Honeywell Stereo System RM7824A User Manual

7800 SERIES  
RM7824A Relay Module  
PRODUCT DATA  
First-out annunciation and system diagnostics are provided  
by a 2-row by 20-column Vacuum Fluorescent Display  
(VFD) located on the optional Keyboard Display Module.  
Five light emitting diodes (LEDs) for sequence  
information.  
Flame signal strength.  
Local or remote annunciation of RM7824A operation and  
fault information (optional).  
Nonvolatile memory; RM7824A retains history files and  
sequencing status after loss of power.  
Plug-in flame amplifier.  
Remote reset (optional).  
Report generation (optional).  
Shutter drive output.  
Burner controller data (optional):  
Hold status.  
Lockout/alarm status.  
Sequence status.  
Sequence time.  
Total cycles of operation.  
Total hours of operation.  
Fault history providing the six most recent faults:  
GENERAL  
The Honeywell RM7824A Relay Module is a 24 Vdc  
microprocessor-based integrated burner control for  
Cycles of operation at the time of the fault.  
Fault message and code.  
Hours of operation at the time of the fault.  
Sequence status at the time of the fault.  
Sequence time at the time of the fault.  
automatically fired gas, oil or combination fuel single burner  
applications. The RM7824A consists of the Relay Module,  
Subbase and Amplifier are required to complete the system.  
Options include Keyboard Display Module, Personal Computer  
Interface, DATA CONTROL BUS MODULE, Remote Display  
Module and COMBUSTION SYSTEM MANAGERSoftware.  
Diagnostic information:  
Device type.  
Flame amplifier type.  
Flame failure response time.  
Manufacturing code.  
The RM7824A is programmed to provide a level of safety,  
functional capability and features beyond the capacity of  
conventional controls.  
On/Off status of all digital inputs and outputs.  
Software revision and version of RM7824A and  
optional Keyboard Display Module.  
Status of configuration jumper.  
Functions provided by the RM7824A include automatic burner  
sequencing, flame supervision, system status indication,  
system or self-diagnostics and troubleshooting.  
Contents  
General ...............................................................................  
Features ..............................................................................  
Specifications ......................................................................  
Ordering Information ...........................................................  
Principal Technical Features ...............................................  
Safety Provisions ................................................................  
Installation ...........................................................................  
Wiring ..................................................................................  
Assembly.............................................................................  
Operation ............................................................................ 10  
Static Checkout ................................................................... 12  
Checkout ............................................................................. 13  
Troubleshooting ................................................................... 18  
1
1
2
2
5
5
6
7
9
FEATURES  
Safety features:  
Closed loop logic test.  
Dynamic input check.  
Dynamic safety relay check.  
Dynamic self-check logic.  
Expanded safe-start check.  
Internal hardware status monitoring.  
Tamper resistant timing and logic.  
Access for external electrical voltage checks.  
Application flexibility.  
Communications interface capability.  
Dependable, long-term operation provided by  
microcomputer technology.  
65-0155-1  
Copyright © 1995 Honeywell Inc.  
All Rights Reserved  
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7800 SERIES RM7824A RELAY MODULE  
Weight:  
RM7824A with Dust Cover: 1 pound, 12 ounces, unpacked.  
CAUTION  
To prevent the control from sequencing on power up,  
RM7824 Relay Modules with software revision 2424  
or less should not be used with R7848 Infrared  
Amplifiers and C7015 Infrared Flame Detectors,  
unless a ten-second delay is provided.  
IMPORTANT  
Flame Detection System available for use with  
RM7824A. To select your Plug-in Flame Signal  
Amplifier and applicable Flame Detector, see Table 2  
and Fig. 3.  
Table 2. Flame Detection Systems.  
Plug-in Flame Signal Amplifiers  
Applicable Flame Detectors  
Flame Failure  
Type  
Color  
Self-Checking  
Model  
R7824Ca  
Response Time  
Fuel  
Gas, oil, coal Ultraviolet  
(Purple Peeper)  
Gas, oil, coal Infrared  
(Lead Sulfide)  
Gas, oil, coal Infrared  
(Lead Sulfide)  
Type  
Models  
Rectification Green Dynamic  
Self-Check  
3 sec  
3 sec  
3 sec  
C7024E,F  
Infrared  
Red  
No  
R7848A  
R7848B  
C7015.  
C7015.  
Dynamic  
AMPLI-CHECK®  
a Circuitry tests all electronic components in the flame detection system (amplifier and detector) 12 times a minute during burner  
operation and shuts down the burner if the detection system fails.  
Table 3. Sequence Timing For Normal Operation.  
Device  
Initiate  
Standby  
Pilot Flame Establishing Period  
Run  
RM7824A  
10 sec  
*
4 or 10 sec  
*
* STANDBY and RUN can be an infinite time period.  
Approval Bodies:  
Mounting:  
Underwriters Laboratories Inc. Component Recognized:  
File no. MP268, guide no. MCCZ.  
Q7800A for panel mount or Q7800B for wall or burner mount.  
Canadian Standards Association certified: LR9S329-3.  
Federal Communications Commission: Part 15,  
Class B-Emissions.  
Required Components:  
Plug-in Flame Signal Amplifier; see Fig. 2.  
Q7800A or Q7800B.  
BURNER CONTROL  
5
1
(127)  
5-1/4 (133)  
5 (127)  
REMOVE ONLY FOR TERMINAL TEST ACCESS.  
1
M5872  
Fig. 1. Mounting dimensions of RM7824A Relay Module and Q7800A Subbase in in. (mm).  
3
65-0155—1  
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7800 SERIES RM7824A RELAY MODULE  
BURNER CONTROL  
5
(127)  
1
6-3/32 (155)  
5 (127)  
REMOVE ONLY FOR TERMINAL TEST ACCESS.  
1
M5873  
Fig. 2. Mounting dimensions of RM7824A Relay Module and Q7800B Subbase in in. (mm).  
Dust Cover is part number 221729A.  
3/4–14 NPT  
MOUNTING FLANGE  
7-7/32 (183)  
Accessories:  
Optional:  
COMBUSTION SYSTEM MANAGER™: Part  
number ZM7850A1001.  
Communication Interface Base Unit: Part  
number Q7700A1014.  
5-1/8  
(130)  
3-3/4  
(95)  
Communication Interface ControlBus Module: Part  
number QS7800A1001.  
3-7/16  
(87)  
ControlBus 5-Wire Electrical Connector: Part  
number 203541.  
DATA CONTROLBUS MODULE™: Part  
number S7810A1009.  
1/2–14 NPSM  
LEADWIRES  
5-1/4 (133)  
FACEPLATE  
Flush Mounting Kit for S7800 Keyboard Display Module:  
Part number 205321B.  
C7024E  
Keyboard Display Module (S7800A): English, Spanish,  
French, German, Italian.  
NEMA 4 and NEMA 1 Weatherproofing Kit for S7800  
Keyboard Display Module: Part number 204718A,B.  
Remote Display Mounting Bracket: Part  
number 203765.  
Remote Reset Module: Part number S7820A1007.  
Sixty-inch Extension Cable Assembly: Part  
number 221818A.  
1–11-1/2 NPT  
FACEPLATE  
PIPE  
UNION  
1(25)  
8
(203)  
DIA.  
5
(127)  
2-1/16  
(52)  
1/2–14 NPT  
2
(51)  
1-1/2  
(38)  
CELL MOUNT  
HEAT BLOCK  
LEADWIRES  
2(51)  
5/16–18 UNC–2B BY  
7/16 [11] DEEP  
1-5/8 (41)  
3 (76)  
9 (229)  
2-3/4  
(70)  
MOUNTING HOLES (2)  
1-1/16 (27)  
C7024F  
Fig. 4. Rectification detectors in in. (mm).  
