on/off
on right side with your thumb. See Figure 4-1. ijl1!!!&-jumper

4. Locate the appropriate adjustment potentiometer or

. DIP switch for the setting that you want to change.
Refer to Thble 4-1 and Table 4-2 on page 4-1 and
) Figure 4-2, Figure 4-3, Figure 4-4 on page 4-2.

5. Use a small screwdriver to turn the potentiometer

clockwise to increase the time delay or counter-
clockwise to decrease it. See Figure 4-3.
S2DIP
6. Use a ball-point pen (or similar pointed.tool) to slide switch
!;he switch actuators left or right so they match the
Figure 4-2. Location of potentiometers.
mustration next tei the setting (left = off, right =
on). RecheCk the setting. See Figure 4-4.

1~~1~~
7 . .Install t~e COVe" 9P !i'e. "",ntrQller t)y 1l()()[(iIlg it Cln
. theieftside ~ridJaiching the .rigilt side. ... .•. . .. .
: ,.":' ;'" " .::' :.. ' '.;:." >,:':;::-.: ::::'~ '.,;:. ">";';; ~.: ':: '. :::: '.,':.. :. :. :.....;
8. Recori.ne~t both harrie~s plugs to the controller by
.aligning and pressing straight in until latches click.
i to decrease
Figure 4·3. Changing time delay potentiometers.

9. ·.Close the enclosure door, then restore both sOUJces: DIP

switches
a. If the trimsf'et switch is in the Noni1al poSition
SW1
first dose the normal source .circuit breaker, then SW2
close the emergency source circuit breaker. SW3
actuator
b. rf the transfer switch is in the Emergency
(8 on each DIP .switch
pOSition, close the normal source circuit i
breaker. The load·will be automatically r
o f f - on ..,.
retransferred to the norruaJ.source. Then close }

the emergency ·source Circuit breaker.

10. Thrn the.enginf') starting control to automatic . . Figure 4-4. Setting DIP switch actuators.
4-2
· ' ....... _----- :...... :.-.•.. ~-' .

SECTION 5 CONTROL FEATURES - ENGINE EXERCISERS

These timers periodically exercise the emergency engine-generator plant. 111ey can be set to exercise with or without
load transfer, or they can be completely disabled. The engine-generator should be .exercised under load once a week for
a minimrnn time period of 20 minutes, or follow the reoommendations of the engine-generator set manufacturer. Refer
to page 4-2 for location of DIP switches, battery .(provided), and jumper block in the controller.

BUILT-IN ENGINE EXERCISER DIP Switch Settings

The engine exerciser included in ASCO Series 300
Automatic Transfer Switches. provides a once a week
20-minute exercise period. It occurs immediately when
the Set Engine Exerciser push button is pressed (and
held for at least 5 seconds), and then at the same time
weekly thereafter. A 9 volt alkaline battery (Duracell
MN1604, Everready 522, or Panasonic 6AM6) is
furnished and installed in the controller toinaintain the
setting. The battery jumper block must be shifted to the
ON position. See Fignre +.2 on page 4-2.
mil Shaded DIP switches are standard. factory settings.
Fill in day and time set. Week Day _ _ Time _ _ _.
status light
'·Press to cancel an active exercise Bypass ~
Set Engine
period (stops generator). :!:!meDelay Ex.rcls~ Press and hold for 5 sec. or until status light
~=';;:i--- blinks rapidly to set· exercise period immediately
If Exercise with Load is set, retransfers load to 119~~~~~~S and every week hereafter (generator starts).
Normal, then stops generator after min.cooldown. If Exerciser with Load is set,
transfers load to Emergency.
Figure 5-1. Operator panel push buttons and light.

Select below either Exercise without Load or Exercise with Load according to the setting of DIP switch Sl, actuator 8. The
load transfers from the Normal source to Emergency source (generator) and back.againif Exercise with Load is selected.
)
EXercise without Load, DIP Switch S1, Actuator 8 off II!!II How to Set Built-In Timer

Exercise the generator now and

1
every week at this time hereafter.

2 Generator starts and runs.

Exercise with Load, DIP Switch S1, Actuator 8 on How to Set Built-In Timer

Exercise the generator now and

1 'set exercise period
every week at this time hereafter.

2 exercise period now active

:
i·
I
3 cancel active exercise period i

NOTE: Every ume SET ENGINE EXE~CISERpush button is presseq (held 5 seconds}the el'erClse Period js changed.
5-1
.....•. , ...

CONTROL FEATURES (continued)

Optional Accessory 11BG - SOURCE AVAILABILITY SIGNAL

, & PROGRAMMABLE ENGINE EXERCISER MODULE

o IIISflllI'II Power
ft IJU Technologies
o
@ ENGINE EXERCISER @

! rg
2-line
display connections
! I&"I} __---t---
ri
for source
.., availability
@
~

3 buttons ----r---_ .
9&
~
signal contacts

o o
Figure 5-2. Accessory 11 BG module (mounted behind operator interface and connected to the controller)
includes source availability signal contacts atid a programmable engine exerciser.

Source Availability Signal Contacts

The module provides one Form C contact each for the
normal and emergency sources sigual the acceptability
:of the source as sensed by the controller. The signal SOURCE
AVAlLA81UTY SIGNALS
',contacts operate in conjunction with the Source
2 AMPS@3OVDC,resistive
A,ccepted lights on the operator interface. Field wiring D.5AMP@125VAC.resislivtl
contacts shown dg....tmetg!ze.d
terntinals are provided as shown in Figure 5-3 and the
wiring diagram.
Contact ratings:
, '2 amps
.
®30 Vdc,
~.
0.5
.
~mp. @ 125 Vac resistive.

'" '.... :.. . ">: \."::

'. \~~ogram~~bleEngin~E~erci~~r"'" ',' "
The module includes a programmable engine exerciser DIP Switch Settings in the Controller
, that provides for weekly or biweekly operation. This (see page 4--2)
, , optional exercise timer may have to be turned on
(enabled) by setting the Sl DIP switch actuator 7 to off,
and S2 DIP switch actuator 5 to off.A backup battery in
the Controller (see page 4-2 and page 5-3) must be
turned on to maintain the settings and to allow
programming with the normal and emergency power
ljIrned off (page 5-1).
The progralfill1able engine exerciser incorporates a 7
day or 14 day time base. Proper controller settings must with Actuator
80n
_ ",I
, , be made to determine whether or not the test will be Load
done with Qnvithout load transfer (Sl DIP switch
:acUiator 8). ',II! Shaded DIP switches are standard factory&ettings.
j":.
'See next page for instructions on setting,the..timer.
,i '

,5-2
'.:, .....".. ,.,..... __ , "",,_,_,"_~'""~_'_','" ,···· .. 'c··~··_·,· . ",. '_ h',._~.~ .,0.,_

CONTROL FEATURES (continued)

How to Set Optional Programmable Engine Exerciser (part of Acc. 11 BG module)
NOTE: When choosing hi-weekly operation, the
exerciser will always run on the week designated "(1)"
Hazardous voltage capable of causing shock, on the date display.
burns, or death is used in this transfer switch.
Deenergize both Normal & Emergency power Run Time Display
sources before programming the exerciser. The Run Time Display shows the run time for the engine
exerciser. The default setting from the factoIy is 30 min.

Navigating the Menu Time Display

Use the UP and DOWN arrow The Time Display shows the present system time. The
keys to move through the displays. format is "hours:minutes:seconds".
NOTE: During total power outages, power to the
Changing the Parameters accessoIy is maintained by a batteIy in the Controller
Use the UP and DOWN arrow (see page 4--:?). Be sure that the 9-volt alkaline batteIy
keys to move though the displays is fresh and enabled (jumper in ON position) so that
to the parameter to be changed. the time and date settings are not lost.
Push the ENTER key to start the Date Display
editing process. The first
The Date Display shows the present system date. The
parameter will flash. Use the UP
format is "day of week (week) month/day of
and DOWN arrow keys to adjust
month/year".
·the parameter to the desired
NOTE: Week is either week 1 or week 2. This is used
value and press the ENTER key
in conjunction with the bi-weekly timer.
to save the value. The next
Pafilmeter will now flash. Repeat Daylight Savings Time Adjust Display
the process until each parameter This display. shows whether the automatic daylight
.is. properly confignred.
saving time adjustment is active. The factory default is
Engine Exerciser Display "NO". If enabled, the uJ;lit will automatically adjust for
daylight saving time at 2 AM on Sunday as follows:
The Engine Exerciser Display
shows the status of the engine Part No. 629857-{)01* 629857-{)02*
exerciser. When the unit is shipped from the factoIy Start first Sunday in April 2nd Sunday in March
the programmable eugine exerciser' is "Disabled" and Stop last Sunday in Oct first Sunday in Nov
must he set to "Enabled" by. the customer. When the
• Part no. on back of ClrCUlt board. New DST starts in 2007.
engine exerciser is running, this display will count down
the remaining time until the end of the exercise period. Fast / Slow Adjust Display·
Start Time Oi~pliiY This display s~()ws the automatic fastM~>:w adjustmeJ;lt
'. .jQ,,~tart JJil!e Pis~[ay~h~\f.!;ih~e~~~ex~r~is~,,~tlIr; Y~\\!f':tjJ:~f\"Rlp;r,<:j~t~\!!tis.Q,.·Ws.~e?:t.,!!,e:9.11·~e.· .• ·.·· .
.'time .. There .are feiur paraI)leters that determirie the start ils~Qto trir.n,a doc!<: that ru,ns fast or:sI9W.for eX~!Ilple,
'time: if your clock runs 10 seconds slow per week, change the
weekly ("Every") or bl-weekly ("Alt") operation fast/slow adjust value tei "+ 10" and the unit will
. day of week ("Sun" through "Sat") automatically add 10 seconds to the clock eveIy week.
start hour (0 through 23) NOTE: Adjustments are made Sunday morning at 2
start minutes (0 through 59) AM. If you want yoilr exerciser period to start at 2 A¥
For example, if the user wants the exerciser to run eveIy onSunday, you cannot use this feature and the
.other Saturday at 3 PM, the proper configuration would adjustment must be set to O.
be: '1\lt Sat @ 15:00"
Fill in your seUingsfor future reference

.5-3
 CONTROL FEATURES (continued)
INPHASE MONITOR
FOR MOTOR LOAD. TRANSFER
Inphase monitoring logic controls transfer and retransfer
.of motor loads, so that inrush currents do not exceed
normal starting currents. It avoids nuisance tripping of
circuit breakers .and mechanical damage to motor
.. couplings.
The Motor Load Transfer feature is built into the
controller. DIP switch Sl (actuator 5) activates this
feature: right = ON, left = OFF.
disable Actuator 5 off
LOAD .DISCONNECT FEATURE
Connect external circuits to the terminals indicated on the
Wiring Diagram provided with tlie ATS.
The double throw (Form C) contact is rated for 28 vpCor
120 VAC (5 amps resistive). The contact operates prior to
a selectable 0, 3, 10, or 20 second delay before transfer· of
the Automatic Transfer Switch. The contact resets either
immediately following transfer or after the same delay !IS
set for pre-signal before transfer.
Time delay between the load disconnect control signal
and initiation of transfer is set on the colltroller with DIP
switch S2 (actuators 6, 7, 8) as shown below:
Delay Before Transfer

II Shaded DIP switches are.staudard factory settings.

Note 3 seconds
If the Motor Load Transfer feature is enabled, ......
it will be activated follOwing the Load
Disconnect Feature Delay Before Transfer
delay.
10 seconds

20 seconds
..
aD
... <»
...,
<»

III Shaded DIP switches are standard factory settings.

Delay After Transfer*

Actuator 6 off
'Enabling the Delay After 1l:ansfer will cause the control .
signal to reset after the same delay as set for the Delay
Before Transfer.

. ·T!J.ese remote control features require a cuStbmer":'supplied normally ciosed contact suitable for a 5 V de low energy
circuit. Refer to the Wiring Diagram provided with the ATS. Activate appropriate DIP switch S2 actuators 1ielow.

Remote Test (terminals CP6-7) Remote Transfer to Emergency (CPS-9)

. Actuator 3 off

Bypass Transfer Time Delay (CP12-13) . Inhibit Transfer to Emergency (CP1()"'11)

,
I.,,
eliable Actuator 4 off ,
.. j",
..... ... -.-.:-.-..- ..:..
~ --~ .. .:..,... .. :.•---.-- ...•..-~- .. :••.••.... '''-->'. . '.'. ' . .• _'.'.i: •• ~._':-' ......... :~.:, •... ; ... ' . . -.' ...... ~ ..: ...... " " ., .... :.: •.. .' ..... " ... .', ..•'.,.'.... _,., .. '..

CONTROL FEATURES (conUnued)

OPTIONAL STRIP HEATER (Accessory 44)

Accessory 44 Strip Heater is designed to keep ambient
temperatures within the Automatic Transfer Switch thermostat
enclosure at acceptable levels. This accessory consists of a 90
mounting bracket' with strip heater, thermostat, and
terminal block. A transfomier with fuses is included when L---l~f-- dial
the power for the assembly is de~ived from voltages above 50 130
120 V ac. The 120 V ac customer powered assembly does 30 140'
not indude a qansfofmer. This optional accessory is
available factory installed or in kit form. turn counterclockwise
to lower temperature
Turn the thermostat's dial to required setting as shown.

.tt6.
U
turn clo.ckwise
to raise temperature

Figure 5-4. Thermostat.