M5818  
1-1/4  
(32)  
1-1/4  
(32)  
2 LEADS IN A  
48 INCH (1.2 METER)  
FLEXIBLE CONDUIT  
APERTURE  
3/4-14  
NPSM  
3/4-14 NPSM  
INTERNAL  
THREADS  
M1982A  
BUSHING WITH  
MAGNIFYING LENS  
COLLAR, 3/4-14 NPSM  
INTERNAL THREADS  
Fig. 3. Infrared detector dimensions in in. (mm).  
65-0155—1  
4
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7800 SERIES RM7824A RELAY MODULE  
Dynamic Input Check  
PRINCIPAL TECHNICAL FEATURES  
All system input circuits are examined to assure that the  
RM7824A is capable of recognizing the true status of external  
controls, limits and interlocks. If any input fails this test, a  
safety shutdown occurs and the fault will be annunciated.  
The RM7824A provides all customary flame safeguard  
functions while providing significant advancements in the  
areas of safety, annunciation and system diagnostics.  
Dynamic Safety Relay Test  
Safety Shutdown (Lockout) Occurs If:  
Checks the ability of the dynamic safety relay contact to open  
and close. Verifies that the safety critical loads, terminals 8, 9  
and 10, can be de-energized, as required, by the Dynamic  
Self-check logic.  
1. INITIATE PERIOD.  
a. 24 Vdc power errors occurred, see Operation  
section.  
b. Configuration jumper has been changed (after  
200 hours).  
c. Four minute INITIATE period has been exceeded.  
2. STANDBY PERIOD.  
Dynamic Self-Check Safety Circuit  
The microcomputer tests itself and related hardware, and at  
the same time, the safety relay system tests the  
microcomputer operation. If a microcomputer or safety relay  
failure occurs and does not allow proper execution of the self-  
check routine, safety shutdown occurs and all safety critical  
loads will be de-energized.  
a. Flame signal is present after 40 seconds.  
b. Ignition/intermittent pilot valve terminal is  
energized.  
c. Internal system fault occurred.  
d. Main valve terminal is energized.  
3. SAFE START CHECK.  
a. Flame signal is present.  
b. Ignition/intermittent pilot valve terminal is  
energized.  
Expanded Safe-Start Check  
The conventional safe-start check, which prevents burner  
start-up if flame is indicated at start-up, is expanded to  
include a flame signal check during STANDBY and a safety  
critical load check.  
c. Internal system fault occurred.  
d. Main valve terminal is energized.  
4. PILOT FLAME ESTABLISHING PERIOD (PFEP).  
a. Ignition/intermittent pilot valve terminal is not  
energized.  
b. Internal system fault occurred.  
c. Main valve terminal is energized.  
d. No flame present at end of PFEP.  
5. RUN PERIOD.  
Off Cycle (Standby) Flame Signal Check  
The flame detection subsystem (flame detector and amplifier)  
is monitored during STANDBY. If a flame simulating condition  
or an actual flame exists for 40 seconds in STANDBY, a safety  
shutdown occurs and startup is prevented. If the flame signal  
exists at any time after the 40 seconds during STANDBY, a  
safety shutdown occurs and is annunciated. The self-checking  
detector is energized for the first 40 seconds during  
a. Ignition terminal is energized.  
b. Internal system fault occurred.  
c. Main valve terminal is not energized.  
d. No flame present.  
STANDBY and the last two seconds before exiting STANDBY.  
If a flame exists after the first 40 seconds during STANDBY,  
the self-checking detector is energized during the last ten  
seconds of the 40 second flame detection period. If a flame  
exists, a safety shutdown occurs.  
e. Pilot valve terminal is not energized.  
SAFETY PROVISIONS  
Safety and logic timings are inaccessible and cannot be  
altered or defeated.  
Internal Hardware Status Monitoring  
The RM7824A analyzes the integrity of the configuration  
jumper and internal hardware. The POWER LED will blink  
every four seconds, signifying an internal hardware check.  
Verified Spark Termination  
The ignition terminal is monitored to assure early spark  
termination (ten seconds ignition and pilot and ten seconds  
pilot and main only).  
Closed Loop Logic Test  
The test verifies the integrity of all safety critical loads,  
terminals 8, 9 and 10. If the loads are not energized properly;  
i.e., the main valve terminal is powered during STANDBY, the  
RM7824A will lockout on safety shutdown. The RM7824A  
must react to input changes but avoid the occurrence of  
nuisance shutdown events. Signal conditioning is applied to  
24 Vdc voltage inputs to verify proper operation in the  
presence of normal electrical line noise such as transient high  
voltage spikes or short periods of voltage dropout.  
First-Out Annunciation and Self-Diagnostics  
Sequence Status Lights (LEDs) provide positive visual  
indication of the program sequence: POWER, PILOT, FLAME,  
MAIN and ALARM. The green POWER LED blinks every four  
seconds, signifying that the RM7824A hardware is running  
correctly.  
Optional multi-function Keyboard Display Module shows  
elapsed time during PILOT IGNITION. As an additional  
troubleshooting aid, it provides sequence timing, diagnostic  
information and historical information during normal operation  
or when a safety shutdown or hold occurs.  
Dynamic Flame Amplifier and Shutter Check  
Self-checking circuitry tests all electronic components in the  
flame detection system and amplifier twelve times per minute  
and shuts down the RM7824A if the detection system fails.  
5
65-0155—1  
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7800 SERIES RM7824A RELAY MODULE  
First-out Annunciation reports the cause of a safety shutdown  
or identifies the cause of a failure to start or continue the  
burner control sequence with an English text and numbered  
code via the optional Keyboard Display Module. It monitors all  
field input circuits, including the flame signal amplifier. The  
system distinguishes 39 modes of failure and detects and  
annunciates difficult-to-find intermittent failures.  
7. All external timers must be listed or component  
recognized by authorities who have jurisdiction for the  
specific purpose for which they are used.  
IMPORTANT  
1. For on-off gas-fired systems, some authorities who  
have jurisdiction prohibit the wiring of any limit or  
operating contacts in series between the flame  
safeguard control and the main fuel valve(s).  
2. Two C7024E,F Detectors can be connected in  
parallel.  
Self-diagnostics add to the First-out Annunciation by allowing  
the RM7824A to distinguish between field (external device)  
and internal (system related) problems. Faults associated  
within the flame detection subsystem or RM7824A are  
isolated and reported by the optional Keyboard Display  
Module. See the 7800 SERIES System Annunciation  
Diagnostics and Troubleshooting, form 65-0118.  
3. This equipment generates, uses and can radiate  
radio frequency energy, and if not installed and  
used in accordance with the instructions, may  
cause interference to radio communications. It has  
been tested and found to comply with the limits for  
a Class B computing device of part 15 of FCC  
rules, which are designed to provide reasonable  
protection against such interference when  
operated in a commercial environment. Operation  
of this equipment in a residential area may cause  
interference, in which case the users, at their own  
expense, may be required to take whatever  
measures are required to correct this interference.  
4. This digital apparatus does not exceed the Class  
B limits for radio noise of digital apparatus set out  
in the Radio Interference Regulations of the  
Canadian Department of Communications.  
INSTALLATION  
WARNING  
FIRE OR EXPLOSION HAZARD CAN CAUSE  
PROPERTY DAMAGE, SEVERE INJURY, OR  
DEATH.  
To prevent possible hazardous burner operation,  
perform verification of safety requirements each time  
a control is installed on a burner.  
When Installing this Product...  
Humidity  
1. Read these instructions carefully. Failure to follow them  
could damage the product or cause a hazardous  
condition.  
Install the RM7824A where the relative humidity never  
reaches the saturation point. The RM7824A is designed to  
operate in a maximum 85 percent relative humidity,  
continuous, noncondensing moisture environment.  
Condensing moisture can cause a shutdown.  
2. Check the ratings given in the instructions and marked  
on the product to make sure the product is suitable for  
your application.  
3. Installer must be a trained, experienced, flame  
safeguard service technician.  
4. After installation is complete, check out the product  
operation as provided in these instructions.  
Vibration  
Do not install the RM7824A where it could be subjected to  
vibration in excess of 0.5G continuous maximum vibration.  
Weather  
CAUTION  
The RM7824A is not designed to be weather tight. If installed  
outdoors, the RM7824A must be protected by an approved  
weather-tight enclosure.  
To prevent electrical shock and equipment damage,  
disconnect the power supply before beginning  
installation. More than one power supply disconnect  
may be involved.  
Mounting Wiring Subbase  
1. To prevent electrical shock and equipment damage,  
disconnect the power supply before beginning  
installation. More than one power supply disconnect  
may be involved.  
2. Wiring connections for the RM7824A are unique;  
therefore, refer to Fig. 6 or the correct specifications for  
proper subbase wiring.  
3. Wiring must comply with all applicable codes,  
ordinances and regulations.  
4. Wiring, where required, must comply with NEC Class 1  
wiring.  
NOTE: For installation dimensions, see Fig. 1 or 2.  
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 in an electrical  
panel. The Q7800 can be mounted directly in the  
control cabinet. Be sure to allow adequate clearance for  
servicing, installation, access and removal of the  
RM7824A, dust cover, flame amplifier, flame amplifier  
signal voltage probes, electrical signal voltage probes  
and electrical field connections.  
5. Loads connected to the RM7824A must not exceed  
those listed on the RM7824A label or the specifications  
(see Table 1).  
6. Limits and interlocks must be rated to carry and break  
current simultaneously to the ignition transformer, pilot  
valve, and main fuel valve(s).  
3. For surface mounting, use the back of the subbase as a  
template to mark the four screw locations. Drill the pilot  
holes.  
4. Mount the subbase securely using four No. 6 screws.  
65-0155—1  
6
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7800 SERIES RM7824A RELAY MODULE  
WIRING  
1. a. For the internal block diagram of the RM7824A,  
see Fig. 5.  
b. The maximum number of wires per terminal is  
two. If more than two wires need to be connected  
to a terminal, wire one of the wires to the terminal  
and use a wire nut to connect the other wires  
inside the subbase.  
b. For proper subbase wiring, refer to Fig. 6.  
c. For proper remote wiring of the Keyboard Display  
Module; refer to the Specifications for the  
Keyboard Display Module (65-0090),  
5. Recommended wire routing for flame detector  
leadwires:  
Communication Interface Base Unit (63-2278),  
DATA CONTROLBUS MODULE™ (65-0091), or  
Extension Cable Assembly (65-0131).  
Do not run high voltage ignition transformer wires  
in the same conduit with the flame detection  
wiring.  
2. Disconnect the power supply from the main disconnect  
before beginning installation to prevent electrical shock  
and equipment damage. More than one disconnect may  
be involved.  
3. All wiring must comply with all appropriate electrical  
codes, ordinances and regulations. Wiring, where  
required, must comply with NEC Class 1 wiring.  
4. a. Recommended wire size and type: Use No. 14, 16,  
or 18 copper conductor (TTW60C or THW75C or  
THHN90C) 600 volt insulation wire for all low  
voltage terminals. For high temperature  
Do not route scanner wires in a conduit with line  
voltage circuits.  
Enclose scanner wires without armor cable in  
metal cable or conduit.  
Follow directions given in the flame detector  
instructions.  
6. Maximum wire lengths:  
a. For the RM7824A, the maximum length of  
leadwire to the control terminal input is 300 feet.  
b. For the flame detector leadwires, the maximum  
flame sensor leadwire length is limited by the  
flame signal strength.  
installations, use wire selected for a temperature  
rating above the maximum operating temperature.  
All leadwires must be moisture resistant.  
+
1
3
L2  
24 VDC  
TEST  
JACK  
CONFIGURATION  
JUMPERS  
FLAME SIGNAL  
F
G
PLUG-IN  
FLAME  
AMPLIFIER  
MICROCOMPUTER  
TEST  
RESET  
22  
PUSHBUTTON  
2K  
RELAY  
DRIVE  
CIRCUIT  
3K  
4K  
RELAY  
STATUS  
FEEDBACK  
AND LINE  
VOLTAGE  
INPUTS  
SAFETY RELAY  
CIRCUIT  
1K  
STATUS LEDs  
CONTROL  
POWER  
POWER SUPPLY  
LIMITS CONTROLLER  
1K1  
4K1  
2K1  
IGNITION  
6
10  
8
PILOT  
2K2  
9
4
MAIN VALVE  
3K1  
ALARM  
OPTIONAL KEYBOARD  
DISPLAY MODULE  
DDL  
INDICATES FEEDBACK SENSING  
TO RELAY STATUS FEEDBACK  
AND LINE VOLT INPUTS  
RS485  
1
2
DDL  
FIELD WIRING  
INTERNAL WIRING  
3
REMOTE  
RESET  
COMMUNICATIONS  
M5821  
1
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.  
Fig. 5. Internal block diagram of the RM7824A (see Fig. 6 for detailed wiring instructions).  
7
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7800 SERIES RM7824A RELAY MODULE  
7. Make sure loads do not exceed the terminal ratings.  
Refer to the label on the RM7824A or to the ratings in  
the specifications; see Table 1.  
8. Check the power supply circuit. The voltage tolerance  
must match those of the RM7824A. A separate power  
supply circuit may be required for the RM7824A with  
the required disconnect means and overload protection  
added.  
9. Check all wiring circuits and complete the Static  
Checkout section before installing the RM7824A on the  
subbase; see Table 5.  
10. Install all electrical connectors.  
11. Restore power to the panel.  
Q7800  
G
L2  
3
12  
13  
14  
15  
16  
24 VDC ALARM  
4
5
2
BURNER  
CONTROLLER/LIMITS  
6
17  
7
8
9
18  
19  
INTERMITTENT  
PILOT/IGNITION  
MAIN FUEL  
VALVE(S)  
20  
21  
22  
IGNITION  
10  
F
3
C7015 INFRARED  
(LEAD SULFIDE)  
DETECTOR  
WHITE  
BROWN  
YELLOW  
24 VDC  
1
+
OR  
MASTER  
SWITCH  
C7024E,F  
ULTRAVIOLET  
FLAME DETECTOR  
BLUE  
WHITE  
WHITE  
RED  
L2  
3
BLACK  
L2  
24 VDC POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.  
DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.  
1
2
FOR A CONTINUOUS OR STANDING PILOT, INSTALL AN EXTERNAL RELAY TO SWITCH THE F LEAD. THE  
RELAY MUST HAVE GOLD-CLAD OR GOLD-FLASH CONTACTS AND A 120 VAC COIL. POWER THE RELAY  
COIL FROM THE Q7800 SUBBASE TERMINAL 8. CONNECT THE RELAY CONTACTS BETWEEN THE F LEAD OF  
THE DETECTOR AND THE F TERMINAL OF THE Q7800 SUBBASE. A 24 VDC RELAY IS ACCEPTABLE TO  
USE IN THIS TYPE OF APPLICATION. USE THE N.O. PILOT DUTY CONTACTS.  
M5820A  
3
Fig. 6. Wiring the RM7824A.  
65-0155—1  
8
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7800 SERIES RM7824A RELAY MODULE  
ASSEMBLY  
Mounting RM7824A  
NOTE: For installation dimensions, see Fig. 1 or 2.  