AVAILABLE KITS FR()M ASCO

Controls Strip Heater - Accessory 44

11BG K629ll3 D
... .·AM .' '. ~1?13127-OO1
: ,'. '.', ~ .
72A

208-480volt
ATS derived vo~age K613127-002 .
(with transfonner}

380vott
ATS derived voltage K613127
(with transformer)

550 - 600 volt

ATS deriVed voltage K613127-Q03
(with transformer)

5-5
.... '••'.~~.!.'. . ' ••.. ,.,. : ..•,._: ... " •.•. ~., •. ,- ...~:, , ................. .. ~'.:,.,;.:.: ... "':'.,-,."':,,;,.. : ..... -........... . ','.' .. '.'. :.. ',. '". ~ .. ;"~' .' . . ; . "~'--'--'"'" :: .'.... ,...:. '. ,> .• ",'

INDEX
A H p
accessories, 5-2, 5-5 handle, .maintenance, 1-3 ·parts,3-1
auxiliary circuits, 1-2 warning, 1-3
problem, 3-2
harness, 1-2
programmable engine exerciser, 5-2,
disconnecrplugs,3-1
B HELP
5-3
battery, 4-2, 5-1 800--800--2726 (ASCO)
buttons, push, 3-1 customercare@asco.com R
bypass time delay, 1-5, 2-1, 3-1 rating label, cover
I remote control features, 5--4
c inphase monitor, 5--4
bypass transfer time delay, 5--4
inhibit transfer to emergency, 5-4
cable inspection, 3-1 remote test, 5-4
.lugs, preparation, 1-1 installation, 1-1 remote transfer to emergency, 5-4
catalog number, cover replacement parts, 3-1
cleaning, 3-1 l
coI)Ilections labels,
engine starting contacts, 1-2
s
. engine control contact, 1-2 service, call 800--800--2726 (ASCO)
line, 1-1 inputs I outputs, 1-2
rating, cover set engine exerciser, 5-1, 5-2, 5-3
contacts
auxiliary, 1:-2 lights, f-4,5-1 settings
engine control, 1-2 load disconnect feature, 5--4 changing, 4-1 .
I)1ain, 1-3, 3-1 factory, 4-1
lubrication, 3-1 frequency, 4-1
source availability signal,· 5-2
phase, 4-1
control features, 5-1 M time delay, 4-1
load disconnect, 5--4 voltage, 4-1
maint~nance1 preventive, 3-1
motor load transfer, 5--4
plant exerciser, 5-1, 5-2, 5-3 manual load transfer, 3-2 source accepted lights, 1--4, 1-5
controller, 4-1, 4-2 warning, 3-2
'codes, cover manual operation, 1-3 T
cover remova4 4-2 illustration of, 1-3 termina.! block, 1-2
disconnecting, 3-1 warning, 1-3
time delay potentiometers, ·4-2 test, functional, 1-3, 1-4,1-5
I)1otor.load transfer feature, 5--4
time delay I:,
1:.
.adjustment, 4-1
.N
" , '. PIP~wit5~~s,H,· 4.::-2,5.";1, ,5:-:4,.$-4 .>\l~m"PI~.t",covet .·~~~j~1ttt~:~W;tl, ........ .
override momentary· outages, 4-1
E o settings, 4-1
transfer to emergency, 4-1
electrical operation, 1-5 operation transfer to normal, 4-1
. electrical, 1-5
engine exerciser, 5-1, 5-2, 5-3 timer (plant exerciser), how to set,
mimt:!al, 1-3
5-1,5-2,5-3 .
. engine starting contacts, 1-2 illustration of, 1-3
warning, 1-3 transfer switch position lights; 1--4,
seqt:!ence of, 2-1 1-5
F optional ac;cesSories transfer test, 1-5,3-1
features, see control features ·programmable engine exerciser trouble-shooting, 3-2
frequency, pickup and dropout, 4-1 & SOurce availability signal
functional-test, 1-3, 1--4, 1'--5
contacts, 5-2, 5-3
se.ria.! communication module, 5-5
. . strip heater, 5-5
v :'.
voltage, phase, 4-1 j"
G voltage, pickup and dropout settings,
;

ground, controller, 1-1 4-1.

Printed in U.S.A. -Copyright' - ASCO Power.T~chnologies, LP. 2007
'.'.--. .. -.. : ... :.......:.,. . '.; .... . .... -:-- ........ . : .. ,...:..... ~. ' '., _. -' . :. ______ c••• "': •••"J:._ .. _:. :'''.... ~., .. _... :-.':_'.,::" ..~'•..• '. "."-"<"":: •. '_' •.. '.. ".'.

rrrTln
· .:
~ O ~,.

I® Safety Instructions
10 Sicller,heitshinweise

Please carefully' read these general supplemental' safety . Bittt) lesen. Sic allfmedPiam" diese 4m~:A\!<;:rk "ggC}nJ,«j!l\l~,
Dangers . and Warnings before perfenning installation, Gefah.Te!J.!Jjnwei~e: 'lInq·. "WaWll11gepD ·;1;r.<t<y<?r.; ,~i!".Plj~ :'I.~r,::
· operatien, or 'se!Yice en 'any ASCO SWitch product. Also read I~.tal!<i~i~n;, ·):n9IltriePlJ.a!J.nl.e.: . :o!\ef. cW~W1g" "ge~c'J~gq ~:

the manual included with the preduct. S.chal!geriite,:begiAnen, Lesen·.·Sie.,.~uc\l/ '¢!S .,<\em G~riit
beiliegende Handbuch.
Saft;lty levels
Only experieJ;lced licensed electricians sllould install the switch. Sicherheitsanforderungen
All standard safety practices should be observed. Die zur Tnstallation und Inbetriebnahme erforderlichen
Arbeiten diinen nur von zugelassenen Elektrofacbkriiften
Nameplate Ratings ausgefiibrt werden. Dabei sind die jeweils· giiltigen gesetz~
T)onot'exceed tile values on the rating label. Exceeding the rat" lichen und behordlichen Vorscbriften und die einscbliigigen..
. g could cause serieus damage or persenal injury. Sicherheitsbestimmungen zu·beli'chten.
)spection and Maintenance Bemessung$daten auf dem Leistungsschild
To prevent tile possibility of fatal electrical sheeks and bucis, de Die auf dem Leistungsschild angegebenen Bemessungs- daten
not werk en .the switch until all pewer 'and contrel circults are diirfen niGht uberschiitten werden. Bin Uber"': schreiten dieser
.disconnected.' .. . . Daten kann' zu· erheblichen Perso:i1en- oder Saclischiiden
fiihren.
Manual Operation with Maintenance Handle
Toprevent tllep"ssibility efpersenal injury or property daQlage, Priifung und Wartupg
dp nqt manually operate the:switch until all power and control Um die Miiglichkeit el;,es gefiihi:lichen eiektrischen Sc!1Iage,;;.
circuits are disconnected. und Verbrennungen anszuschliessen, sind vor Arbeiten' an dem
SchaItgerat'lie Ifaupt- und Steuer- ~tromlq:eise spanilUD.gsfFei·
· To.prevent the possibility of personal injury or property damage, .ZU schalten. ' .
be sure tq ·r,?move. the manual handle after working on the
·switch. Reattach it to the ~witch in the.p!ace provided.
.-:..... ,-'.
.
'.'.. .. : ... : .... '- :'j ",' . '
'B~Q~!i~t~tig~!l9))lit,q~l1)~ediei1!Jng~nellel' .
.'" ·.!!;ohinoldOperator Coil Replacement ·uri;:;ri5gudii6'V;i:i6~ge~~de;S~chsc~;iii~~'~';e;.:.riteiden, '
sind vor der Betiitigung des Schalters·von Harid aile Haupt- und
.To prevent the possibility of personal injury, hold the COre tube Steuerstromkreise spannungsfrei zu schalten.
· assembly securely away from yourself when removingand instal-
. ling the Coil; the spring exerts substantial force outward on the Um m6gliChe Verletzungen oder Sachschiiden ~ ver~ meiden;
core and liIik:, .' entfernen Sie den Bediellungshebel wieder, wenIi die Arbeiten
:)Ill . Schalter abgescblossen. sind. Befestigen. Sie :dell;
'Bedienungshebel in der dafiir vorgesehenen Halterung a)ll
Schalter.
Betiitigungsmagnet Spulentausch
Um . mogliche Verletzungen zu vermeiden, halten Sic die
Baug'ruppe Maguetanker und.Fiihrungsrohr beim Ausbau und
Einbau der Magnetspule nicht in Ihr.e Richtung. Die
eingebaute Feder ubt eine' erhebliche Kraft auf den
Magnetkern und das Schaltgestiinge aus.

ASCO ·Power '. Technologies·

50 Hanover Road, Florham Park, New·jersey 01932-1591 USA
. For sales or service call 800 801}-2726 (ASCO) www.ascopower.com
381339-190 F 1
~ 2/07
ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road,.Brantford, Ontario, Canada N3T 5T3
telephone 519 758-8450, fax 519 758-'0876, for-iervic. call 1 88.8 2340-2726 (ASCQ) www.asco,ca .
EMERSON.
 ....::';~..:. ;.::,.: :.:: ..:..
' . .. : ....... :~.:.: .. ' .. : .:.... ::( ....

Hazardous Substances

0 0 0
i§!$IJ~PCB
Contact () 0 .X 0.. p. '.
~:!l;~#*'1
Pins 0 0 0
~*li:!l;:JBi!lll
o· 0 0 0 0
ti]$IJ.**
);
( 1. Meaning of 0 and x( o.!fjxfl:;![);
0; The hazardous substance content in a/l types of homogeneous materials of the pari is lower than the
Ithresh'old' required in the SJIT-11363 - 2006. 0;
';![ffi i$ffililfj!f/P.IJ!JitEi$fI!#PJfN:#J(jfjf14tf:1@;Jt.ifl:#J/ESJIT-11363-2006 fFJiI!Ii!JE@INJilN::ftJ;< Fe
x; The hazardous substance content in more than one type of homogeneoas material of the pari is higher than
threshold required in the SJIT11363 - 2006. x;
I;![,r.ij·NI!.Ur,f1ffJWlJ.fI.1-"t£i}.'rfI!!f1=fI91it--;/!jJ(jf$}'!4ljl1@g.llfJilfifSJIT11363 - 2006 fFift!li!JE@INJIIN::ft

'ASCB
. Power .
Technolog.ies·
50 Hanover Road, Florham Park, New Jersey' 07932-1591 USA
For sales or-service call 800 8~272S (ASCO) www.ascopower.com
381339-190 F 4

ASCQ POWER TECHNOLOGIES CANADA PO -Sox 1238,17 Airport Road, Brantford, Ontario, Canada N3T 5T3
t 2/07
EMERSON.
telephone 5)9 758-8460, fax 519 758-0arS, for service call 1 8~a 234-2726 (I\S90) www.asco.ca ~etw~rkPo.wl!r
 ·I~

,---,,--,
8 ",J 7 I 6 I 5~ 4 I 3 I 2 I
SINGLE PHASE WIRING FOR Aseo· SERIES 300 AUTOMATIC TRANSFER SWITCHES RATED 30. 70. 104. 150. 200. a 230 AMPERES WITH GROUP I CONTROLS
!
CONTROL FEATURES FIELD CONNECTIONS
Val TAGE AND FREOUENCY SENSING REMOTE CONTROl fEATURES TS CP
r--
CP

D
A. DIfFERENTIAL TYPE VOLTAGE SENSING ON ALL PHASES OF NORMAL SOURC£'
DROPOUT SOONG SElECTABLE AT 90. 65, 80 OR 70~ OF NOhllNAL
FACTORY SIT AT 65:(. PICKUP VOLTAGE ADJUSTABLE AT 90 OR 95"
OF NOMINAL (DEfAULT IS 957. If OROPOUT IS SIT TO 90';).
fACTORY SIT AT 907.. (REFER TO THE OPERATOR'S MANUAL FURNISHED
WITH EACH TRANSFER SWITCH REGARDING CONTROL PANEl SffiINGS).
THE fOLLOWING CONTROL PANEL INPUTS PROVIDE REMOTE CONTROL
FUNCTIONS FOR THE AUTOMATIC TRANSfER SWITCH. EACH CONTROL
FUNCTION CAN 9E IMPLEM8HED BY THE CUSTOMER PROVIDUIG THE FORM OF
CONTROL CDflTACT DESCRIBED. EACH CONTROL CONTACT MUST 6E SUITABLE
fOR A 5 we LOW ENERGY C!RCUIT. EACH CONTROL FEATURE IS ACTIVATED
BY SffilNG A DIP TYPE: SELECTOR SWITCH ON THE COtlTROL PANEl.
(REFER TO THE DPERATOR'S MANUAL FURNISHED WITH EACH TRANSFER
r::ci.r~
:
I
H:
I
:LJ,-~TI3_ :
r--O? -, Op-'l

I I I
__J
REMOTE CONTROL FEATURES

D
8. SINGLE PHASE VOLTAGE SENSING OF EMERGENCY SOURCE. SWITCH REGARDING CONTROL PANEL SffiINGS). I I I
NON-ADJUSTABLE DROPOUT SETTlNG AT 757. OF NOMINAl. I I I
NON-ADJUSTABLE PICKUP SE.TllNG AT 90~ Of NOMlt'IAL A. REMOTE TEST FEATURE - REQUIRES A CUSTOMER SUPPLIED, REMOTE. I I I
C. FREQUENCY SENSING OF EMERGENCY SOURCE. NORMALLY CLOSED CONTACT. OPENING OF THE CONTACT S1MULATES A I I I
NON-ADJUSTABLE OROPOLrr SEmNG AT 657. OF NOMINAL. fAILURE Of THE NORMAL SOURCE SIMILAR TO THE SEQUENCE OUTUNED FOR I I I
NON-ADJUSTABLE PICKUP SffilNG AT 957. OF NOMINAl. THE TRANSFER SWITCH TEST PUSH-BUTTON. THE TRANSFER SWITCH WIll T8 I I I
REMAIN CONNECTED TO THE EMERGENCY SOURCE UNDER ALL CONDITIONS

J ST~~~~G
TIME DELAYS I I I REMOTE REMOTE INHIBIT 9YPASS

A. MOMENTARY NORMAL SOURCE OLrrAGE: DELAY - ACnvATED WHEN

WHILE THE CONTACT IS OPEN.
" E E
I I I TEST TRANSFER
TO
TRANSFER
TO
TRANSFER
nNE
THE NORMAL SOURCE fAILS. DEACTIVATED WHEN THE NORMAL SOURCE
IS ACCEPTABLE. PROVIDES A SELECTABLE (1 OR 3 SECOND)
B. REMOTE TRANSFER TO EIJERGENCY .fEATURE - REQUIRES A CUSTOMER
SUPPLIED, REMOrE, NORMALLY CLOSED CONTACT. OpENING OF THE CONTACT
i,s :
L..----+51 FEATURE 7
COMMON ]

SIGNALS
I
,~---~,
I I EMERGENCY EMERGENCY DEiN
,--------~,

-
DELAY ON TRANSFER AND ENGINE STARTING SIGNALS. fACTORY SET AT
3 SECONDS. (REFER TO THE OPERATOR'S MANUAL FURNISHED WITH
CAUSES ENGINE START AND TRANSFER TO THE EMERGENCY SOURCE.
RECLOSURE OF TI-lE CONTACT ACTIVATES THE RETRANSFER TO NORMAL ! ,Ct.OSf.:S TO STAAT (to AMPS. J2VOC)
LOAD DISCONNECT CUSTOMER SUPPLIED CONTACTS FOR fEATURES -
'-~
EACH TRANSFER SWITCH REGARDING CONTROL PANEl SffilNGS). DEu..Y PRIOR TO RETRANSfER. !N THE EVENT THAT THE EMERGENCY SOURCE
fAILS WHILE niE TRANS(ER SWITCH IS CONNECTED TO EMERGENCY AND THE TS
+0
L..J
I FEATUREOP01S TO STAAT
8 CONTACTS
5 AI.IPS RESIsnVE
/oS DESCRIBED IN STANDARD CONTROL ffATURES
NOTES. COflTACT MUST BE SUITABLE FOR 5V DC
8. TRANSFER TO EMERGENCY OEtAY- ACnVATED AFTER THE REMOTE COtlTACT IS OPEN, THE TRANSfER SWITCH WILL AUTOMATICALLY LOW ENERGY CIRCUIT. ACTIVATED BY SEllING

P·~-""~#.l-'-------'---"-----
TS 28 vac OR 120 VAC MAX.
MOMENTARY NORMAL SOURCE OllfACE DELAY EXPIRES RETRANSfER TO THE NORMAL SOURCE.
] FEATURE 14A AUXILIARY (LOCATED ON
OF DIP SELECTOR SWITCHES ON CONTROL PM<EL

]
AND THE EMERGENCY SOURCE IS SENSED TO BE ACCEPTABLE. (REFER TO OPERATOR'S UANUAL FDR REQUIRED
TRANSFER TO EMERGENCY IS CDMJ.tIITED TO ON INITIAT!ON OF C. INHIS!T TRANSfER TO EMERGENCY FEATURE - REQUIRES A CUSTOMER CONffiOL PANEL) SETTINGS.)
, ' TS " ctOSfll 011 IIORWJ.. CONTACTS
It~j-----'-----------'---
DELAY. DEACTIVATED WHEN THE EMERGENCY SOURCE IS UNACCEPTABLE. SUPPUED. REMOTE, NORMAllY CLOSED CONTACT. OPENING OF THE CONTACT FEATURE
PROVIDES .&.N ADJUSTABLE DELAY FROM 0 TO 5 IAINUTES. fACTORY WILL PROHIBIT THE TRANSfER SWITCH FROM TRANSFERRING TO THE
1-4A & 148 ACC. 1 I BG SOURCE AVAlU,81! IlY SIGNA! S
SET AT 0 MINUTES. (REfER TO OPERATOR'S MANUAL fURNISHED EMERG8~CY SOURCE WHILE CONNECTED TO THE NORMAL SOURCE.
---,--"--------------
,:I !
WITH EACH TRANSFER SWITCH REGARDING CONTROL PANEl SElT1NGS). :r;~-""~#.::jr: (10 AMPS, J2WC)
'8G ~_... ~OCATED ON INSIDE OF DOOR BEHIND OPERATOR INTERFACE

J I--mv
(10 MIPS, 48OVAC)
D. BYPASS lR/INSfER TIME DEu..Y FEATURE - REQUIRES A CUSTOMER SUPPUED. FEATURE 148 GENE!W. PUR?<ISE 1 ON "ENGINE EXERCISER" MODULE
C. RETRANSFER TO NORMAL DELAY - ACTIVATEO WHEN THE NORMAL
SOURCE IS ACCEPTABLE. DEACTIVATED WHEN THE NORMAL SOURCE REMOTE, NORMALLY CLOSED CONTACT. OPENING OF THE CONTACT BYPASSES TS :, ClOSfll ot{ O.!ffiGENCY
'L~,h1jc---------------------

I'ctmm~m._-
FAILS WITH NO TRANSFER TO NORMAL Al.SD DEACTIVATED WHEN THE RITRANSfER TO NORMAL DElAY IF ACTIVE.