Relay Module Mounting  
1. Mount the RM7824A vertically, see Figs. 7 or 8, or  
mount horizontally with the knife blade terminals  
pointing downward. When mounted on the Q7800A, the  
RM7824A must be in an electrical enclosure.  
2. Select the location in the electrical enclosure. Be sure to  
allow adequate clearance for servicing, installation and  
removal of the RM7824A, dust cover, flame amplifier,  
flame amplifier signal voltage probes, electrical signal  
voltage probes and electrical connections.  
a. Allow an additional two inches below the  
RM7824A for the flame amplifier mounting.  
b. Allow an optional three-inch minimum to both  
sides of the RM7824A for electrical signal voltage  
probes.  
Fig. 8. Wall or burner installation.  
3. Make sure no subbase wiring is projecting beyond the  
terminal blocks. Tuck in wiring against the back of the  
subbase so it does not interfere with the knife blade  
terminals or bifurcated contacts.  
Mounting Dust Cover  
1. Align the two interlocking ears of the Dust Cover with  
the two mating slots on the RM7824A (see Fig. 9).  
2. Insert the two interlocking ears into the two mating  
slots, and with a hinge action, push on the upper  
corners of the Dust Cover to secure it to the RM7824A.  
3. Be sure the Dust Cover is firmly in place.  
IMPORTANT  
The RM7824A must be installed with a plug-in  
motion rather than a hinge action.  
4. Mount the RM7824A by aligning the four L-shaped  
corner guides and knife blade terminals with the  
bifurcated contacts on the wiring subbase and securely  
tightening the two screws. Do not tighten the screws to  
the point where they deform the plastic of the RM7824A  
case.  
Fig. 9. Dust Cover mounting.  
Installing Plug-In Flame Signal Amplifier  
1. Disconnect the power supply before beginning  
installation to prevent electrical shock and equipment  
damage. More than one disconnect may be involved.  
2. Align the amplifier circuit board edge connector with the  
keyed receptacle on the RM7824A. Verify that the  
amplifier nameplate faces away from the Relay Module  
(see Fig. 10).  
3. Push in the amplifier until the circuit board is fully  
inserted into the receptacle and then push the amplifier  
toward the RM7824A retaining clasp.  
Fig. 7. Electrical panel installation.  
4. Verify the amplifier is firmly in place.  
5. Perform all required checkout tests.  
9
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7800 SERIES RM7824A RELAY MODULE  
INFRARED (C7015)  
WHITE  
F
BROWN  
G
SOLID STATE SELF-CHECKING  
ULTRAVIOLET (C7024E,F - E SHOWN)  
Fig. 10. Flame signal amplifier mounting.  
BLUE  
F
1
Installing Flame Detector  
YELLOW  
G
WHITE  
22  
NOTE: Table 2 and Fig. 11 list the flame detectors available  
for use with the RM7824A. Make sure the correct  
WHITE  
24Vdc (–)  
3
RED  
combination of amplifier and flame detector(s) is used.  
BLACK  
24Vdc (–)  
Proper flame detector installation is the basis of a safe and  
reliable flame safeguard installation. Refer to the instructions  
packed with the flame detector and the equipment  
manufacturer instructions.  
1
FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD  
MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW  
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING  
TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN  
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.  
M7594  
Keep the flame signal leadwires as short as possible from the  
flame detector to the wiring subbase. Capacitance increases  
with wire length, reducing the signal strength. The maximum  
permissible leadwire length depends on the type of flame  
detector, leadwire and conduit. The ultimate limiting factor in  
the flame detector leadwire is the flame signal (see Table 6).  
Fig. 11. Flame detector wiring.  
OPERATION  
Sequence of Operation  
The RM7824A has the following operation sequence (see Figs. 12 and 14).  
00  
00  
PFEP  
4 OR 10 SEC  
POWER  
PILOT  
10  
RUN  
2
SAFE-  
INITIATE  
POWER  
STANDBY  
POWER  
STANDBY  
START  
POWER  
POWER  
POWER  
LED  
PILOT  
FLAME  
MAIN  
DISPLAY  
FLAME  
MAIN  
ALARM  
ALARM  
10  
IGNITION  
BURNER  
START  
INTERMITTENT PILOT  
MAIN VALVE  
8
9
1
OPERATING  
CONTROLLER  
AND LIMITS  
+
6
LIMITS AND BURNER CONTROL CLOSED  
TO  
FLAME  
SIGNAL  
SAFE START CHECK  
FLAME PROVING  
S S C  
1
2
MAIN FUEL VALVE WILL BE ENERGIZED DURING PFEP IF FLAME IS PROVEN.  
RM7890A1031 PFEP IS FIXED 30 SECOND.  
M5135B  
Fig. 12. RM7824A sequence.  
65-0155—1  
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7800 SERIES RM7824A RELAY MODULE  
CAPTIVE  
MOUNTING  
SCREW  
Initiate  
The RM7824A enters the INITIATE sequence if the Relay  
Module verifies voltage fluctuations of outside 22 to 28 Vdc  
during any part of the operating sequence. The INITIATE  
sequence lasts for ten seconds unless the voltage tolerance  
is not met. When the tolerance is not met, a hold condition will  
be initiated and will be displayed on the optional Keyboard  
Display Module for at least five seconds. When the tolerance  
is met, the INITIATE sequence will restart. If the condition is  
not corrected and the hold condition exists for four minutes,  
the RM7824A will lock out. Causes for hold conditions in the  
INITIATE sequence are:  
DUST  
COVER  
RELAY  
MODULE  
FLAME  
AMPLIFIER  
Vdc dropout is detected.  
Internal timing functions are not synchronized.  
The noise that can prevent a sufficient reading of the low  
voltage inputs.  
RESET  
PUSH-  
BUTTON  
FLAME CURRENT  
TEST JACK  
FLAME  
SIMULATOR INPUT  
SEQUENCE  
STATUS LEDS  
M7593  
Brownouts caused by low input voltage.  
Fig. 13. Sequence status LEDs.  
STANDBY  
HOLD: F/G  
(FLAME  
SAFE-  
START  
CHECK  
RESET/  
ALARM  
TEST  
PILOT  
IGNITION  
DETECTED)  
INITIATE  
POWER  
STANDBY  
POWER  
RUN  
POWER  
PILOT  
POWER  
POWER  
POWER  
POWER  
PILOT  
FLAME  
MAIN  
PILOT  
PILOT  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
PILOT  
FLAME  
MAIN  
FLAME  
MAIN  
FLAME  
MAIN  
FLAME  
MAIN  
ALARM  
ALARM  
ALARM  
ALARM  
ALARM  
ALARM  
ALARM  
M3362  
Fig. 14. LED sequence status display information (see Fig. 13).  
Standby  
Selectable Site-Configurable Jumper  
The RM7824A is ready to start an operating sequence when  
the operating control input determines a call for heat is present.  
The burner switch, limits, operating limit control and all  
The RM7824A has one site-configurable jumper option, see  
Fig. 15 and Table 4. The site-configurable jumper should be  
clipped with side cutters and the resistor removed from the  
Relay Module.  
microcomputer monitored circuits must be in the correct state  
for the RM7824A to continue into the SAFE-START CHECK.  
SELECTABLE CONFIGURATION JUMPER  
Normal Start-Up Safe-Start Check  
The RM7824A verifies that a flame does not exist and  
proceeds into the ignition trial. If a flame is present, the  
RM7824A will recycle to the STANDBY period. If the critical  
loads are not in the correct state, a safety shutdown occurs.  
Ignition Trials  
Pilot Flame Establishing Period (PFEP):  
1. The pilot valve and ignition transformer, terminals 8 and  
10, are energized. The RM7824A has an intermittent  
pilot valve, terminal 8.  
2. Flame must be proven by the end of the 4 or 10 second  
PFEP to allow the sequence to continue. If flame is not  
proven by the end of PFEP, a safety shutdown occurs.  
3. With flame proven, the ignition, terminal 10, is de-  
energized and the main valve, terminal 9, is energized.  
M7592  
Fig. 15. Selectable site-configurable jumpers.  
Run  
The RM7824A is now in RUN and will remain in RUN until the  
controller input, terminal 6, opens, indicating that the demand  
is satisfied or a limit has opened.  
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65-0155—1  
7800 SERIES RM7824A RELAY MODULE  
Table 4. Site-Configurable Jumper Options.  
Jumper  
Equipment Recommended  
1. Voltmeter (20K ohm/volt minimum sensitivity) set on the  
0-30 Vdc scale.  
Number  
Description  
Intact  
Clipped  
2. Two jumper wires: No. 14 wire, insulated, 12 in. (305 mm)  
long, with insulated alligator clips at both ends.  
JR1  
Pilot Flame  
Establishing Period  
10 seconds 4 seconds  
General Instructions  
IMPORTANT  
1. Perform all applicable tests listed in Static Checkout,  
Table 5, in the order listed.  
After 200 hours of operation, the configuration  
jumper cannot be changed. If it is changed after  
200 hours of operation, the RM7824A locks out. The  
RM7824A cannot be reset and has to be replaced.  
2. MAKE SURE THAT ALL MANUAL FUEL SHUTOFF  
VALVE(S) ARE CLOSED.  
3. Perform only those tests designated for the specific  
RM7824A model being tested.  
4. Raise the set point of the operating controller to  
simulate a call for heat.  
SERVICE NOTE: Clipping and removing a site-configurable  
jumper enhances the level of safety.  
5. For each test, open the master switch and install the  
jumper wire(s) between the subbase wiring terminals  
listed in the Test Jumpers column of Table 5.  
6. Close the master switch before observing operation.  
7. Read the voltage between the subbase wiring terminals  
listed in the Voltmeter column of Table 5.  
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.  
STATIC CHECKOUT  
CAUTION  
1. Use extreme care while testing the system. Voltage  
is present on most terminal connections when  
power is on.  
2. Open the master switch before installing or  
removing a jumper on the subbase.  
3. Before continuing to the next test, be sure to  
remove the test jumper(s) used in the previous  
tests.  
4. Replace all limits and interlocks not operating  
properly. Do not bypass limits and interlocks.  
5. Close all manual fuel shutoff valve(s) before  
starting these tests.  
11. Obtain normal operation for each required test before  
continuing the checkout.  
12. After completing each test, be sure to remove the test  
jumper(s).  
Table 5. Static Checkout.  
RM7824A  
Models  
Test  
If Operation is Abnormal, Check  
the Item Listed Below  
Test No.  
Jumpers Voltmeter  
Normal Operation  
WARNING  
Make sure all manual fuel shutoff valves are closed.  
IMPORTANT  
Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static tests (if required).  
1
All  
None  
3-L2  
24 Vdc at terminal 3  
1. Master switch.  
2. Power connected to the master  
switch.  
3. Overload protection (fuse,  
circuit breaker) has not opened  
the power line.  
2
3
All  
All  
None  
3-10  
6-L2  
24 Vdc at terminal 6  
1. Limits.  
2. Burner controller.  
Ignition spark (if ignition  
transformer relay is  
1. Watch for spark or listen for  
buzz.  
connected to terminal 10).  
a. Ignition electrodes are clean.  
b. Ignition transformer is okay.  
(Continued)  
65-0155—1  
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7800 SERIES RM7824A RELAY MODULE  
Table 5. Static Checkout (Continued).  
RM7824A  
Models  
Test  
If Operation is Abnormal, Check  
the Item Listed Below  
Test No.  
Jumpers Voltmeter  
Normal Operation  
4
All  
3-8  
1. Ignition spark (if ignition  
transformer relay is  
1. Watch for spark or listen for  
buzz.  
connected to terminal 8).  
a. Ignition electrodes are clean.  
b. Ignition transformer is okay.  
2. Listen for click or feel head of  
valve for activation.  
2. Automatic pilot valve  
opens (if connected to  
terminal 8).  
a. Actuator if used.  
b. Pilot valve.  
NOTE: Refer to wiring  
diagram of system  
being tested.  
5
All  
3-9  
3-4  
Automatic fuel valve(s)  
opens.  
Same as test no. 4. If using direct  
spark ignition, check the first stage  
fuel valve(s) instead of the pilot  
valve.  
If using direct spark ignition,  
check the first stage fuel  
valve(s) instead of the pilot  
valve.  
6
All  
All  
Alarm (if used) turns on.  
1. Alarm.  
Final  
CAUTION  
After completing these tests, open the master switch and remove all test jumpers  
from the subbase terminals. Also remove bypass jumpers from the low fuel  
pressure limits (if used).  
CHECKOUT  
CAUTION  
WARNING  
If an RM7824A is replaced with a lower or higher  
functioning 7800 SERIES Relay Module, the burner  
will not sequence unless wiring changes are made.  
Do not allow fuel to accumulate in the combustion  
chamber. If fuel is allowed to enter the chamber for  
longer than a few seconds without igniting, an  
explosive mixture could result. It is recommended that  
you limit the trial for pilot to ten seconds, and limit the  
attempt to light the main burner to two seconds from  
the time the fuel has reached the burner nozzle. In  
any case, do not exceed the nominal lightoff time  
specified by the equipment manufacturer. Close the  
manual shutoff valve(s) if the flame is not burning at  
the end of the specified time.  
IMPORTANT  
1. If the system fails to perform properly, refer to  
7800 SERIES System Annunciation Diagnostics  
and Troubleshooting, form 65-0118.  
2. Repeat ALL required Checkout tests after all  
adjustments are made. ALL tests must be  
satisfied with the flame detector(s) in its FINAL  
position.  
CAUTION  
Equipment Required  
1. Use extreme care while testing the system. Voltage  
is present on most terminal connections when  
power is on.  
Volt-ohmmeter (20K ohm/volt minimum sensitivity):  
0-6000 ohm capability.  
0-30 Vdc capability.  
2. Open the master switch before removing or  
installing the RM7824A.  
3. Make sure all manual fuel shutoff valve(s) are  
closed before starting the initial lightoff check and  
the Pilot Turndown tests.  
4. Do not put the system in service until you have  
satisfactorily completed all applicable tests in this  
section and any others required by the equipment  
manufacturer.  
Checkout Summary  
Preliminary inspection—all installations.  
Flame signal measurement—all installations.  
Initial lightoff check for proved pilot—all installations using  
a pilot.  
Initial lightoff check for direct spark ignition of oil—all  
burners using DSI.  
Pilot turndown test—all installations using a pilot.  
13  
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65-0155—1  
7800 SERIES RM7824A RELAY MODULE  
Hot refractory hold-in test—all installations.  
Ignition spark pickup—all installations using Ultraviolet  
Flame Detectors.  
Response to other ultraviolet sources—all installations  
using Ultraviolet Flame Detectors.  
Flame signal with hot combustion chamber—all  
installations.  
Safety shutdown tests—all installations.  
2. Flame detector(s) is clean, installed and positioned  
properly. Consult the applicable instructions.  
3. Correct combination of amplifier and flame detector(s)  
is used. See Table 2 in the Specifications section.  
4. Plug-in amplifier is securely in place.  
5. Burner is completely installed and ready to fire; consult  
equipment manufacturer instructions. Fuel lines are  
purged of air.  
6. Combustion chamber and flues are clear of fuel and  
fuel vapor.  
7. Power is connected to the system disconnect switch  
(master switch).  