"Ir-liii-CiiiT~-11
THE EMERGENCY SOURCE FAILS WHILE n-tE NORMAL SOURCE !S
ACCEPTABLE WITH TRANSfER TO NORMAl... ADJUSTABLE DEtAY , ~
...1._________ COMMON
C FROM I SECOND TO 3D IJINUTES. FACTORY SET TO 30 ~INUTES. GENERAL NOTES ~-----------·r--------------------"
TS C
(REFER TO THE OpERATOR'S MANUAL FURN!SHED WITH
ii i ffi i[ ACCESSORY 14A
] ClOSED 01'1 1!ORWJ.. AUXIUARY : 2 : SOURCE

:I~~~:~~~:jl::::::::::::::::=::: +---------- NC
EACH TRANSfER SWITCH REGARDING CONTROL PANEL SETTlNGS). L SWITCH SHOWN DE-ENERGIZED CONNECTED TO NORMAL SOURCE.
D. UNLOADED RUNNING (ENGINE COOL DOWN) DELAY - ACTIVATED ON DEVlCE SYMBOLS AND DESIGNA110NS ARE IN ACCORDANCE WITH NElJA PUB. ICS 1-1983.
PART 1-101A.
CONTACTS
ACCESSORIES I, J , NORMAL NOr AVAl!.'Jli£
AVAILABILIlY SIGNALS
(2 AMPS I) JOVOC, RESISTiVE)

i, E+--------
EXPIRATION OF REiRANSFER TO NORw.t.. DELAY OR FOllOWING

:1
2. ALL WIRING IS 116 AWG, nNNED, STRANDED COPpER UNLESS OTHERWISE INDICATED. 14M & 148A (0.5 AMPS 0 125 vAt, RESISTIVE»

~o",~ "M~
EXPlRAnON Of THE NORMAl. SOURCE OUTAGE DELAY WITHOUT A COMMIT CONTACTS SHOWN DE-ENERGIZED
TO TRANSFER TO EMERGENCY. NON-ADJUSTABLE DUAY OF 5 MINUTES. 3.
4.
0 IND!CATES CUSTOMER CONNECTION POINTS.
• INO!CATES FACTORY CONNECTION POINTS.
"
lilTS"
" , 'I ACCESSORY t 48 (IO AMPS. J2WC)
(10 AMPS, 4aOVAC)
E. MOMENTARY EMERGENCY SOURCE OUTAGE DELAY-ACTIVATED WHEN n-tE ] CLOSED Ofl ().1m-GOleY
,
i r---------
5. CONNECTION POINTS THAT HAVE BOTH CUSTOMER CONNECTIONS AND FACTORY CONNECTlO:1S ", I, "
GENERAL PURPOSE
SWITCH IS IN THE EMERGENCY POSITION AND THE EMERGENCY SOURCE fAILS.
ARE SHOWN OPEN AS CUSTOMER CONNECTiON POINTS. ll:~~L[,§l---------------------
FACTORY SET AT -4 SECor·4QS. RESET IF EMERGENCY RESTORES WITHIN 4 SECONDS. 6. THE TRANSFER UNIT !S MOUNTED ON THE BACK INSIDE SURFACE Of THE ENCLOSURe 5 COMMON
THE CONTROL PAllEL AND Am OpnONAl ACCESSORIES ARE MOUNTED ON THE INSIDE
ENGINE CONTROl CONTACTS
ONE SET OF FORM C CONTACTS (1 N/O &: 1 N/C) THAT Cl-Wl.GE
SURFACE OF THE ODOR. ISrruP' HEATER
ITHERMDSTAT
l r sffiip HEATrnl
I llWISFORI.IER
,
l 6
~-'-----------
'
NC
().IfJlGENCl' IlOT AVlJt).Gi£_
POSITION ON EXPIRAnON OF THE NORt.lAL SOURCE OUTAGE DELA.Y
7. AN OPERATOR'S MANUAL IS FURNISHED WITI-I EACH AUTOMATlC
TRANSFER SWITCH. REFER TO THIS PUBUCAnON PRIOR TO INSTALLATION AND :&: CUSTOMER TB: : &: THERMOSTAT : L __ ...::.J
AND RESET ON EXPIRATION OF lliE UNLOAOEO RUNNING
(ENGINE COOL DOWN) DELAY. OUTPUT CONTACTS (NR)
ARE RATEO 5 AMPS RES!STIVE AT 28V DC OR 120V AC MAXIMUM.
B.
OPERATION OF THE SWITCH.
GROUNO STRAP ON CONTROL PANEL IS AffiXED TO CHASSIS (ENCLOSURE)
AT LOWER LEFT CONTROL PANEL MOUNTING STUD.
u..,-_'_T~;J
: I
L~c __ ~J
1 !
OPERAIDR INTERFACE INDICATORS & CONTROl S
MEMBRANE TYPE OPTIONAL ACCESSORIES ! ! I, ,:
A. TRANSfER SWITCH TEST - MOMENTARY PUSH-BUTTON TO ACCESSQRY 11 BG PBOGRA,W,lARI f ENGtNE EXERCISER &: SOURCE AYNj AeI!!JY StGMAI ; 6 6 LLI~ ~U2
SIMULATE NORMAL SOURCE FAILURE SEQUENCE OF OPERAnDN.
PRESS AND HOLD fOR AT LEAST 15 SECONDS TO ALLOW TIME
J.1QJlll1£i '-----' '-----'
ACCESSORY 4~A ACCESSORY HG
FOR ENGINE-GENERATOR SIT TO START. PRQGRAWMBIE ENC1NE EXERC!SER' A PROGRAl.tMAELE SEVEN (7) DAY OR FQURTE£N (1-4-)' STRIP ilEATER STRIP HEATER
DAY ELECTRONIC TIME SWITCH FOR AUTOMATIC WEEKLY TESTING Of THE ENGINE GENERATOR. CUSTOMER POWER POWER SUPPLY
B. BYPASS TIME DELAY - MOMENTARY PUSH-BUlTON TO BYPASS EITHER SET EITHER WITH OR WITHOUT LOAD. .
THE TRANSFER TO EMERGENCY DE! AY ENGINE EXERCISER PERIOD OR THE SUPPLY 120 VAC FROM LOAD OF TS
EACH DAY OF THE WEEK IS' INOMDUALLY PROGRAMIAABLE. THE nME OF DAY IS PRESERVED (opnoNJI.L)
RfTRANSFfR TO NORMAl OF! AX DEPENDING ON WHICH DELAY IS (OpnONAL)
BY A BATTERY BUILT INTO THE GROUp 1 TRANSFER SWITCH CONmOL PANEL
ACTIVE AT THE TIME THE PUSH-BUTTON IS ACTIVATED.
THE FEATURE IS ACnvATED BY SEITlNC A DIP SELECTOR SWITCH ON THE CONTROL PANEL:
B C. SET ENGINE EXERCISER - MOMENTARY PUSH-BUTTON TO AcnVATE ENGINE STAAT WITH OR WlTHOUT LOAD TRANSFER IS SELECTED WITH A SECDtlD DIP SELEqQR ACC 72A SERIA! COMMUNICATIONS OPTION B
A SEVEN {7} DAY TIMER FOR AUTOMATIC WEEKLY TESnNG OF SWITCH ON THE CONTROL PANEL (REFER TO THE OPERATOR'S MANUAL FURNISHED WITH .E·,~:eH COM!,(IJI.tIO.TIflCl WI1Il CROIJI> :; COUTItOl PAAa (cp)
THE ENGINE GENERATOR SET EITHER WITH OR WITHOUT LOAD TRANSFER TRANSFER SWITCH REGARDINC CONTROL PANEL AND nMER S£TTlNGS).
mE TIMER IS POWERED BY A NON-RECHARGEABLE 9V BAmRY WHEN TO OTHER
NORMAl AND EMERGENCY SOURCES ARE UNAVAILABLE. DEPRESSING THE SOIlRCE (WA!! A81! ax SIGNAl! INC· ONE fORM C CONTACT EACH fOR THE NORMAL &. 72A ASCO
MOMENTARY PUSH-BUTTON FOR 5 SECONDS SETS THE nME Of WEEK AT WHICH
~~
EMERGENCY SOURCES SIGNAL THE ACCE?TABIUlY 'OF THE SOURCE AS SENSED BY THE GROUP SERIAL COMMUNICATiONS
TESllNG IS TO OCCUR. THE fEATURE IS ACTIVATED I CONTROL PANEL THE SIGNAL CONTACTS OPERATE IN CONJUNCTION WITH THE SOURCE
BY SOl!NG A DIP SElECTOR SWITCH ON THE COtrrROL PANEL AVAIlABlUTY LEO STATUS INDICATION PROVIDED ON THE OPERATOR INTERFACE. fiElD WlR..ING I (=-~ , DEVICES

I, (~ 0---'-----1
ENGINE START WITH OR WlTHOllf LOAD TRANSFER !S SElECTED WITH TERMINAlS ARE PROVIDED AS SHOWN, LOCATED ON Tl-iE 1NSIDE DOOR B£H1l1O THE OPERATv~
A SECOND DIP SELECTOR SWITCH ON TI-lE INTERFACE. CONTACTS RATED 2 AMPS I) 30v0C, 0.5 AMPS C 125 VAC (RESISTIVE). 5 I: r----- 72A NOTES:
.",1
CONTROL PANEL fACTORY SET TO DISABLED, NO LOAD.
(REFER TO THE OPERATOR'S MANU.AL FURNISHED WITH
EACH TRANSfER SWITCH REGARDING CONTROL PANEL 5ffilNGS).
""I' . I
, .. I\IJ~ (+1 __
I
..... , ~',
-'---1",-1,--\.".r--r, -,,----
~4,w/o Il>«-
1. fARllI GROUHD SHlELO AT HOST Of.V)C( ONLY. H '
, ' PRODUCTS. 2. FIELD WIRING: USE UL USTED, STfWIDED,
D. LOAD CONNECTED TO IND!CATORS
GREEN LED INDICATOR TO INDICATE WHEN THE TRANSFER SWITCH ACC. 14M (2) AUXIUAR'l' CONTACT CLOSED ON NORMAL
I, . . [liJ'A (-) 0--,_.I___~_~_Jv\._+_{~t!_ 11<- :;:~~~~IT~OR~~_S:i~Q~~gED ~
- LOAD IS CONNECTED TO lliE NDRI.W.. SOURCE. I I:: 11 ~
REO LED INDICATOR TO INDICATE WHEN THE TRANSFER SWITCH IS ACC. 148A (2) AUXIUARY CONTACT CLOSED ON EMERGENCY.
I r.!><fA o---~--~-~--, . r-+-{!l!-
(tl Tot ~~~C~~ :~~c BELDEN !l8~2 OR 9829 DR }.U'HA F '
CONNECTED TO THE EMERGENCY SOURCE. ACC. 44A STRIP HfATER, THERMOSTAT &: m. CUSTOMER POWER SUPPLY 12OVAC.
I VV J: 3,:: E~
0~
E. SOURCE AVp,lLABLE INDICATORS ACC. HG STRIP HfATER, THERMOSTAT &: TRANSFOMER. POWER SUPPLY FROM , • • I ," , (Pt£tl.UM MUO) BELDEN 1.19729 OR 82729 OR
GREEN tEO INDICATOR TO mDICATE WHEN THE NORMAl SOURCE IS LOAD TERMINALS OF TRANSfER SWITCH. L:.:~~)1j---~9--JV\.--t:y~t!~ T._ ALPHA 56902
AVAIlABLE:. . .

~~~~~~~~~~~~~~~~~~~i
~~~~~lI~~~~~~~~~~~~~~~~~f;;;~~~~~~~~~~~~~~~~CATAlOG
RED LED IND!CATOR TO INDICATE Wl-l£N THE EMERGENCY SOURCE IS
AVAIlABLE. I DAD OISCONNEq' FEATURE
~ ICATAlOG~I:~~
TS '''~ NEU~.1YPE ""Iil"",,~CODES ASCO·C~~IFIED __T_O__ C~
ONE SET OF FORM C CONTACTS (I N/O &:·1 H/C) ll-IAT CHANGE PDsmoN'.ON
ACTNATION of" A S8-E:CTABLE TiME DEL4.Y BEFORE TRANSFER (LD TDaT) AND'·
RESET EITHER IMlJEOIATELY FOLLOWING TRANSfER OR FOR THE SAME DElAY 1.c60'F' ~ ~'__ CODE CODE TYPE I 8Y·--,--_ _
NUMBER
B~
~ '~' g:';:k1ZP~Ug;gSE. ~::~ ~
;.s SET FOR PRE-SIGNAL BEFORE TRANSfER. SELECTABLE AS 0, 3, 10 OR 20
SECONDS. fACTORY SET AT O. (REfER TO THE OPERATOR'S I.W4UAL fURNISHED
wITH EACH TRANSFER SWITCH REGARDING CONTROL PAN8- SETTINGS).
C 181r".· ,. I. C 'lOlO'o , INDOOR 00' u 1
I -
F
1 F 3R OUTDOOR, RAINPROOF, SLEET &: ICE RES!$TANT 'V"'" " ...... I
A
A , rr~~~~S;~;;~~~~;~i~~::::~~~~~~~~~~~1
O\JTPUT CONTACTS (OP) ARE 'RATED 5 AlJPS RESISTIVE AT 2B. VOC OR 120 VAC
x Jl(~1
~'~I!~ I~
~
MAXIMUM.
MOTOR LOAD TRANSFER FEATURE ° 300 8
C
2 L
G F
H
240
380
L
G 12
4 INDOOR, INDUSTRIALWATERTIGHT
INDOOR/OUTDOOR, ENVIRONhlENTS, DILnGHT &: DUSlTlGHT
&: ousrnCHT
~
N I<>.

. INPKlSE: TRANSFER CONTROL LOGIC TO INITIATE AN INPKlSE TRANSFER OF 1l11: ~ !~~ (SECURE ENCLOSURES) ~~~~.?':OO_:~.lP1H[_.~?.:~~?_JJlPS ..

~~
MOTOR LONIS BElWEEN UVE SOURCES. USED TO HElF PREVENT NUISANCE l 440 M 3R OUTDOOR, RAINPROOF. SLEET & ICE RESISTANT . JJ l'HAJ.{l>. t;1..:uUi CUNTt(U~
mlPPING OF DISTRIBUTION CIRCUIT BREAKERS AND POSSIBLE DAMAGE TO
MECH.ANICAL LOADS ASSOCIATED WITH OUT OF PHAsE TRANSfER. ACTIVATED J,!
N
460
4BD
~~
ex SETTING A DIP SWITCH ON THE CONTROL PANEL FACTORY SEt IS
P 550' ,. 1- OS·
OISABLED. (REfER TO OPERATOR'S I.W4UAL fURNISHED WITH EACH TRANSFER
SWITCH REGARDING CONTROL PANEl SETTlNGS). BlANK BLANK
Q 575' _OIU'.. ~
-"foif R 600' .' 200 &. 230 AMP SIZES ARE 480V MAX. 18516
FOR
.ONE 100,PPE".i'm'EII,,,o"·"·· ~-I ASCO- "::::'" HM:l' 2t 3405 11'oF4
 8 7 6 5 4 3 2 1
MAIN POWER POLES TS OPERATOR CIRCUIT

NL1
D OPTIONAL SWITCHING NEUTRAL
NL2 D
NORMAL
EMERGENCY

ELI ELO EL2 N~O / OPTIONAL OVERLAPPING NEUTRAL

?I I TS
I I (~~
I I i--------l
I I
,, ,,
TS
:
I
,,,-- ...,
TS ---.f, ELO ',1 T5 EL2
TS I
I
I

-NN 9----<,NLO)
,"'---'\
-4 -EN.... -5
I ' ... __ J I ' ... __ .f
I
I
I
I
I
I
I
I
r-----
, 11-'~9
I 7'0
TS

+-'
I I
I I
TS (Ell) TS (ELO) I TS (EL2) TS (NLO) I
C _.1._ -.1.", C
7'r-
OPTIONAL NEUTRAL TYPES
REFER TO BEXPLANAT!ON OF CATALOG NUMBER CODES"
TS IN CATALOG NUMBER CHART ON SHEET 1.
LLi o-___-~2"'O+__-< Lll I
I
I • NONE
I • SOLIO BUS PLATE
I
I • SWITCHING (LOCATED BETWEEN Ll & L2 POLES)
I • OVERLAPPING CONTACTS
I
I
I
LOAD TS
I
I
I
I
LL2 o------4----------T-----~-~242~LL2 I
I Ell EL2
I
;---"'\ I

-------:~~~~~~~---
TS II
-LN-t /LLO'-
r" _ _ - '

LLO 0------ --------

I
---~
' .... __ ..'
I

B
I
I I EMERGENCY B
I I
TS (NLl) TS (NLOj 1", TS (NL2) TS (ELOjL
'"'r- -T-
I I
I I
I I
I I
I I
I I
I I
I ,.---... I ... --."
TS TS+ __./NLO\ IS TS+ __ iELO\
-I -NN ' , -3 -EN \ ,
I ''--_./ I '... __ ./

b b
NLi NLO NL2 ELO

NORMAL
NOTE:
ATS SHOWN CLOSED ON NORMAL SOURCE.
A A
 8 I 7 I 6 I 5 4 I 3 2 I 1
WIRE RUN LISTING CONTROL SIGNALS & INDICATION NORMAL SOURCE CIRCUITS
I FOR 30- 230 AMPS I NORMAL
i <c: LOCATOR ~

D • I~I-:: ACCESSORY 11 BG
NL1 L
D
PROGRAMMABlE
ENGINE EXERCISER &. SOURCE
AVAJtA8llflY SIGw.L
- (OPTIONAl)
CP
-CP
r---------"l L _ _ _ _ _-"'-';-.'.,~1 ~~~~~E ,JJ."",,--,_ _ _ _ _ _ _ _ _- '
lr..'ll
=
- L S- 4 CONTR~
SEHS~G 'l2l' '-

l
-~;~:,"p.
- I -------l
: 113-9 ACCESSORY IIBG:
PROC"","""," I EMERGENCY SOURCE CIRCUITS
L __Q!Q1!:'ls EXE!tC~SQ!J

EMERGENCY
EL1 E

C C
CP

I OPTIONAL ACC. 11 BG I
I<V ' Ace. !mG
V::~E I
CLR AWG I
26 CP-T8 411BG TB 9
"I

LOAD TERMINAL CIRCUITS

LOAD

B B

A A

I
 8 7 6 5 4 3 2 1
PHYSICAL DIAGRAM·

ENCLOSURE OPTIONAL DOOR (INSIDE)

SWITCHING
OPERATOR lmt:RFAC£
NEUTRAL MEMBRANE ACCESSORY /£C. IIBG ASSY.
PH 47370B PH 629830
MOUNTS ON BACK OF OPERATOR
D OPERATOR CONTROLS INTERfACE MEMBRANE JSS'(.
D
TS (TRANSFER SWITCH) OPTIONAL MEMBRANE PANEL
OVERLAPPING
VIEW FROM INSIDE FRONT NEUTRAL FIELD CONNE:CTIONS
ODS! SOURCE AVAlLA81UTY
slmws
30,70,100,150,200,& 230 REfER TO SHEET 1
0 0"
EMERGENCY
r-----------l
! TS COIL: Lli LL2 LNO FACTORY
CONNEcnONS
NLO '?
:.8 :
!eAOi
,
:
,
,
:
,
ELI ELO

1 IN
EL2

1: Q, ,i
:L __________
CKT

71 9 70 6
l:

.
,EN!
,,, ,,,
,, ,,
: GROUP 1 CONTROL PANEL

~~tt LAJ FlAT CABLE

20 22 PH 607761
NOTE: CONNECT PI OF PH 607761

72 8 69 7 •:i TO J3 OF OPERATOR INTERfACE

MEMBRANE />sSY. PN 413708 WHEtl

,NN
ACe. 11BG IS NOT USED.

17 15 NN 3
C C
ENGINE
CONTROL
CONT ACTS
~ fI\AT
L
F~A T
fit
16 18 14
Nli NLO
NORMAL
NL2
(,
ELO

STANDARD TRANSFER SVITCH HARNESS

(TYPICAL ALL S\HTCH£S)
ASCO OPTIONAL
SERIAL COMMUNICATION
DEVICE

TO LOAO Of ATS
(OPTIONAl ACC. 44G)
OR
TO CUSTOMER POWER
8 SUPPLY 120VAC
(OPTIONAL Ace. 44A) 8
t
!i
,1
r-----.L-----1
,, ,,
: HEATER :
,,
: ACCESSORY : ,
,, ,,,
,, ,,
t. ___________ J

A A
DOOR HINGE - - - - '

BONDING STlW'
PN 09832;;-019
 ''''~

5 4 3
8 7 6
CHES RATE D 30, 70, 100, 150, 200 & 230 AMPERES
OUTL INE & MOU NTIN G FOR ~. SERI ES 0940 , D300
, 0386 TRAN

D
D PHASE A PHASE"S PKo\SE C
GENERAL NOTES
I I 1. THE STANDARD SWITCH CONFlGURATlDN IS FOR TOP EMERGENCY
&. lOAD ANO BOTTOM NORMAL

1I l2 2. NEIJTRAL CONFlGURATlQtIS:
2 POLES 2 POLES
TION FOR EACH SOURCE
DJOO-A fULL RATED sauo (COPPER BUS) NElJTRAL COHFlGUERA
NEl./TAAl POLE MAY BE PRQ\IIOED
AND THE LOAD IS PROVIDED STANDARD. opnONAllY A SWITCHED
AS SPECIFIED BY THE CATALOG NUMBER:
(B) SWTICHEO NEUTRAL POl£
(C) OVERLAPPING NWlRAL POLE
10.:25"
[260.4 mm] 0940/0J85 -AH OPTIONAl fi.Jl1. RATEO NEVTRAl CONfiGURAT
ION fOR EACH SOURCE AND THE LOAD
FOLlOWn4G FORfMTS IS SPECIFIED BY
MAY BE PR0V10EO. WH~ EQUIPPED IT IS IN ONE OF THE
THE CATALOG NUMBER NO. NEUTRAl. TYPE:
CA) souo (COPPER 8US) NEUTRAl.
7.75'· (8) swnCHED NEUTRAl POl£
[196. (C) OVERlAPPING NEUTRAL POLE
1.63" :,1
5.31 "
[ 41. 0.97" 0.87" ." [l'S ( ) m n n l - - - - ARE SHOWN fOR REfERENCE.
J. THE STANDARD I.IECHmCAl (SCREW TYPE) AL/Cu TERMINAL LUGS
[2.4.5mm] [22,lm m1 MAX. DEPTH 4. WHEN INSTALUNG CONDUCTORS. CONNECT TO SIMILARLY
MARKED PHASES OF tlORINIL. EMERGENCY & LOAD.

S. ALL INTERNAl CONNEcnONS ARE MADE AT FACTORY.

LOAD
.90") 6: MAINTAIN ELECTRICAL C\.f.ARAHCE OF .50· (12,7 mm) BElWEEN

7. WHEN MOUtffiNG THE TRANSFER SWITCH IN AN ENCLOSURE ,

UVE METAL PARTS AN!> GROUNDED METAL

MOUtfT THE TRANSfER SWITCH UNIT ON T1-1E INSIDE

c
c [22.9mb,] SACK SURFACE OF THE ENCLOSURE.. THE CONTROL(S) PNiEL AND
ON THE IKSIOE. REAR SURFACE OF THE DOOR. A MINIMUM
OEPnl
OPERATOR CONTROLS SHOULD BE MOUNTED
or
CLOSED.
S.OO~ (IS2,4mrn) IS REQU!REO BOW£EN THE
TRANSFER SWITCH mD THE CONTROLS WHEN nlE DOOR IS
* NOlE: COtfTROLS ARE NOT PROVIDE!> ON 0940 w/ ACC. 9SA..

B -1 fOR CUTOUT DATA..

9. FOR TYPE 1 ENCLOSURE SEE DETAIL A -I -*10 D£rAIL
DETAIL B -2 fOR CUTOUT DATA
FOR TYPE JR. 4, &. 12 ENCLOSURE SEE DETAIL A -2 AND S.
GASKETS ARE PR0V10ED FOR TYPE JR, 4. &. 12 ENCLOSURE
TYPE JR, 4, &. 12 ENCLOSURES.
A BEZEl fOR THE CONTROL PANEl IS AlSO PRCMOED FOR
TRANSFER SWITCH. REfER TO THIS
10. AN OPERATOR'S MANUAl IS FURNISHEQ Wffi{ EACH AUTOfMTIC SWITCIl.
PUBUCATlON PRIOR TO INSTAllATION AND OPERATION Of THE

5] 11. WHEN OPTIONAL OVERLAPPlflG NEUTRAl. IS SUPPUEO nlE

ARE REVERSED. NORMAl ON TOP, EMERGENcy AT BOTTOM.
CONTACTS ON THE OVERLAPPING IIEViRAL

MINIMUM REQUIRED ENCLOSURE SIZE IN(mm)

S~ITCH RATING DEPTH
HEIGHT ~lOTH
(AMPS)
1N
8.75" [MERG ENCY . 30-200 AMPS
31.00
(787 ,4)
0
17.50
(444.5)
11.63
(295.4) om
[222.3 mm] 48.00 18.00 13.00 1N
!pO AMPS ( 1219.2) (457.2) (330,2) om
10.25" :..,..
[260.4 mm] APi:IRJX~~f;:TE SHIPPING ~EIGHT.LBS (KG)

(\.fEIGKT...INc(~S STANDARD TRANSFER SV!TCH f. CCX>ITRClLS) B

B
POLES ~EIGHT

BOLT SIZE FOR MOUNTING A.T.S"

I INCH LONG MINIMUM QUANTITY (4)

S\.IITCH RATING RANGE OF WIRE

(AMPS)
30-150 (I) #14 TO 4/0·A~G AL-CU WIRE
200-230 .. (I) #14 TO 4/0 AYG COPPER \lIRE

0.75"
[19.1m m]
NORMAL A
A
,f
¢O:312." [7.9mm ] .'"
MOUNTING "l;iOLE DIA. (~RbNT (SIDE VIEW)
;}~. *SOLIDNEUTRAL NOT SHOWN
-')'
 • }._n,

7 6 5 4 3 2 1
8
RATED 30, 70, 100, 150, 200, & 230 AMPERES
OUTLINE & MOU NTIN G FOR ~. SERI ES D940 , D300 , D386 TRANSFEFI SWIT CHES

t'PD U;, NElIT/W.

o
o PHASE A PHASE B PHASE C
SWiTCHEO OR
OVERlAPPING

1025"
[260.4 mm]

7.75"
[196.9 mm]
1.63" 5.31"
[41.4m m] 3.83" 0 .87" [ 135. 0mm ]---- --i
[97.2m m] 0.97" [2 2.1 mm] MAX. DEPTH
[24.5m m]
~ LOAD
0.90 c
c /' t\
, - r- I -
~r@ ,~ ~
1'---./
[22.9 mm]

:$:C§JI~O i@ ~
!