See Fig. 13 for location of component parts and see Fig. 6 or  
Q7800 Specifications for terminal locations.  
8. Lockout switch is reset (push in reset pushbutton) only  
if the RM7824A is powered. See Fig. 1 and 2.  
9. System is in the STANDBY condition. POWER LED is  
energized.  
Preliminary Inspection  
Perform the following inspections to avoid common problems.  
Make certain that:  
1. Wiring connections are correct and all terminal screws  
are tight.  
10. All limits and interlocks are reset.  
Table 6. Flame Signal (See Fig. 15).  
Minimum Acceptable  
Maximum Expected  
dc Voltage  
Flame Detector  
C7024E,F  
Flame Signal Amplifier  
R7824Cb  
Steady dc Voltagea  
1.25 Vdc  
5.0 Vdc at the Keyboard Display Module or  
5.0 Vdc at a 20K ohm/volt voltmeter.  
C7015A  
R7848A,Bc  
a This minimum or a stronger signal should be easily obtained if the detector is correctly installed and positioned to properly  
sense the flame. This voltage must be obtained before completing checkout.  
b The flame signal amplifier circuitry is tested one-half second every five seconds during burner operation and shuts down the  
burner if the amplifier fails (all installations).  
c The amplifier is an AMPLI-CHECK™ type.  
4. Allow a few seconds for the meter reading to stabilize.  
Flame Signal Measurement  
5. When using a shutter check amplifier, read the average  
Measure the flame signal at the appropriate times defined in  
stable voltage, disregarding the peaks and valleys  
the following checkout tests. Read the flame signal volts dc at  
caused by the self-checking program.  
the flame amplifier test jacks (+) and (-) (Com).  
6. The meter reading must be as specified in Table 6 after  
1. Use a 20K ohm per volt voltmeter with a 0 to 30 Vdc  
all tests are completed and all adjustments are made.  
capability.  
2. Set the voltmeter to the 0 to 10 Vdc range.  
3. Insert the positive (red) probe into the (+) jack of the  
As an option, the flame signal can be checked by using the  
optional Keyboard Display Module.  
flame amplifier and the negative (black) probe into the  
If the signal is unstable or less than the minimum acceptable  
( -) (Com) jack of the flame amplifier (see Fig. 16).  
voltage, check the flame detector installation and circuitry.  
1. Check the supply voltages at terminals 3 and L2 (N).  
Make sure the master switch is closed, connections are  
POSITIVE (+)  
correct and the power supply voltage is correct.  
2. Check the detector wiring for defects including:  
METER LEAD  
ONE  
MEGOHM/VOLT  
METER  
NEGATIVE (-)  
METER LEAD  
Deteriorated wire.  
Incorrect connections.  
Leakage paths caused by moisture, soot or  
accumulated dirt.  
Open circuits.  
Short circuits.  
Wrong wire type.  
3. For all optical detectors, clean the detector viewing  
window and inside the sight pipe as applicable.  
4. With the burner running, check the temperature at the  
detector. If it exceeds the detector maximum rated  
temperature:  
Add a heat block to stop conducted heat traveling  
up the sight pipe.  
M7382  
Add a shield or screen to reflect radiated heat.  
Add cooling (refer to sight pipe ventilation in the  
detector instructions).  
Fig. 16. Flame signal measurement.  
5. Make sure that the flame adjustment is not too lean.  
65-0155—1  
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7800 SERIES RM7824A RELAY MODULE  
6. Make sure that the detector is properly sighting the  
flame.  
7. If necessary, resight or reposition the detector.  
7. When the 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 RUN period is displayed by the MAIN LED,  
make sure the automatic main fuel valve is open; then  
smoothly open the manual main fuel shutoff valve(s)  
and watch for main burner flame ignition. When the  
main burner flame is established, proceed to step 16.  
10. If the main burner flame is not established within five  
seconds or the normal lightoff time specified by the  
equipment manufacturer, close the manual main fuel  
shutoff valve(s).  
Initial Lightoff Check for Proved Pilot.  
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 manual main fuel shutoff valve(s) is  
closed. Open the manual pilot shutoff valve. If the pilot  
takeoff is downstream from the manual main fuel  
shutoff valve(s), slightly open the manual main valve to  
supply pilot gas flow. Make sure the main fuel is shut off  
just upstream from the burner inlet, or disconnect power  
from the automatic main fuel valve(s).  
3. Close the master switch and start the system with a call  
for heat by raising the setpoint of the operating  
controller (see Fig. 12 or RM7824A sequence). The  
primary sequence should start the SAFE-START  
CHECK sequence.  
4. Let the sequence advance through STANDBY and  
SAFE-START CHECK. Ignition spark should occur and  
the pilot should light. If the pilot ignites, the FLAME LED  
will be energized. Proceed to step 7.  
5. If the pilot flame is not established in four or ten  
seconds, safety shutdown occurs. Let the sequence  
complete its cycle. Consult the equipment operating  
manual for further information.  
11. Recycle the system to recheck lightoff and pilot flame  
signal.  
12. Let the RM7824A recycle to the RUN period. Smoothly  
open the manual fuel shutoff valve(s) and try lightoff  
again. (The first 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 valve(s). Check all burner adjustments.  
14. If the main burner flame is not established after two  
attempts:  
a. Check for improper pilot size.  
b. Check for excess combustion air.  
c. Check for inadequate 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 10 through 14 to establish the main  
burner flame, then proceed to step 16.  
16. With the sequence in RUN, make burner adjustments  
for flame stability and Btu input rating.  
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  
RM7824A from the subbase.  
b. On the subbase, jumper terminal 3 to ignition  
terminal 8 or 10; refer to the appropriate subbase  
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 3 to the pilot terminal 8. 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.  
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 the  
burner. Make sure the automatic fuel valve(s) closes.  
18. Restart the system by closing the burner switch and/or  
raising the setpoint of the operating controller. Observe  
that the pilot is established during PILOT IGNITION and  
the main burner flame is established during RUN within  
the normal lightoff time.  
19. Measure the flame signal. Continue to check for the  
proper signal, see Table 6, through the RUN period.  
20. Run the burner through another sequence, observing  
the flame signal for:  
a. Pilot flame alone (unless using direct spark  
ignition).  
b. Pilot and main flame together.  
c. Main flame alone (unless monitoring an  
intermittent pilot).  
Also observe the time it takes to light the main flame. Ignition  
of the main flame should be smooth.  
21. Return the system to normal operation.  
22. Make sure all readings are in the required ranges  
before proceeding.  
i.  
If the pilot does not ignite and if the ignition spark  
is still continuous, adjust the pressure regulator  
until a pilot is established.  
j.  
When the pilot ignites properly and stays ignited,  
open the master switch and remove the jumper(s)  
from terminals 3 to 8 or 3 to 10 of the subbase.  
NOTE: Upon completing these tests, open the master  
switch and remove all test jumpers from the subbase  
terminals, limits/controls or switches.  
k. Check for adequate bleeding of the fuel line.  
l.  
Reinstall the RM7824A on the subbase and close  
the master switch.  
m. Return to step 4.  
15  
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65-0155—1  
7800 SERIES RM7824A RELAY MODULE  
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 valve(s)  
close.  
Initial Lightoff Check for Direct Spark  
Ignition  
This check applies for gas and oil burners that do not use a  
pilot and 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 pressure fuel limits, if used, could be open. If so,  
bypass them with jumpers during this check.  
19. Restart the system by closing the burner switch and/or  
raising the setpoint of the operating controller. Observe  
that the burner flame is established during PILOT  
IGNITION, within the normal lightoff time specified by  
the equipment manufacturer.  
20. Measure the flame signal. Continue to check for the  
proper signal, see Table 6, through the RUN period. Any  
pulsating or unsteady readings will require further  
attention.  