8 I\J I@ ~
I@ I~ I~ Em
1

1
1:ME RGEN CY
8.75" ** WHEN OPTIONAL OVERLAPPING NEUTRAL IS SUPPLIED
[222.3 mm] ED
I- THE CONTACTS ON THE OVERLAPPING NEUTRAL ARE REVERS
1 0.25"
NORMAL ON TOP, EMERGENCY AT BOTTOM.
[26 0.4mm ]
B
B
Lr-

~
~ ~
~010~I(o'@
~ '--t~~ pt O - .
075"
. ,-
118.9m m]
J
0.46" ,
[11.7m m]
**NORMAL A
A
¢ 0.312" [7.9mm ]
MOUNTING HOLE DIA. (FRONT VIEW) (SIDE VIEW)

7
 5 4 3 2 1
8 7 6

l®mJ' SERIES 0940 , 0300 , 0386 TRANSFER SWITCHES RATED 30, 70, 100, 150, 200, 8< 230 AMPERES
OUTLINE &: MOUNTING FOR

o
o CONTROL PANEL & CONTROLS MOUNTING
CONTROL PANEL & CONTROLS MOUNTING DATA

6.25" 2.25" PANE! MOIJNTING DATA

CONTROl S (CUTOlff ) DETAil "A" CeNTROJ
[158.8mm] [57.2mm]
RO.2S" 2.00'
[R6Amm] 2.00'
3.00' [50.8mm]

j
(SO.amm]
[76.2mm}
A A A A A

II
+

+-
RO.2S"
'B I I

-+-
B [R5.Jmm]
SEE DETAIL 3.75" 3.75"
4.25" 4.25" A A 9.50'
"A" \ (107.9mm ] (95.2mm] nf-- --"f t- -
[10a,Dmm [95.2mm)
(241.3mm ]
CONTROL

III
OPERATOR I
PANEL I J A
10.37"
[263,Smm]
CONTROLS 0.25" 5.75" 0.«" C
CUTOUT [6.4mm] [H6.Dmm ] (11.tmm]
C =
MOUNT DIN
RAIL HERE~
I
6.50·
B B 0.25"
[6.4mm]
DETAI! NAil 1 (EOR TYpE I) DETAI! HA" - 2
6.25"
[15B.8m m)---I
(FOR TYpE 38 12. t. 4)
*
*CAPTURE GROONDING STRAP AT LOVER LEFT COONER OF
[165.2mm )
CONTROL PANEL ·\lITH J.\Ol.ffi"It-t3 HARD\lARE ON MOUNTING STUD.
1__ =
I. CUTOUT DETAIL"A "-I IS FOR TYPE! ENa....OSURE.
su:;GESTE D HDI NT I NG
0.137
HOLE 'A'- - - OIA. FOR
st IGGfSrm Hot IN! I NG
C C 0.140 0.249
C C 2. CUTOUT DETAIL "A"-2 IS fOR TYPE 3R. TYPE 12 0-32 x 0.025 LONG PENN. ENGINEERING ~ HOLE 8- ~ OlA. FORO.250-20 x 1.50
AI-D TYPE 4 EN:LoSURE.
J
MFG. CO. SELF CLIN:HING CAPTIVE STUD NO. LONG PENN CAPTIVE STUD FH-0420- 24-ZI
FH-632-I O-ZI 0.163
HOLE c- 0.106 01A.. FOR 0.10.4-32 )( 0.313

LONG PENN CAPTIVE STUD FH-632-5 -ZI

FRONT VIEW

-NOTE I CONTROLS ARE NOT PROVIDED ON D940 w/ Ace. 96A. B

B

,__--CUS TOMER
SUPPUED

I
I I
I
_ _ _R
ILTRANSFE SWITCH
__ _ _, , _ ____ J
6.00· (152.4mm ] MIN DEPTH TO TRANSFER

,
SWITCH FOR CONTROLS
MOUHTED ON THE DOOR

A
A NTROL PANEL

TOP VIEW

7 6 5 4 3
8
.,
 (Mounting Direction)
SWITCHING POWER SUPPLY
idee INSTRUCTION SHEET
PS5R Series
IOE;C IZUM I QQRP 9RAT ION
e&fore o~ th~ switc~ Power sUPPly, Iiad 'tN~ ihstrUdion sheet'and keep'it
(or fu~ rcf~re!1:::e. Mounting A Mounting' B
Mciunting A " Sta-nda'rd Moutfting oil Venical Plane
1. Safety Slandard'Coh-iJilions Mounting B : Mounting on Horizonta l Plan'e
Applicable standard: UL SOa, CSA C2'2.2 No. 14. ~'N'60950 5. Terminal Marking and Description
Pbliution rlegte"c:
Lea~~f;e current:
2
0.75 rnA Max.
CD (L) tCflip(it Terminal
® (N) 'tr..C Input Tenninal"
@ (@) Grourid Tennin<tf tProtective Earthing TenninaD
2, Type No, Development
<:D (- V) DC OutPufThmiirra:i
8S5R ;c"DO ® (+ V) DC Output Ten'ninili
.. (i) (i)
® (V. A 0' J) Output Voltage Adjustme nl
Q) .: GUlpurpower ®:. Output Volt,age
(l) (D CON) Operation Indicator
Q ~,'15W 24: 2~V DC
F : t20W PSSR-QO
G : 210W
3,. Rating,
Use the switching power supply with the 'output capacity within
the
vafiJes,sl.lOwn below.
PSSR-OO
Inp,uI : 10Q-240V AC, lA:SO-60 Hz
Output , -
- .. PSSR-FO
Type QUlp'ul V6ltage Output Currenl' output Capa'cJty
V DO M<'\x.A Ma~.V'{:;
24 21.6-26.'1 3,1 ,:".,1.5
11111\
PS5A-FO
Inp,ul : 100-249V AC, 1.5A, SO-60H'z
dulPlJ't .r''--'-',,;~",'-'"r'--"'-'"·--'."'-'"-'-''+·:·f'--·''''''''c.-~,-"--'.'-"'-'''-'r--''~~~
~''''
;·Ol!lput:·Vo.!tag(L ~o.l!!p'\IpCur(!lnt 9U~Ptd ~.ap'a!=ily
",;,,-', ,V_DC Ma.:ts:.~ Ma~.W PSSR·GO
24 . 2t.6,-26.4 120..
PS'sR·dO
"
Input : 100-240V AC. 4A. 50-60Hz
Output
Type Output Vol1age Output Current Ompul Capacily
V DC Max.A Max.W
24 ,2h":'2~A ."1.0... 2~Q
.. 6. Pqwer Supply !nst~lIaljoll
" (D Make ,ore of co'QJectici"n'l~ tO~i(leratioa of'SuffiQ:ent heat radIation.
4. Output Derating
Do not bloclf(h~"opeiting '(ith~ swUching powel"s~ppli··
®Keep at least 30 mm clearance around tbe switching powet' supply
I
PS5R-IlO 'SSR-FO .GO elCccp.t foethc .op',esU~.~J .
@When the' derating is i~ q!:l~~tion P.rilvi9.c (O(t;,~~.;"ir~o.gJif.tg.
; <DUse m;~i'u.4p,l fjO·C-.~ife.~· ,:.~;;"i, . . . . 1," " .....
(D'j @Terminal '{otqU'e d.S' N " m.. .'"', . .-
®Use copper wire only.
}
...•.... ..........
>\" , .:'.
C1lWhe~ mounting the :switchiifi,(pi)w-erJ.sii"pplY: directfy: on.' a panel
surface. see the mounting. hole I~YQut',shown bel.ow!>, ~:
,~ PS5R·QO ;:f!~5R·.FO '

. "" . . ,l:":::fj::·i"
1 : ·,.\t

M~~f~~:<]'~'
.~~' II 111 til 3'0 ~o 50 60 70' ~Q II ';0' 20' 30 ~g- 5'0. ~ }o
. Ambient OperatingTem~rature (-C) Ambient Ope~tiri~Temp<:ntiU~ rc)
Q):M6unting A
,.@:M~\I.nting·a> ,I i ' I ' ,
-~.~--:-1 '
-:;.

--',L--l
LJ..L j l'DS!
Note~ In orderlo comply,.-witli..UL50B.·CSN~22.:2 Nt!"~'i4·• .a'Oa'
EN;60950}-' PSSRc(;,i;J.. ,
~e ambient operating temperat ure is as follows. MQ.bn~ng Role layout

T::::~~:tl
r--,---------.---:'-Am~:-:~,71.~.-:q~.,Q7·~~"~:.'''~-:'tln-.-J'-'e.,·~~~-",,-!u-,"'e-,""n
~"
"Type No, tJL, eSA'ZEN60~5b), ('C) .,,' i :0

PSSR·QO s{j~· '....: .. .... :.: '< " 'il-<'40" ..', .

PSSR:CO +--'--'-'-'-'~'-<lJ
\ I gO I
 ®Mounting on 35-mm-w'ide DIN Rail
(Mounting on' DIN RaiD
(I) Fast~n th~ DIN Rail to a pane! firmly.
(2) Nt the grooVe of th,e switching power suPPlY 'on the DIN Rail, with
the 'outPut" terminal ~ide up, press the sWitching power supply· to
the panel.
(3) Use BNLSP mou"nting dips on both the sides· of the switching
power supply to prevent from moving sideways_
(Remo~ng from DIN Rail)
Insert a flat screwdriver into the slot in the damp, Pull the damp out
until the damp dicks, and tUrn the switching power supply bottom out.
"Caution on DIN Rail Mounwur'
No other mounting directions than specified are·:illo·W'ed.
Also observe the specified mounting directions durifJg Transportation,
When PS5R series are mounted on the DIN rail in oUler directions
than specili~d, cla,mp$ may bteak or PS5R series may fall off the DIN
rail d~e-t6. sli9~Rs. :
@Adju"li'ting th~ ·Output Voltage
TIle output'vtlltage·-can be adjusted within ±IO% of the rated output
voltage u~ing the V.ADJeoutput voltage adjustment). Note that the
overvoltage protection may work when the output voltage is raised.
@Overcurrent Protection
When an overcurrent flows due to an overload. the output voltage
drops. When t~~,IQ~d is reduced to a normal·level, the normal output
voltage is·:r~srored, Note that an overload or short·circuit condition
continuink·fo~.'<!-r· extended period of time w'U! deteriorate or damage
internal; e.~tt~,·~~\s:
®OverVoltag~':P.rote'ction
) These rriod~l'~ ~s~ a manual reset method after power sl~utdown. To
recover Crom output voltage drop due to an overvoltage, tum off the
AC inpuC·and tum on the AC input after approximately 1 minute.
@Serie~. Qp~ration
T»'o PSSR .s:wit~h~ng power s(,!pplies can b~ connected'in series.
When to~g¢c'~lrl.g t~e switching pow~r ·~J.~pplies in. series, insert a
Schottky.9.!<idj! i~:·~he output line;Qftia:cn sWitching power supply.
@lnsulatio'l,·l\eslsti(r(ce and Dielectnc'~Strihgth Tests
When maki~k:tliese tests, conh~ct tl).~ AC input terminals together
and the output + and . terO}inals together. Rapid application and
il1t.erruption o( the test voltag;e '''fill ~geiie:rai~ a surge voltage. which
may damage the· switching power supply.
@ParaUel·Operation . ..' ,
Th~ PS5R switching power supp.4es can be .~'nr}!cte9 in parallel.
. Lt.. CAUTION
When using PSSR series for parallel oper'atlon;'olis~rve the following
precautions.
(1) When connecting two through. five units' in parallel. conned a
diode to the output of each unit Outputs of PS5R ~nits can not be
connected directly. (Fig.!)
(2)Adjust the output of each unit to the same voltage wittii~ a tolerance
of SOmV. . or foreign objects such as. pa'per clips oi screWS enter.. into. ihe
(3)Tum on inputs to all units at ·the same time:
(4) Use the sam.e wires for cono'ecting outputs of alllinits:
(S)W"hen cooneJ:tjng.dioQ!'!s to the output, rais~ the output voltage
to compensate for the voltage drop due to lhe diode fOlW<:Jrd
voltage (VF),
(6) Recommended diodes for outputs are listed below;
BYV54V-50', BYV54V-1OO, BYV54V-150, BYV54Y:200, BYV541V-
200 (Sf Microelectronics) When u.shig diodes, provide a proper
heat sink in consideratIon of diode heatin~,
L L +Y
-y
",.ru
N N
'- L +Y ~
- N -y >--
Fig.1
SAFETY PRECAUTIONS
· Read the following safety precautions t9. mi3k~ ~ure q'~·;,¢or."r~QA
operation before starting installation. wiring, and operation:'
• In th'iS instruction sheet. safety precautions ·are· categorized in
order of Importance to Warnin"9:~and ,C~!Jtion,
r-I.\-.--------" "·Warning ··n6tkes a~'e used to emphasize that
illWARNING irI)prope,~ operaW~n may ca\..!se ~.evere
personal" Injury or d~ath.
' & WARNING
• Do not use the switchin9 power supply on control eq~ip.!Jlf:!,l)ts in
aircrafts, trains. and atomic equipments where malfunction' of, the
switching po~er supply may cause severe pers6hal injury or
threaten human life, These switching power supplies are deSigned
·for use on general electronic equipment ~!Jc.h a$ off.lce .rqiip~ent,
communication equipment. instrumentatIon equipme-r'lt",' and
industrial control equipment The power' supply is a unit of Class
A. This me·ans. that they can be used in all estilbn$li)fHfflts 6the.r
than domestic and those directly connected to a Ipw ¥'pI~,age
power supply network which supplies building used for domestic
purposes.
, Make sure that the operating conditions satiSfy the values
described In the catal09. Comfirm the specification values before
designing the equipment to use the switching power" supply and
before supplying power, Contact IDEC if you have any·question.
• Do not modify or repair the switching power sUJ~p!y.
Modification or r~pairing of the switctling pow~r supply Qy' ll!:;e·rs
may cause' elect~i6al shocks. damag~; fire ha1:ards. 'a·h(f dther
heavy accidents.
• Do not install the switching power supply.where a·humah body
may come Into contact· while power is supplied'to the swit9hing
power supply. Oo.noftouch the sWitch'ing power supply during
operation'or ·immeqiatefy'-a·fter turning'off because. somE! parts a·re
heated and at a hi'gh voltage. causing burns or electrical shocks.
The standard swItching power supplies are designed for
installation in equipment.
• Do not connect the output terminals or output lead wire together.
Fire hazards or damage maY resuit..
• Include a protection in the equipment u~if"!g t.he switching p·ower
supply in C9r"1sider.atiol"J ..of.,malftlnctiQfl OT damage of the load in
case the switching 'pdWet supply should fall. If the switching
power sUP~IY should fail, 'a very :hlgh 'voltage or voltage drop may
occur at the output terminals.
· TUrn power off before wiring the switching poWer supply. Make
sure of correct wiring. Incorrect wiring may cause· electrical
shocks or damqge.
r\-I.\-.------,.\
4 GAUTION
'''Caution notices are used where inattention
might cause personal' injury or damage to
~9uipmEln~.
· Make surEi of-'the correct input voltage. Indorfect jnp~t volt~ge
may ca"Use blown fuses .. fuming. or fire h~zah:fs.· Make sure·:of
correct p.olarity of input' arid".' 0~4tput tenT\in~is' before suppIY!r!~
power t9 tlie.'s~itching PQwer'supply. ,,~ .
• 00 nof touch· any part hislde the sw!tc~ing po~er stJPply;
Prevent: foreign obiects ·:trorrf·ehtering into :the housing oJ'the
switching powe:r supplY_If thc'·internal parts are touched by hand;
houSing'; acCidents dr darr(age' may occur. .
, Observe 'the temperatUre derating. The operating rempe"fature is
the temperature around the switching power supply: ~s"e ~he
switchiilg power ~upply withil) the temperature derating"ctrr·ve.. .
Otherwise. the Internal temperature will rise and dami!g~Ymay:j~e
caused.
• Db not turn the output voltage adjustment beyond the limits.
Otherwise. the switching power supply. may be deteriorated and
damage may be caused.
• When. _d~,!ll~~.e or m~l.fun~tion ·~hOl.Jlq· oqcur duriJ19 gperstiol).
Immediately turn power off and stop the switching power
supply. Contact IDEC. .
• Do ·not use or store~jthe·, switchig power· supply In environments
subjected to .? larg~:a:mt)unt';Qf vibrations. or shocks. Otherwise,
damage may lj¢ caused. : ,;.';
• 00 not instalhti·e:swltching power .sUpply in"environm.ents exposed
to dir'eGt sunfight. Iron partlcl.ss. 011 splashes. c:h~m:k:als, and
hydr9gen sulfide, 00 not. use th~'swttching ppwer ~.up·~I~:·ro humlp
place's such as basements or greenhouses, ·or In low...,.temperature
in
places such ·as In freezers or front 'of cooler outlet.
8-616(1)
 © 1004.
BlackAllBoxrights reseNed.
Corporation.
BLACK BOX·
NETWORK 5 ERVICES
I Black Box Corporation' 1000 Park Drive' lawrence, PA 15055-1018 I Tech Support: 724-746-5500' www.blackbox.com • e-mail: info@blackbox.com
STANDARD MEDIA CONVERTER SWITCHES
Key features
~ Support VLAN tagging
.
Media Converter Switches from
Black Box are the versatile
and spanning tree way to extend your network.
passthrough. They're easy to use-literally
plug-and-play-and offer many
~ Suitable for office choices of fiber types, power
environments. types, and mounting options.
~ Provide one 100-Mbps It's a media converter and a
fiber port and two switch!
10-/100-Mbps UTP Media Converter Switches do
switch ports. more than just adapt from one
cable type to another. They're
~ RJ-45 ports support true Ethernet switches and
autonegotiation, so behave like switches within your
you can easily attach Ethernet network. This means you
any 10- or 100-Mbps can connect them together
indefinitely without worrying
device.
aboutinterrepeater links. Each
Media Converter Switch features
non-blocking switching archi-
tecture with a 2K MAC address
table. The 128K buffer memory
makes it easy to interconnect
IO-and 100-Mbps devices.
~ ___1~W~W~20~04~~#~1~OO~92~______________________________________________________________
Media Converter Switches
for the office environment.
Use them in your office;
extend them to the factoryfloor.
Standard Media Converter
Switches are for use in clean.
temperature-controlled environ-
ments such as offices and wiring
closets.
Media Converter Switches are
also available in hardened
versions for industrial environ~
ments and extreme versions for
outdoor environments. Because
all three types work together
seamlessly, you can use inexpen-
sive Standard Media Converter
Switches in the protection of the
wiring closet and choose the
more robust Hardened or Extreme
Media Converter Switches for
harsh locations at your network's
edge.
Distance isn't a problem.
Because they're switches as
well as media converters, Media
I
Converter Switches provide more
options in network topology,
overcoming the distance
limitations inherent with simple
media converters-to add extra
distance, just daisychain another
Media Converter Switch. If you
need more ports at your remote
location, just add a Convenient
Switch.
Multimode models support up
to 2 kilometers (1.2 miles) be-
tween Media Converter Switches.
For longer distances, choose
single-mode models for up to
20 kilometers 112.4 milesi.
The features you're looking for.
Media Converter Switches are
simple to set up and use-just
plug and go!
Both copper ports are auto-
sensing for speed and duplex,
adjusting to the connected device
automatically.
 Plus, the UTP ports feature
auto-MOl/MOl-X, eliminating the
need for crossover cables.
Media Converter Switches
each have two full sets of LED
indicators: one set on the front for
viewing convenience when the
Media Converter is DIN rail or
wallmounted, and one set
mounted in the end next to the
media ports for easyview'lng
when units are in a rackmount
tray.
The Media
Converter Switch
mounts on a DIN
rail with the
optional DIN Rail
Mounting Bracket.
Specifications
Distance (Maximum): Multimode
models: 2 km 11.2 mi.);
Single~mode SC models: 20 km
1124mi.)
Single·mode LC models: 15 km
19.3mi.)
MAG Addresses; 2K
Standards; IEEE B02.3,IEEE B02.3u,
IEEE B02.1p/q
~----------------------------------
115-VAG orZ40-VAG power.
Standard Media Converter
Switches come with 115~VAC
power supplies for use in the
United States or with 240-VAC
power supplies for overseas use.
The 240-VAG versions feature IEC
power connectors for use with
any lEG standard power cord,
making them adaptable to most
internat1onallocations.
Connectors:
lBH IOOA-ST, lBH IDOAE-ST:
(2) RJ-45,ll) pair of Sf';
lBHIDOA-SC,lBHIDOAE-SC,
lBHIOOA-SSG,lBHIDOAE-SSC.
lBHIDOA-SSGl,lBHIOOAE-SSCc
(2) RJ-45,11I pair'of SC;
lBHIOOA-MllBH100AE-MT:
(2) RJ-45,11I pair of MT-RJ;
lBH100A-SlG,lBH100AE-SlC:
(2) RJ-45,11) pair oflC
Mounting options galore.
Media Converter Switches fit
in where you need them. They
come with neat. removable
rubber feet so you can use them
as standalone units. Or you can
easily panelmountthem with the
included brackets and screws.
To use Standard Media
Converter Switches with DIN
rails, order the optional DIN Rail
Mounting Bracket This handy
bracket features springmounting,
Indicators; 114)lEDs: (2) Power,
(4)10/l00,16)lK/ACT,12)IDO
Temperature Tolerance:
Storage: -40 to +18Se F (~40 to
+85"C);
Operating: 32 to 104°F 10 to 40°C(
Humidity: 5to 95%, noncondensing
Allilude; -200 to 13,000 ft 1-60.9 to
3962.4 m)
Enclosure: Steel
enabling you to easily pop your
Media Converter Switches on and
off the DIN rail without using a
screwdriver or tightening set
screws, DIN-rail-ready Media
Converter Switches are also
available-for details, contact
Tech Support
For rackmounting in a central
location, choose the Rackmount
Tray or the Powered Rackmount
Tray, The powered tray provides
power for up to eight units,
power.1l5-VAG models: 115-VAG,
60-Hz external power supply;
240-VAC models: 240-VAC, 50-Hz
external power supply with
IEC power connector
Size; 3.5"H x 3'W x 1'0 18.9 x 7.6x
25cm)
Weight: Media Converter Switch:
0.3 lb. 10.1 kg);
Power Supply: 0.4 lb. 10.2 kg)
 Ordering Information
ITEM CODE
Standard Media Converter Switches, 10-/100-Mbps Copperto 100-Mbps Fiber
11S-VAC, Multimode, ST ..................................................................... LBH100A-ST
240-VAC, Multimode, ST .................................................................... LBH100AE-ST
11S-VAC, Multimode, SC ............•........................................................ LBH100A-SC
240-VAC, Multimode, SC .................................................................... LBH100AE-SC
11S-VAC, Multimode, MT-RJ ................................................................. LBH100A-MT
240-VAC, Multimode, MT-RJ ................................................................ LBH100AE-MT
11S-VAC, Single-Mode, SC ................................................................. LBH100A-SSC
240-VAC, Single-Mode, SC ................................................................ LBH100AE-SSC
11S-VAC, Single-Mode, Long-Distance, SC .................................................. LBH100A-SSCL
240-VAC, Single-Mode, Long-Distance, SC ................................................ LBH100AE-SSCL
115-VAC, Single-Mode, SLC ................................................................. LBH100A-SLC
240-VAC, Single-Mode, SLC................................................................ LBH100AE-SLC
Spare AC Power Supply for Standard Media Converter Switches, 11S-VAC ................... LBHl OOA-ll S-VAC
Spare AC Power Supply for Standard Media Converter Switches, 240-VAC ................. LBH100AE-240-VAC
DIN Rail Mounting Bracket. .................................................................. DIN-RAIL MC2
RackmountTray .............................................................................. LE1S0S-RACK
Powered RackmountTray ................................................................... LH150SP-RACK
 HARDtNtD MtDIA CONVtRTtR SWITCHtS
Key features edia Converter Switches are
~ Function as both a
media converter and
M the versatile way to extend
your network. They're easy to
a switch. use-literally plug-and-play-
and offer many choices of fiber
~ Suitable for dusty or types, power types, and mounting
dirty environments options.
with a temperature
range between -13 It's a media converter and a
and +140°F(-25to switch!
Media Converter Switches do
+60°C). more than just adapt from one
~ Provide one 100-Mbps cable type to another. They're
fiber port and two true Ethernet switches and
behave like switches within your
10-/100-Mbps UTP Ethernetnetwork. This means you
switch ports. can connect them together
~ RJ-45 ports support ind efin itely with out worrying
about interrepeater links. Each
autonegotiation, so
Media Converter Switch features
you can easily attach non-blocking switching archi-
any 10- or 100-Mbps tecture with a 2K MAC address
device. table. The 128K buffer memory
makes it easy to interconnect
10- and 100-Mbps devices.
Tough enough forthe factory
floor.
Hardened Media Converter
Switches are -for dusty or dirty
environments with temperatures
that range between -13 and
+140'F (-25 to +60°C). They use
the metal case as a heat sink so
no internal airflow is needed for
~----------------------------------
Media Converter Switches for
industrial environments.
cooling. The case is sealed to
resist environmental contam-
inants such as dust dirt, moisture,
smoke, and insects. They're an
ideal choice for demanding
industrial applications such as
factory floors.
Media Converter Switches are
also available in standard versions
for office or wiring closet environ-
ments and extreme versions for
outdoor environments. Because
aU three types work together
seamlessly, you can use
inexpensive Standard Media
Converter Switches in the
protection of the wiring closet and
choose the more robust Hardened
or Extreme Media Converter
Switches for harsh locations at
your network's edge.
Distance isn't a problem.
Because they're switches as
well as media converters, Media
Converter Switches provide more
options in network topology,
overcoming the distance limit-
ations inherent with simple media
converters-to add extra
distance, just daisychain another
Media Converter Switch. If you
need more ports at your remote
location, just add a Convenient
.' Switch.
Multimode models support up
to 2 kilometers (1.2 miles)
between Media Converter
Switches. For longer distances,
choose single-mode models for
up to 20 kilometers (12.4 miles) or
single-mode, long-distance
models for an incredible 40
kilometers (24.9 miles) between
links.
The features you're looldng for.
Media Converter Switches are
simple to set up and use-just
plug and gal
Both copper ports are auto-
sensing for speed and duplex,
adjusting to the connected device
automatically. Plus, the VTP ports
feature auto-MOl/MOl-X. elimin-
ating the need for crossover
cables.
Media Converter Switches
each have two full sets of LED
indicators: one set on the front for
viewing convenience when the
Media Converter is OIN rail or
wallmounted, and one set
mounted in the end nextto the
media ports for easy viewing
when units are in a rackmount
tray.
AC or DC power
Hardened Media Converter
Switches have the power options
to support harsh environments,
too. Models with AC power
supplies support 100-240-VAC
power. The power supplies with
recessed IEC power connectors
work with any IEC standard
power cord, making them adapt·
able to most international
locations.
Typical application.
Dtr=E~~~~---.J
Server
aa.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Specifications
Distance (Maximum): Multimode
models: 2km (1.2 mi.);
Single-mode SC models: 20 km
{12,4 mi.l;
Single-mode LC models: 15 km
193mi,);
Single-mode, long·distance SC
models: 40 km (24.9 mi.)
MAC Addresses; 2K
Standards; IEEE B02,3,IEEE B02,3u,
IEEE B02.1 p/q
Connectors: LBHlDOA-H-ST,
LBH lDOAE-H-ST, LBH 100A-H-ST-
12, LBHlDOA-H-ST-24, LBHIOOA-
HO-ST-24, LBH100A-H-ST-48:
12) RJ-45,11I pair 01 ST';
LBHlDOA-H-MT, LBHlDOAE-H-
MT, LBHlDOA-H-MT-12,
DC·powered units have
internal screw terminals for
connecting DC power in addition
to an AC power jack. Because
these models have dual power
connections, you can use them
simultaneously with both your DC
power supply and an AC power
adapter Isold separately) to
provide redundant power input
Distribution·Style Fiber
Optic
Media Converter
Switch t
Bulk Cable IEXN2002A)
Media Converter
Switch
ILBH100A-H-SSCL) ILBH100A-ST)
Single·Mode Duplex Fiber
Optic Cable
IEFN501O)
Media Converter
Switch
ILB H100A-ST)
Media Converter
Switch
ILBH100A-H-SSCL)
Connectors (continued):
LBHlDOA-H-MT-24,lBHlDOA-
HO-MT-24, LBH100A-H-MT-4B:
12) RJ-45,ll) pair 01 MT-RJ;
LBHlDOA-H-SC, LBH100AE-H-SC,
lBH100A-H-SC-12,lBH100A-H-
SC-24,lBH100A-HO-SC-24,
lBH100A-H-SC-4B,lBHlDOA-H-
SSC,lBH100AE-H-SSC,
lBH100A-H-SSC-12, LBH100A-H-
SSC-24, LBHlDOA-HO-SSC-14,
LBHlDOA-H-SSC-48, LBHlDOA-H-
SSCl, LBHlDOAE-H-SSCL,
LBHlDOA-H-SSCL-12, LBH100A-
H-SSCL-24, LBH100A-HO-SSCl-
14, LBHIOOA-H-SSCL-48:
12) RJ-45,ll) pair 01 SC;
LBH100A-H-SLC, LBHlDOAE-H-
SLC, LBH100A-H-SLC-12,
LBHlDOA-H-SLC-14, LBH100A-
HO-SLC-24, LBH100A-H-SLC-48:
12) RJ-45,ll) pair 01 LC
Mounting options galore.
Media Converter Switches fit
in where you need them. They
come with neat, removable
rubber feet so you can use them
as standalone units. Oryou can
easily panelmountthem with the
included brackets and screws.
For use with DIN rails, order
the optional DIN Rail Mounting
Bracket This handy bracket
features spring mounting, enabling
PLC ....
- PLC
Eth.ernet vid eo
--
sUlveiliance camera
Indicators: Ilj Power LED; Per port
LEOs: lO/lDO, luIVhall-duplex.
link/Act
Power: AC models:
100-140-VAC, 47-63-H,
external power supply;
12-VDC models: Internal terminal
block for 12·VDC power plus
jack for AC power supply (not
included);
24-VDC models: Internal terminal
block for 24NDC power plus
jack for AC power supply (not
included);
-48-VDC models: Internal
terminal block for ·48-VDC
power plus jack for AC power
supply (not included)
you to easily pop your Media
Converter Switches on and off the
DIN rail without using a screw·
driver or tightening set screws.
DIN·rail·ready Meola Converter
Switches are also available.
For rackmounting in a central
location, choose the Rackmount
Tray orthe Powered Rackmount
Tray. The powered tray provides
power for up to eight units.
PLC
Temperature Tolerance:
Storage: -40 to +185"F (-40 to
+B5°C);
Long·term operating: ·13 to
+140°F 1-25 to +60°C);
Short·term operating: -40 to
+185°F 1-40 to B5°C);
Cold start to _4°F I_20°C)
Humidity: 5 to 95%, noncondensing
Altitude; -200 to 13,000 1l1-60,9 to
3962.4 m)
Enclosure: Steel
Size; 3,5"H x3"Wx 1"0 18.9 x 7,6 x
2,5cm)
Weight: Media Converter Switches:
0,3Ib, 10.1 kg);
Power Supplies. 0,4Ib, 10,1kg)
 Ordering Information
ITEM COOE
Hardened Media Converter Switches, 10-/100-Mbps Copper to 100-Mbps Multimode Fiber
100--240-VAC, SC .......................................................................... LBH100A-H-SC
100--240-VAC, ST .......................................................................... LBH100A-H-ST
100--240-VAC, MT-RJ ..................................................................... LBH100A-H-MT
100--240-VAC with IEC, SC ................................................................ LBH100AE-H-SC
100--240-VAC with IEC, ST ................................................................ LBH100AE-H-ST
100--240-VAC with IEC, MT-RJ ............................................................ LBH100AE-H-MT
12-VDC, SC ............................................•............................... LBH100A-H-SC-12
12-VDC, ST ............................................................................ LBH100A-H-ST-12
12-VDC, MT-RJ ........................................................................ LBH100A-H-MT-12
24-VDC, SC ............................................................................ LBH100A-H-SC-24
24-VDC, SC, DIN Rail Mountable ....................................................... LBH100A-HD-SC-24
24-VDC, ST ............................................................................ LBH100A-H-ST-24
24-VDC, ST, DIN Rail Mountable ........................................................ LBH100A-HD-ST-24
24-VDC, MT-RJ .......................................................... ; ............. LBH100A-H-MT-24
24-VDC, MT-RJ, DIN Rail Mountable ................................................... LBH100A-HD-MT-24
48-VDC, SC ............................................................................ LBH100A-H-SC-48
48-VDC, ST ............................................................................ LBH100A-H-ST-48
48-VDC, MT-RJ ........................................................................ LBH100A-H-MT-48