1. Open the master switch.  
2. Complete the normal 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) are 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 Fig. 11 or RM7824A sequencing. The  
primary sequence should start with the SAFE-START  
sequence.  
5. Let the sequence advance through STANDBY and  
SAFE-START CHECK to Ignition Trial. Ignition spark  
should occur. Listen for the click of the first stage fuel  
solenoid valve(s).  
21. Make sure all readings are within the required ranges  
before proceeding.  
NOTE: Upon 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.  
6. Let the program sequence complete its cycle.  
7. Open the manual fuel shutoff valve(s).  
8. Push the reset pushbutton and recycle the program  
sequence through STANDBY and SAFE-START  
CHECK.  
9. Watch for the FLAME LED to help determine when the  
first stage burner flame is established. If it is  
established, proceed to step 15.  
10. If the first stage burner flame is not established within  
four seconds, or within the normal lightoff time specified  
by the equipment manufacturer, close the manual fuel  
shutoff valve(s) and open the master switch.  
11. Check all burner adjustments.  
Pilot Turndown Test (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 will hold in the flame amplifier  
and energize the FLAME LED. Clean the flame detector(s) to  
make sure that it will detect the smallest acceptable pilot  
flame. When using Self-checking Amplifier and 20K ohm/volt  
voltmeter, the flame signal will fluctuate every time the  
amplifier does a self-check or a shutter check.  
12. Wait about three minutes. Close the master switch,  
open the manual fuel shutoff valve(s), and try again to  
light off the burner. The first attempt may have been  
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 normal lightoff 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 proceed to step 15.  
15. When the first stage burner flame is established, the  
sequence will advance to RUN. Make burner  
adjustments for flame stability and input rating. If a  
second stage is used, proceed to step 18.  
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 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 by raising the setpoint of the operating  
controller. The primary sequence should start and  
PILOT IGNITION should begin.  
6. After the sequence has entered the normal burner run  
period, very slowly turn the pilot gas pressure down,  
reading the manometer (or pressure gauge) as the  
pressure drops. Stop immediately when the FLAME  
LED goes out. Note the pressure at this point.  
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 make sure all  
automatic fuel valve(s) 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) has opened, check the  
lightoff as follows. Otherwise, proceed to step 19:  
a. Open the manual second stage fuel valve(s).  
NOTE: If there is not flame present for the selected  
Flame Failure Response Test (FFRT), the  
RM7824A will lock out.  
a. Push the reset pushbutton and allow the  
RM7824A to recycle to PILOT IGNITION.  
65-0155—1  
16  
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b. As the control attempts to relight the pilot,  
increase the pilot pressure immediately until the  
FLAME LED comes on, and then slowly turn it  
down to obtain a pressure reading just above the  
dropout point or until the flame signal increases  
to approximately 1.25 Vdc. This step must be  
completed within four or ten seconds, depending  
on the selected PFEP, or lockout will occur.  
c. Turn the pilot back down slightly but not enough  
to cause the FLAME LED to go out. (Keep the  
pilot gas pressure just above the reading noted in  
step 6 above.)  
Response to Other Ultraviolet Sources  
Under certain conditions, an ultraviolet detector will respond  
to other ultraviolet sources as if it is sensing a flame. These  
ultraviolet sources include artificial light, such as  
incandescent or fluorescent bulbs, mercury and sodium vapor  
lamps or daylight. To check for proper detector operation,  
check the Flame Failure Response Time (FFRT) and conduct  
Safety Shutdown tests under all operating conditions.  
Flame Signal with Hot Combustion  
Chambers (All Installations)  
After all initial start-up tests and burner adjustments are  
completed, operate the burner until the combustion chamber  
is at the maximum expected temperature. Observe the  
equipment manufacturer warm-up instructions. Recycle the  
burner under these hot conditions and measure the flame  
signal. Check the pilot alone for non-DSI applications or the  
main burner flame for DSI applications.  
NOTE: Step d requires two people to complete,  
one person to open the manual main  
fuel valve(s) and one to watch for  
ignition.  
d. With the sequence in the normal burner run mode,  
make sure that the automatic main fuel valve(s) is  
open. Smoothly open the manual main fuel shutoff  
valve(s) and watch for main burner lightoff.  
e. If the main flame is not established within five  
seconds or the normal lightoff period specified by  
the burner manufacturer, close the manual main  
fuel shutoff valve(s) and open the master switch.  
Then return to step 6.a. If the burner flame is  
established in the normal lightoff period, proceed  
to step 10.  
Check the FFRT of the Flame Amplifier. Lower the setpoint of  
the operating controller and observe the time it takes for the  
burner flame to go out. This should be within three seconds  
maximum.  
If the flame signal is too low or unsteady, check the flame  
detector temperature. Relocate the detector if the temperature  
is too high. If necessary, realign the sighting to obtain the  
proper signal and response time. Then if the response time  
continues to be too slow, replace the Plug-in Flame Signal  
Amplifier.  
7. Recycle the burner and let the sequence advance to  
the PILOT IGNITION period.  
8. Increase the pilot flame size by increasing its fuel flow  
until a smooth main flame is accomplished.  
9. Reposition the flame scanner sight tube or use orifices  
until the pilot flame signal voltage is approximately  
1.25 to 1.50 Vdc.  
10. When the main burner lights reliably with the pilot at  
turndown, disconnect the manometer (or pressure  
gauge) and turn the pilot gas flow up to that  
recommended by the equipment manufacturer.  
11. If used, remove the bypass jumpers from the subbase  
terminals, limits/control or switches.  
Safety Shutdown Tests (All Installations)  
Perform these tests at the end of Checkout section after all  
other tests have been completed. If used, the external alarm  
should turn on. Press the RM7824A reset pushbutton to  
restart the system.  
1. Detect flame 40 seconds after entry to STANDBY.  
a. Simulate a flame to cause the flame signal  
voltage level to be at least 1.25 Vdc for 30 sec-  
onds after the initial 40 second entry into  
STANDBY.  
b. Safety shutdown will occur.  
2. Failure to ignite pilot.  
12. Run the system through another cycle to check for  
normal operation.  
13. Return the system to normal operation.  
a. Close the pilot and main fuel manual shutoff  
valve(s).  
b. Depress the reset pushbutton.  
c. Start the system.  
d. Automatic pilot valve(s) should be energized but  
the pilot cannot ignite.  
Ultraviolet Sensor, Ignition Spark Response  
Test (All Ultraviolet Detectors)  
Test to be sure that the ignition spark is not actuating the  
FLAME LED:  
1. Close the pilot and main burner manual fuel shutoff  
valve(s).  
2. Start the burner and run through the PILOT IGNITION  
period. Ignition spark should occur, but the flame signal  
should not be more than 0.5 Vdc and the FLAME LED  
should not turn on.  
3. If the flame signal is higher than 0.5 Vdc and the  
FLAME LED does come on, consult the equipment  
Operating Manual and resight the detector further out  
from the spark, or away from possible reflection. If 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.  
e. Safety shutdown will occur.  
3. Loss of flame during RUN.  
a. Open the main fuel manual shutoff valve(s).The  
manual pilot shutoff valve(s) must also be opened.  
b. Depress the reset pushbutton.  
c. Start the system. Startup should be normal and  
the main burner should light normally.  
d. After the sequence is in the normal RUN period  
for at least ten seconds with the main burner  
firing, close the manual main and pilot fuel shutoff  
valve(s) to extinguish the main burner flame.  
e. The flame signal should drop below 1.25 Vdc within  
three seconds after the main flame goes out.  
f.  
Safety shutdown will occur.  
17  
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65-0155—1  
7800 SERIES RM7824A RELAY MODULE  
IMPORTANT  
The Expanded Annunciator Terminal Status is not available  
with the RM7824A. With this information, most problems can  
be diagnosed without extensive trial and error testing.  