Hardened Media Converter Switches, 10-/100-Mbps Copper to 100-Mbps Single-Mode Fiber

100--240-VAC, SC ........................................................................ LBH100A-H-SSC
100--240-VAC, LC ......................................................................... LBH100A-H-SLC
100--240-VAC with IEC, SC ............................................................... LBH100AE-H-SSC
100--240-VAC with IEC, LC ............................................................... LBH100AE-H-SLC
12-VDC, SC ........................................................................... LBH100A-H-SSC-12
12-VDC, LC ........................................................................... LBH100A-H-SLC-12
24-VDC, SC ........................................................................... LBH100A-H-SSC-24
24-VDC, SC, DIN Rail Mountable ...................................................... LBH100A-HD-SSC-24
24-VDC, LC ........................................................................... LBH100A-H-SLC-24
24-VDC, LC, DIN Rail Mountable ...................................................... LBH100A-HD-SLC-24
48-VDC, SC ........................................................................... LBH100A-H-SSC-48
48-VDC, LC ........................................................................... LBH100A-H-SLC-48
100--240-VAC, Long-Distance, SC ........................................................ LBH100A-H-SSCL
100--240-VAC with IEC, SC .............................................................. LBH100AE-H-SSCL
12-VDC, Long-Distance, SC ........................................................... LBH100A-H-SSCL-12
24-VDC, Long-Distance, SC, DIN Rail Mountable .............•........................ LBH100A-HD-SSCL-24
24-VDC, Long-Distance, SC ........................................................... LBH100A-H-SSCL-24
48-VDC, Long-Distance, SC ........................................................... LBH100A-H-SSCL-48
AC Power Supply for Hardened Media Converter Switches, 100--240-VAC, 47--63-Hz ............. LBH100A-H-PS
AC Power Supply for Hardened Media Converter Switches, 100--240-VAC,
47--63-Hz with IEC Connector ............................................................. LBH100AE-H-PS
DIN Rail Mounting Bracket. .................................................................. DIN-RAIL MC2
RackmountTray .............................................................................. LE1505-RACK
Powered RackmountTray ................................................................... LH1505P-RACK

~----------------------------------
 EXTREME MEDIA CONVERTER SWITCHES
Key features edia Converter Switches are
~ Suitable for harsh M the versatile way to extend
your network. They're easy to
outdoor environments.
use-literally plugvandvplay-
~ Provide one 100-Mhps and offer many choices of fiber
fiber port and two types, power types, and mounting
1O-/100-Mbps UTP options.
switch ports.
It's a media converter and a switch!
~ RJ-45 ports support Media Converter Switches do
autonegotiation, so more than just adapt from one
you can easily attach cable type to another. They're
true Ethernet switches and
any 10- or 100-Mbps behave like switches within your
device. Ethernet network. This means you
~ Available with many can connect them together
choices of AC and DC ind efinite Iy without worrying
about interrepeater links. Each
power supplies. Media Converter Switch features
non-blocking switching archi v
tecture with a 2K MAC address
table. The 128K buffer memory
makes it easy to interconnect
10- and 100·Mbps devices.
Tough enough for outdoor use.
Choose Extreme Media
Converter Switches for outdoor
use in exposed locations with
temperature ranges of-40to
t16JOF (·40 to t75'CJ-ali they
need in the way of protection is
shelter from direct rainfall. Like
our hardened models, Extreme
Media Converter Switches
feature a sealed case that uses its
Media Converter Switches
for harsh outdoor environments.
own metal shell as a heat sink.
Choose them for applications such
as traffic signal control or for
sensors or surveillance cameras
in outdoor plants. Extreme Media
Converter Switches are rated for
above~the-ceiling plenum
installation.
Media Converter Switches are
also available in standard versions
for office or wiring closet environ-
ments and hardened versions for
demanding indoor environments
such as factory floors. Because
all three types work together
seamlessly. you can use inexpen-
sive Standard Media Converter
Switches in the protection of the
wiring closet and choose the
more robust Hardened or Extreme
Media Converter Switches for
harsh locations at your network's
edge.
Distance isn't a problem.
Because they're switches as
well as media converters, Media
Converter Switches provide more
options in network topology, over~
coming the distance limitations
inherent with simplemedia
converters -to add extra distance,
justdaisychain another Media
Converter Switch. If you need
more ports at your remote loca~
tion, just add a Convenient Switch.
Multimode models support up
to 2 kilometers (1.2 miles)
between Media Converter
Switches. For longer distances,
choose singlevmode models for
up to 20 kilometers (12.4 miles) or
singlevmode, long-distance
models for an incredible 40 kilo-
meters (24.9 miles) between links.
The features you're looking for.
Media Converter Switches are
simple to setup and use-just
plug and go!
Both copper ports are auto-
sensing for speed and duplex,
adjusting to the connected device
automatically. Plus, the UTP ports
feature auto-MOl/MOl-X. elimiv
nating the need for crossover
cables.
Media Converter Switches
each have two full sets of LED
indicators: one set on the front for
viewing convenience when the
Media Converter is DIN rail or
wallmounted, and one set
mounted in the end next to the
media ports for easy viewing
when units are in a rackmount
tray.
AC or DC power.
Extreme Media Converter
Switches have the power options
to support harsh environments,
too, Modelswith AC power
supplies support 1OD-240-VAC
power. The power supplies with
recessed IEC power connectors
work with any lEG standard
power cord, making them adapt~
able to most internationalloca~
tions.
DC~powered units have
internal screw terminals for
connecting DC power in addition
Specifications
Dis~ance (Maximum): Multimode
models: 2 km (1,.2 mi,);
Single~mode SC models: 20 km
(12A mi.J;
Single~mode LC models: 15 km
19.3mL);
Single~mode, lang.-distance SC
models: 40 km 124.9 mi.)
MAC Addresses: 2K
Siandards: IEEE BOl3,IEEE B01.3u,
IEEE B02.1 p/q
Connectors: lBHIOOA-P-ST,
lBH 100AE-P-ST,lBHIOOA-PO-
SC,lBHIOOA-P-ST-12,lBH100A-
P-ST-24,lBH100A-PO-ST-24,
lBHIOOA-P-ST-4B:
11) RJ-45, II) pair of ST';
~----------------------------------~.
to an AC power jack, Because
these models have dual power
connections, you can use them
simultaneous[ywith both your DC
power supply and an AC power
adapter (sold separately) to
provide redundant power input.
Mounting options galore.
Media Converter Switches fit
in where you need them. They
Connectors (continued):
lBHIOOA-P-MT,lBHIOOAE-P-
MT,lBHIOOA-P-MT-12,
lBHIOOA'P-MT-24,lBH100A-PO-
MT-24,lBHIOOA-P-MT-4B:
11) RJ-4S,11) pair of MT-RJ:
lBHIOOA-P-SC,lBHIOOAE-P-SC,
lBHIOOA-P-SC-12,lBHIOOA-P-
SC-24,lBH100A-PO-SC-24,
lBHIOOA-P-SC-4B,lBHlOOA-P-
SSC,lBHIOOAE-P-SSC,
lBHIOOA-P-SSC-12,lBHIOOA-P-
SSC-14,lBH100A-PO-SSC-24,
lBHIOOA-pcSSC-4B,lBH100A-P-
SSCl,lBH100AE-P-SSC~
lBHIOOA-P-SSCl-24,lBH100A-
PO-SSCl-14,lBH100A-P-SSCl-
4B: 12) RJ-45,(1) pair of SC;
come with nea~ removable
rubber feet so you can use them
as standalone units. Or you can
easily panelmountthem with the
included brackets and screws.
For use with DIN rails, order
the optional DIN Rail Mounting
Bracket This handy bracket
features spring mounting, enabling
you to easily pop your Media
Connectors (continued):
lBHIOOA-P-SlC,lBHIOOA-P-
SlC,lBHIOOAE-P-SlC,lBHIOOA-
P-SlC-12,lBHIOOA-P-SlC-24,
lBH100A-PO-SlC-24,lBH100A-
P-SlC-4B:
12) RJ-45,(1) pair of lC
Temperature Tolerance:
Storage: ~40 to +185°F (~40 to
tB5'C);
Long~term operating: -40 to
tl67'F 1-40t0+7S'C);
ShorHerm operating: ~58 to
t112'F I-50 to tl0Il"C);
Cold startto -40'F 1-40'C)
Humidity: 5 to 95%, non condensing
Altitude: -200 to 13,000 It 1-60.9 to
3962.4 m)
Enclosure: Steel
Converter Switches on and off the
DIN rail without using a screw~
driver or tightening setscrews.
DIN~rail~ready Media Converter
Switches are also available.
For rackmounting in a central
location, choose the Rackmount
Tray or the Powered Rackmount
Tray. The powered tray provides
power for up to eight units.
Power: AC models: 100-240-VAC,
47-63·Hz external power
supply:
12-VDC models: Internal terminal
block for 12~VDC power plus
jack for AC power supply
(not included);
24-VDC models: Internal terminal
block for24·VDC power plus
jack for AC power supply
(not included);
~48-VDC models: Internal
terminal block for ~48-VDC
power plus jack for AC power
supply (not included)
Size: 3.5'H x3'Wx I'D IB.9 x 7.6 x
2.5 em)
Weight: Media Converter Switches:
0.3 lb. 10.1 kg);
Power Supplies: O.S lb. 10.1 kg)
 Ordering Information
ITEM CODE
Extreme Media Converter Switches, 10-/100-Mbps Copper to 100-Mbps Multimode Fiber
100-240-VAC, SC .......................................................................... LBH100A-P-SC
100-240-VAC, SC, DIN Rail Mountable ..................................................... LBH100A-PD-SC
100-240-VAC, ST .......................................................................... LBH100A-P-ST
100-240-VAC, MT-RJ ..................................................................... LBH100A-P-MT
100-240-VAC with IEC, SC ................................................................ LBH100AE-P-SC
100-240-VAC with IEC, ST ................................................................ LBH100AE-P-ST
100-240-VAC with IEC, MT-RJ ............................................................ LBH100AE-P-MT
12-VDC, SC ............................................................................ LBH100A-P-SC-12
12-VDC, ST............................................................................. LBH100A-P-ST-12
12-VDC, MT-RJ ........................................................................ LBH100A-P-MT-12
24-VDC, SC ............................................................................ LBH100A-P-SC-24
24-VDC, SC, DIN Rail Mountable ....................................................... LBH100A-PD-SC-24
24-VDC, ST.. ........................................................................... LBH100A-P-ST-24
24-VDC, ST, DIN Rail Mountable ........................................................ LBH100A-PD-ST-24
24-VDC, MT-RJ ........................................................................ LBH100A-P-MT-24
24-VDC, MT-RJ, DIN Rail Mountable ................................................... LBH100A-PD-MT-24
48-VDC, SC ............................................................................ LBH100A-P-SC-48
48-VDC, ST............................................................................. LBH100A-P-ST-48
48-VDC, MT-RJ ........................................................................ LBH100A-P-MT-48
Extreme Media Converter Switches, 10-/100-Mbps Copper to 100-Mbps Single-Mode Fiber
100-240-VAC, SC ........................................................................ LBH100A-P-SSC
100-240-VAC, LC ......................................................................... LBH100A-P-SLC
100-240-VAC with IEC, SC ............................................................... LBH100AE-P-SSC
100-240-VAC with IEC, LC ........................................... , ................... LBH100AE-P-SLC
12-VDC, SC ........................................................................... LBH100A-P-SSC-12
12-VDC, LC ........................................................................... LBH100A-P-SLC-12
24-VDC, SC ........................................................................... LBH100A-P-SSC-24
24-VDC, SC, DIN Rail Mountable ...................................................... LBH100A-PD-SSC-24
24-VDC, LC ........................................................................... LBH100A-P-SLC-24
24-VDC, LC, DIN Rail Mountable ...................................................... LBH100A-PD-SLC-24
48-VDC, SC ........................................................................... LBH100A-P-SSC-48
48-VDC, LC ........................................................................... LBH100A-P-SLC-48
100-240-VAC, Long-Distance, SC ........................................................ LBH100A-P-SSCL
100-240-VAC with IEC, SC .............................................................. LBH100AE-P-SSCL
12-VDC, Long-Distance, SC ........................................................... LBH100A-P-SSCL-12
24-VDC, Long-Distance, SC, DIN Rail Mountable ...............•.•.................... LBH100A-PD-SSCL-24
24-VDC, Long-Distance, SC ........................................................... LBH100A-P-SSCL-24
48-VDC, Long-Distance, SC ........................................................... LBH100A-P-SSCL-48
AC Power Supply for Hardened Media Converter Switches, 100-240-VAC, 47--B3 Hz .............. LBH100A-P-PS
AC Power Supply for Hardened Media Converter Switches, 100-240-VAC, 47--B3 Hz
with IEC Connector ...................................................................... LBH100AE-P-PS
DIN Rail Mounting Bracket. .................................................................. DIN-RAIL MC2
RackmountTray .............................................................................. LE1505-RACK
Powered RackmountTray ................................................................... LH1505P-RACK

~----------------------------------
 CONVrNlrNT SWITCHrS
Quickly add Ethernet ports anywhere in your
network-even in harsh outdoor environments.
Key features Convenient Switches are
~ Use this handy four- versatile, autosensing, four-
port switch to quickly port switches that enable you to
add additional ports quickly add ports anyvvhere on
your Ethernet network. They're
anywhere in your designed as a part of our Media
network. Converter Switch family and are
... Models available to available in the same chassis
choices to fit environments
stand up to environ-
ranging from comfortable offices
ments ranging from the to demanding outdoor install-
friendly wiring closet ations. You can also choose from
to harsh outdoor a wide range of power supplies
applications. and mounting options.
Although Convenient
~ Provide four 10-/ Switches were designed to match
TOO-Mbps UTP switch our Media Converter Switches,
portS. you can also use them just like
any other 10-/1 OD-Mbps Ethernet
... All ports support switch to add ports anywhere on
autonegotiation, so your network or even to build a
you can easily attach small freestanding network.
any TO- or 100-Mbps
device. Adaptto nearly any environment
Convenient Switches come in
three versions to adaptto nearly
any environment Because all
three types work together
seamlesslywith each other and
also with our family of Media
Converter Switches, you can use
inexpensive switches in the
protection of the wiring closet and
choose the more robust Hardened
or Extreme Convenience
~--------------------------------------------
Switches for harsh locations at
your network's edge.
S.tandard-These are our
basic Convenient Switches for
use in clean, temperature-
controlled environments such as
offices and wiring closets. Even
though these models are
designed for use in controlled
environments, you'll find that they
feature the same heavyweight
metal case as our more robust
models.
Hardened-These Convenient
Switches are for dusty or dirty
environnients with temperatures
that range between -13 and
+140°F (-25 to +60°C). They use
the metal case as a heat sink so
no internal airflow is needed for
cooling. The case is sealed to
resist environmental contami-
nants such as dust. dirt.. moisture"
smoke, and insects. They're an
ideal choice for demanding
industrial applications such as
factory floors.
Extreme-Choose these
robust units for outdoor use in
exposed locations with temper-
ature ranges of -40 to +16JOF (-40
to +75°C}--all they need in the
way of protection is shelterfrom
direct rainfall. Like our hardened
models, Extreme Convenient
Switches feature a sealed case
that uses its own metal shell as a
heat sink. Choose them for appli-
cations such as traffic signal
control orfor sensors or
surveillance cameras in outdoor
plants. Extreme Convenient
Switches are rated for above-the-
ceiling plenum installation.
The features you're looldng for.
Convenient Switches are
literally plug-and-play.
All four UTP ports are
autosensing for speed and
duplex, adjusting to the
connected device automatically.
Plus, all ports feature auto-MOil
MOl-X, eliminating the need for
crossover cables.
Each switch features non-
blocking switching architecture
with a 2K MAC address table. The
12BK buffer memory makes it easy
to interconnect 10- and 100-Mbps
devices.
The switches each have two
full sets of LED indicators: one set
on the front for viewing conven-
ience when the switch is DIN rail
orwallmounted, and one set
mounted in the end next to the
media ports for easy viewing
when units are in a rackmount
tray.
AC and DC power.
like our Media Converter
Switches, Convenient Switches
have the power options to support
harsh environments. Standard
models are available with AC
power adapters only, in a choice
of 115 or 240 VAC. Hardened and
Extreme Convenient Switches
with AC power supplies feature
10Q-240-VAC power suppnes built
to the same tough standards.
The power supplies with
recessed IEC power connectors
Specifications
MAC Addresses: 2K
Siandards: IEEE 802.3. IEEE 802.3u.
IEEE 802.1p/q
Connectors: (4) RJ-45
Indicators: 12) Power. 181 10/100.
(8) LKiACT
Temperature Tolerance:
All models: Storage: -40 to +185°F
(-40 to +85"C):
Standard models: Operating:
32 to 104"F {Oto 40"CI;
Hardened models: Long-term
operating: ·13 to +140°F (-25 to
+60"C);
Short-term operating: -40 to
+185"F {-40 to +85"CI;
work with any IEC standard
power cord, making them
adaptable to most international
locations.
DC~powered Hardened and
Extreme units have internal screw
terminals for connecting DC
power in addition to an AC power
jack. Because these models have
dual power connections, you can
use them simultaneouslywith
both your DC power supply and
an AC power adapter (sold
separately) to provide redundant
power input
Temperature Tolerance
(continued):
Cold start to -4"F (-20"C):
Extreme models: Long-term
operating: -40 to +167°F
(-40 to +75"C);
Short-term operating: -58 to
+212"F {-50 to +100°CI;
Cold start to -40°F {-40°CI
Humiditv: 5 to 95%, non condensing
Altitude: -200 to 13.000 It {-60.9 to
3962.4 ml
Enclosure: Steel
Power: Standard 115-VAC models:
115-VAC, 60-Hz external
power supply;
Mounting options galore.
Convenient Switches fit in
where you need them. The
switches come with neat,
removable rubber feet so you can
use them as standalone units. Or
you can easily panelmount them
with the included brackets and
screws.
For use with OIN rails, order
the optional DIN Rail Mounting
Bracket This handy bracket
features spring mounting, enabling
you to easily pop your Convenient
Power (continued):
Standard 240·VAC models:
240-VAC, 50-Hz external
power supply with lEe power
connector;
Hardened and Extreme AC
models: 1OQ-240-VAC.47--63-Hz
external power supply;
12-VDC models: Internal
terminal block for 12~VDe
power plus jack for AC
power supply (not
included);
24-VDC models: Internal
terminal block for 24-VOC
power plus jack for AC
power supply (not
included);
Switches on and off the DIN rail
without using a screwdriver or
tightening set screws. DIN·rail~
ready Media Converter Switches
are also available-for details,
contact Tech Support
For rackmounting in a central
location, choose the Rackmount
Trayorthe Powered Rackmount
Tray. The powered tray provides
power for up to eight units.
Power (continued):
-48·VOe models: Internal
terminal block for ·48-VDC
power plus jack for AC
power supply (not included)
Size: 3.5'H x 3'W x 1"0 18.9 x 7.6 x
25cml
Weight: Switch: 0.3 lb. {0.1 kgl:
Standard and Hardened Power
Supplies: 0.4 lb. {0.2 kg);
Extreme Power Supplies: 0.5 lb.
{0.2kgl
 Ordering Information
ITEM CODE
Convenient Switches
Standard
115-VAC ..................................................................................... LBH101A
240-VAC .................................................................................... LBH101AE
Hardened
100-240-VAC . .............................................................................. LBH101A-H
100-240-VAC with IEC ..................................................................... LBH101AE-H
12-VOC ................................................................................. LBH101A-H-12
24-VDC with DIN Rail Mountable ........................................................ LBHl 01A-HD-24
24-VDC ................................................................................. LBH101A-H-24
48-VDC ................................................................................. LBH101A-H-48
Extreme
100-240-VAC ............................................................................... LBH101A-P
100-240-VACwith IEC ..................................................................... LBH101AE-P
12-VDC ................................................................................. LBH101A-P-12
24-VDC with DIN Rail Mountable ........................................................ LBH101A-PD-24
24-VDC ................................................................................. LBH101A-P-24
48-VDC ................. , ............................................................... LBH101A-P-48
AC Power Supplies for Convenient Switches
Standard
115-VAC ............................................................................. LBH100A-115VAC
240-VAC ............................................................................ LBH100AE-240VAC
Hardened
100-240-VAC, 47-ll3-Hz .................................................................. LBH 1OOA-H-PS
100-240-VAC, 47-ll3-Hz with IEC Connector .............................................. LBH100AE-H-PS
Extreme
100-240-VAC, 47-ll3-Hz .................................................................. LBH100A-P-PS
100-240-VAC, 47-ll3-Hz with IEC Connector .............................................. LBH100AE-P-PS
DIN Rail Mounting Bracket. .. ""'"'''''''''''''''''''''''''' ............................... DIN-RAIL MC2
Rackmount Tray.................................................................................... LE1505-RACK
Powered RackmountTray ......................................................................... LH1505P-RACK
 SIEMENS
For replacement parts information or an application guide, visit
our website at WWVI/.sea.siemens.com or contact your local
Siemens sales office. .

Instructions 52-HPA2C

August. 2003 Oill1ght Push-Pull Operator

Supersedes Issue of Momentary & Maintained .
February. 2002 Class 52
Cat. No. 52PA2. 52PA3. 52PX2. 52PX3

Notes for BlackMax 4X devices:

" The trim ring is not needed Of supplied.
as indicated, thes~
operators suitable for use in Type .. Only use the index locking ring when using
1. 3, 3R. 4.12. or la"E!IiClC1Stlres~~·""· ....8 metal.l)amepr~~..oj:tcard. when· not ushig.
a nameplate or when using a plastic name plate.
Black Mal. (52PX) suitable for Type .. Use the locknut wrench, 52MAWB.
4X enc10S(es.

AWARNING

·~II
Hazardous voltage.
Can cause death. serious personal
injury, or property damage.

W To avoid electrical shock,. turn off

electrical power to controls before
perlorming installation maintenance.

1.:210
LEGEND PLATE
LockNut

Typeial spacing shown.

J Automotive legend requires 211z~ spacing.

Some. lIccessories also require addmonal spacing. Push-Pull

Large
81
Automotive
Head

3WIRE CONTROL POSITION

TO INSTALL Momentary Operator
1. Be sure the set screw is loosened. Shaft must be in the p~11
L1 l2
position.
2. Remove Push-Pull head. (Pull) ,------ - Push to Push to
---,I
3. Remove locknut, locking ring and trim ring. I Stop Start
4.'" Mount unit in p~nel as shown. I LU~-7I~
5. Reassemble head, and secure with set screw. I • I
., Trim ring not used on black 4X devices. I ..... .... . I
I
CONTACT OP.ERATION '----- --- -'
Maintained Push-Pull
Normally Open Contacts - use 52BAK contact block.
Holding
Normally Closed Contacts - use 52BAJ contact block. Interlock
Momentary Push-Pull (Factory assembled)
Normally Open Contacts - use 52BAJ contact block.
(Becomes Normally Open when assembled.)
Normally Closed Contacts - use Special 52BAU cont$ct
block which must be mounted last.
)
(For Engineering Reference Only ~ Rev. G)

Siemens Energy & Automation. Inc. 3333 Old Milton Parkway Alphar I a. GA 30005
 ~ :,
"
I
!

SIEMI;NS
Accessory
Contact Block Kit
Type: (1) NC
For: Class 51 & 52
Contact Rating: NEMA A600/P600
,/

CONTAINS
1 Contact Block Assembly
Red Actuator/Actuador Rojo

See back for mounting of contact block

11111/1 -.~
7 09325 6

Series H
52BAJ
Siemens Energy & Automation, Inc. Alpharetta, GA U.S.A.
Made in Mexico
" ~
'\
 ' ..,'

Ncrmanv, I' '\ ,Normally

Closed Open
'Terminals n K A ;;:-'II]n Terminals

.~ \
~TabS
' Lf\.WARNING

~I
rlaza:~ous vollage.,
Can cause death. serious i
personal injury, or property
damr;ge.
Disconnect power'before
workinq on this .CClulQmcnt. I
MOUNTING CONTACT BLOCKS
The contact blocks can be attached before or after installing the
operator. Mounting the contaCt blocks first avoids the problem
o"f limited, access in an enclosure. From 1 to 4 contact blocks
can be used with the 3-peshien spring return eperator: arranged
not to exceed two. levels. All other operaters can accept up to
eight contact blocks each; arranged not to exceed four levels.
Check' the enclo$ure depth fer adequate space and maintaiTi~'-
1.12 inch mh1imum Clearance through air, between unj'nsulated
live parts !such as contact block terminals a'nd enclosure.
To mount a contact block to another contact block, align, the
two tabs of the top contact block whh the two recessed pockets
of the 'contact block below. Thread the two--:mounting screws
'into the heads of the mounting screws below.SeriesF. contact
blocks can be mounted to any series contact block. However,
prior series contact blocks cannot be mounted to Series F
contact blocks.
See the above figures tor terminal identification.
.., 'c::-~
-'
 a)
Temperature Controls
Notice d'utilisation
'A;Pe'~B!~:~.prl'l?a,ny
b) '. tAOf.fM~N"
Manual para regulador mecfmico de temperatur'3 2100 Hoffman Way
Anoka, MN 55$P3:~17:4~ I,l~A
(763) 4;1:.1-2240, F.~j- (793) 422-217B
Custollll:lr_,$.er:vrc~: (76;3)'42~~2211
W'mI.hoffmanonline.com
c)

d)

safely and protection against

tHrough proper installation~
The technical specifications (voltage and current) as stated' b(l the
. product must not be. exceeded! .
L'lnslallalion du ~~g~!ateur de lemp6rature ne doH Nre. realisee que par !-In
personnel quaUeie' dans Ie r~spect des reglements locaux'~n vigue-ur ,~ncetnal1f
I'Jllmentalion electrlquc.
Le montage dolt garaniir Ie n:lspei:\ ,~e.s normes de securih~ et 1a proteCtion &mtre
les contacts accide;ltels: . ,,':- .
les caractllristiques techniques, (Ien;;!qn el co,urant) indiqulles sur la p!aqu~
sJgnaltiUque dolilent litre Impllralivemenl respecM,es I
La hstalad6n del regulaqo~ de temperatura ~~ realizani s,!1<!m!'!fl1e por p·e.r.;}~ri~1
calificado, balo el cumplirnlento de las directivas locales,de aliinentaci6n'de~c()rrl!:niai
Mediante el montaJe se deben asegurar las medidas de protecci6ri y fa proleccl6;;-7,;
contra contacto~ '. .
Las !ndicaciones 'Iecnicas (tensi6n y corriente) en la placa de caraclerlsticas no
deben ser superadas! .
ENGLISH

. Versions:
a) Nonnally closed contact (swItching contact opens al rising temperature)
b) Normally open contact (switching contact closes at risIng temperature)
c) Change-over contact (switching contact opens one and closes the other c9ntact at rising temperatures)
dl Combination (combinaUon of a) and b))

Applications: ..
The temperature controls are used to regulate healing equipment, cooling e(t'~ipnient, filter fans and heal exchangers. In addition, tflf~Y can also be
used as switching contacts for signa! devices used as low- or high lemperal~N alarms. '

Inslai!:Won guidelines:
The temperature controls are designed to measure the temperature in enclosures. When used In heating applications, they should be Installed In the
upper area of the enclosure as far away as possible from heaters or other heal-generating components. When used in cooling applications, they
should be instaUed at the bottom of the enclosure as far away as possible from the cooling device.

Clip-mounting onto 35 mm DIN rails according 10 EN50022 is standard.

The ventilation openings of the temperature' controrshould not be covered at any time.
Operating temperature range: ~20 °C to ao
°C (-4 OF to 176"F)

Important: as operating conditions vary widely, safe operation of the lemp.erature conlrol is to be checked in the final application,

Setting recommendations:
The hysteresis (switching difference) of the temperature control should be taken Into account:
a), b) and d): 7 K± 4 K (Kelvin) ,_
c): 4 K 1.5 K (Kelvin). Upon connection of the' RF heating resistor (thermal coupling), the hysteresis Is reduced to approx. 0.5 K

In ordcr to determine the actual set polnl of the nonnaUy closed contact and changEKlver contact (when used as normally closed contact), the
maximum rated hysteresis should be added to the required minimum operating temperature:

Example for a):

required minimum temperature in enclosure: 5"C (41°F)
HystereSiS of temperature control: + 11 K("'7K±4K)
Set point on adjuslment knob: 1S"C{61"F)

r----l r----l r---------l

a) I I b) I I d) I I
I <9 I I < I I §I l§jl
I I I I I I
I I I I I I
L_ _--1 L_ _--1 L _....J
2 2 --1 11 12 23 24
2 3 L N

L L u 12

N N NI N2
N --b---6-+-.I---
L----.4---

Rev. B 117383 © 2007 Hoffman Enclosures Inc. PIN 87920846 87920845

·.·.H. OLO-DQWN'SPRING &: FIT TIN GS (OPTIONAL)
.'.
. ·.~';tfO~. •
Mus t_ ~ _pa~
.'

wn •..,.
. '

iP.ri..gdo. iQ\O t com e inclu ded with ~cke.•• ·

.HPic ,.(j()W Ol?p ring calJbeu~d to secu re relay to sock et

. . . When Vibr'atiOflbecomes afacto
. . ." .,
r. .' ."

I· ;I~ {Ins ert fittings into slots, as show n in dia-

I .gram. With the lip facirm irisi(i ePar t of sock et 2. Plac e the
. ends of the hoid- down spring into the hole of each fitting :
....
Ho!'e:'Afor 8M, SY, SHS ocke tsarl d Hole -8 for SR sock ets. ,,,...

!.
I.
Hold-down Spring

ffit- - FittIng
Fitting
(.. ..
Oi-- A
1

l 8
II
I, .,
\ .

,.i'
1
,, Cau tion : 1. Once inser ted. fitting s cann ot be removed.
. 2. For SR2 P-06 sock et. inser t fitting s into the inner slots.
I
\

!
j.-
...

..'<
idee·
.'
IDE C COR POR ATI ON