Information available in the Diagnostic Information file  
includes: Device Type, Device Suffix, Software Revision,  
Manufacturing Code, Flame Amplifier Type, Flame Failure  
Response Time, Selectable Jumper Configuration Status and  
Terminal Status.  
1. If the RM7824A fails to shut down on any of these  
tests, take corrective action (refer to  
Troubleshooting, RM7824A diagnostics and  
return to the beginning of all Checkout tests).  
2. When all Checkout tests have been completed,  
reset all switches to original states.  
Diagnostic Information Index  
TROUBLESHOOTING  
The RM7824A with the optional Keyboard Display Module  
can monitor input/output terminals and can display the status  
of the terminal at the VFD (eg, Pilot Valve T9 ON<), see  
S7800A Keyboard Display Module Specifications. A complete  
terminal description and terminal number are provided. The  
display will show the actual status of the terminal. If voltage is  
detected at the terminal, ON is displayed; but if voltage is not  
present at the terminal, OFF is displayed.  
RM7824A System Diagnostics  
Troubleshooting control system equipment failures is easier  
with the RM7824A self-diagnostics and first-out annunciation.  
In addition to an isolated spst alarm relay (audible  
annunciation), the RM7824A provides visual annunciation by  
displaying the ALARM LED.  
Self-diagnostics of the RM7824A enable it to detect and  
annunciate both external and internal system problems.  
External faults such as flame failures and false flame signals  
are annunciated by a lockout of the RM7824A that energizes  
the ALARM LEDs by using the optional Keyboard Display  
Module or 7800 SERIES System Annunciation Diagnostics  
and Troubleshooting, form 65-0118.  
Historical Information  
The RM7824A has nonvolatile memory that allows the Relay  
Module to retain historical information for the six most recent  
lockouts. Each of the six lockout files retains the cycle when  
the fault occurred, the hour of operation when the fault  
occurred and the fault message and burner status when the  
fault occurred. The historical information can be viewed by the  
optional S7800A Keyboard Display Module.  
The RM7824A provides diagnostic information to aid the  
service mechanic to obtain information when troubleshooting  
the system; see Table 7 and Table 8.  
SERVICE NOTE: To check voltages, remove the access slot  
covers on the sides of the Q7800A,B.  
The optional Keyboard Display Module displays sequence  
status messages indicating: INITIATE, STANDBY, SAFE-  
START CHECK, PILOT IGN and RUN. The selectable  
messages also provide visual indication, current status and  
historical status of the equipment such as: Flame Signal, Total  
Cycles, Total Hours, Fault History and Diagnostic Information.  
CAUTION  
Reinstall access slot covers on the Q7800A,B  
Subbase after performing voltage checks.  
65-0155—1  
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7800 SERIES RM7824A RELAY MODULE  
Table 7. Sequence And Status Hold Information.  
NOTE: Normal sequences are in bold type, while abnormal sequences are in standard type.  
Sequence  
Information  
INITIATE  
The LED indicates the burner status, POWER, which is a stabilization period for  
the RM7824A to check for any fluctuations in dc voltage inputs or control input on  
power-up or during normal operation.  
If the RM7824A is in a HOLD status, the following conditions could exist:  
INITIATE HOLD (Vdc Frequency/noise)  
The LED indicates the burner status, POWER, and that the RM7824A is waiting  
for excess line noise to clear up. The burner sequence will not advance into  
STANDBY until the excess line noise, which prevents sufficient read of the voltage  
inputs, ceases.  
INITIATE HOLD (AC Line Dropout)  
INITIATE HOLD (AC Frequency)  
INITIATE HOLD (Low Line Voltage)  
STANDBY  
The led indicates the burner status, POWER, and that DC Bus power has  
momentarily dropped out. The burner sequence will not advance into STANDBY  
until the DC Bus voltage has stabilized throughout the INITIATE sequence.  
The LED indicates the burner status, POWER, and that the internal timing  
functions are out of synchronization. The burner sequence will not advance into  
STANDBY until the internal timing is synchronized.  
The LED indicates the burner status, POWER, and that low DC Bus voltage has  
occurred. The burner sequence will not advance into STANDBY until the DC Bus  
voltage is at a sufficient level for proper operating parameters.  
The LED indicates the burner status, POWER. The burner can be placed in  
STANDBY by opening the burner switch or if the operating controller indicates its  
setpoint has been satisfied. If a demand is present for burner operation, the burner  
sequence will not advance from STANDBY to SAFE START CHECK until the  
recycle limits close.  
If the RM7824A is in a HOLD status, the following conditions could exist:  
STANDBY HOLD: F/G (Flame Detected) The LEDs indicate the burner status, POWER and FLAME, and that a flame is  
detected. A demand is present for burner operation. The burner sequence will not  
advance to SAFE START CHECK because a flame is detected as being present.  
The sequence will not advance to SAFE START CHECK until the flame signal  
clears. If the flame signal does not clear within  
40 seconds, the RM7824A will lockout.  
SAFE START CHECK  
PILOT IGN  
The LED indicates the burner status, POWER, which is the period of time after  
STANDBY. The RM7824A is verifying that a flame is not present before the start  
of Ignition Trials. If a flame is present, the RM7824A will recycle to STANDBY.  
The LEDs indicate the burner status, POWER, PILOT and FLAME, which is the  
period of time the RM7824A permits the pilot valve and ignition to be energized  
and the pilot flame to be established.  
RUN  
The LEDs indicate the burner status, POWER, PILOT, FLAME and MAIN, which is  
the period of time after the Ignition Trials and before the operating controller  
setpoint is reached. During this time, the burner is firing under the control of the  
operating controller.  
RESET/ALARM TEST  
The LED indicates the burner status, POWER and ALARM. This condition  
indicates that the reset pushbutton is pressed. If it is held for more than four  
seconds, the alarm output is energized. The alarm output will be de-energized  
after the reset pushbutton is released.  
19  
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65-0155—1  
7800 SERIES RM7824A RELAY MODULE  
Table 8. Hold And Fault Message Summary.  
Fault Number  
Annunciation Message  
*Main Valve On*  
*Ignition On*  
Fault Number  
Annunciation Message  
*AC Frequen/Noise*  
*AC Line Dropout*  
*AC Frequency*  
*Low Line Voltage*  
*Flame Amplifier*  
*'Flame Amp/Shutr*  
*Flame Detected*  
*Main Flame Fail*  
*Main Flame Ign.*  
*Call Service*  
Fault 41  
Fault 2  
Fault 43  
Fault 3  
Fault 46  
*Flame Amp Type*  
*Jumpers Changed*  
*Flame Too Strong*  
*Call Service*  
Fault 4  
Fault 47  
Fault 5  
Fault 51  
Fault 7  
Fault 52-70  
Fault 71-75  
Fault 76-93  
Fault 94-108  
Fault 110-111  
Fault 118-119  
Fault 123  
Fault 8  
*Device Specific*  
*Accessory Fault*  
*Call Service*  
Fault 9  
Fault 17  
Fault 19  
Fault 24  
Fault 25  
Fault 28  
Fault 35-40  
*Call Service*  
*Call Service*  
*Call Service*  
*Call Service*  
*Pilot Flame Fail*  
*Call Service*  
Fault 125-127  
*Call Service*  
Home and Building Control  
Honeywell Inc.  
1985 Douglas Drive North  
Golden Valley, MN 55422  
Home and Building Control  
Honeywell Limited-Honeywell Limitée  
740 Ellesmere Road  
Scarborough, Ontario  
M1P 2V9  
Helping You Control Your World  
65-0155—1 Rev. 6-95 G.R. Printed in U.S.A.  
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