FULTON RM7895A User manual

PRODUCT DATA
32-00122-01
SIL3
Capable
RM7895A
Relay Module
APPLICATION
The RM7895A Relay Module is a microprocessor based
integrated burner control for automatically fired gas, oil or
combination fuel single burner applications. The
RM7895A consists of the Relay Module. Subbase,
Amplifier and Purge Card are required to complete the
system. Options include Keyboard Display Module (KDM),
Personal Computer Interface, Data ControlBus™* Module,
Remote Display Module, First-Out Expanded Annunciator
and Combustion System Manager™* Software.
The RM7895A is programmed to provide a level of safety,
functional capability and features beyond the capacity of
conventional controls.
Functions provided by the RM7895A include automatic
burner sequencing, flame supervision, system status
indication, system or self-diagnostics and
troubleshooting.
FEATURES
• Safety Features
— Closed loop logic test.
— Dynamic input check.
— Dynamic safety relay test.
— Dynamic self-check logic.
— Internal hardware status monitoring.
— Tamper resistant timing and logic.
• Access for external electrical voltage checks.
• Application Flexibility.
• Communication interface capability.
• Dependable, long-term operation provided by
microcomputer technology.
• First-out annunciation and system diagnostics
provided by an optional Keyboard Display Module.
• First-out expanded annunciation with 26 Light
Emitting Diodes (LEDs) for limit and interlocks
(optional).
• Five LEDs for sequence information.
• Interchangeable plug-in flame amplifiers.
• Local or remote annunciation of RM7895 operation
and fault information.
• Nonvolatile memory; RM7895 retains history files
and sequencing status after loss of power.
• Remote reset (optional).
• Report generation (optional).
• Selectable recycle or lockout on loss of airflow.
• Selectable recycle or lockout on loss of flame.
• Shutter drive output.
Contents
Application ............................................................................................ 1
Features .................................................................................................. 1
Specifications ...................................................................................... 2
Principal Technical Features ........................................................ 5
Safety Provisions ................................................................................ 5
Wiring ....................................................................................................... 8
Assembly ................................................................................................ 10
Operation ............................................................................................... 12
Checkout ................................................................................................ 16
Troubleshooting ................................................................................. 21

RM7895A RELAY MODULE
32-00122-01 2
• Burner controller data (optional):
— Expanded annunciator status.
— Flame signal strength.
— Hold status.
— Lockout/alarm status.
— Sequence status.
— Sequence time.
— Total cycles of operation.
— Total hours of operation.
— Fault history providing for the six most recent
faults:
• Cycles of operation at the time of the fault.
• Expanded annunciator data at the time of the
fault.
• Fault message and code.
• Hours of operation at the time of the fault.
• Sequence status at the time of the fault.
• Sequence time at the time of the fault.
— Diagnostic information:
• Device type.
• Flame amplifier type.
• Flame failure response time.
• Manufacturing code.
• On/Off status of all digital inputs and outputs.
• Selected prepurge time.
• Software revision and version of RM7895 and
optional Keyboard Display Module.
• Status of configuration jumpers.
SPECIFICATIONS
Model:
RM7895A Relay Module. Provides primary control.
Provides automatic burner sequencing, flame
supervision, system status indication, system or self-
diagnostics and troubleshooting. Intermittent pilot
valve operation.
Electrical Ratings (see Table 1):
Voltage and Frequency:
120 Vac (+10/-15%), 60 Hz (±10%).
Power Dissipation: 10W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing: Total Connected Load: 15A maximum, Type SC or
equivalent, fast blow.
Table 1. Terminal Ratings.
aThe RM7895 must have an earth ground providing a connection between the subbase and the control panel or
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 RM7895 needs a low impedance ground connection to the equipment frame, which, in
turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at rf frequencies, the
connection must be made with minimum length conductors that have maximum surface areas. Wide straps or brackets,
rather than leadwires, are preferred. Be careful to verify that mechanically tightened joints along the ground path, such
as pipe or conduit threads or surfaces held together with fasteners, are free of nonconductive coatings and are
protected against mating surface corrosion.
b2000 VA maximum connected load to RM7895 Assembly.
cCan also be 120 Vac, 1A pilot duty.
dCan also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to +140°F (-40°C to +60°C).
Storage: -40°F to +150°F (-40°C to +66°C).
Humidity: 85% rh continuous, noncondensing.
Vibration: 0.5G environment.
Dimensions: See Fig. 1.
Weight: RM7895 with dust cover: 1 pound, 15 ounces
(0.87 kg).
Terminal Number Description Ratings
G Flame Sensor Ground —
Earth G Earth Grounda—
L2(N) Line Voltage Common —
3 Alarm 120 Vac, 1A pilot duty.
4 Burner Motor 120 Vac, 9.8 AFL, 58.8 ALR (inrush).
5 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz (±10%)b,c.
6 Burner Control and Limits 120 Vac, 1mA.
7 Airflow Interlock 120 Vac, 9A.
8 Pilot Valve/Ignition 120 Vac, 4.5A ignition and 50 VA pilot dutyc.
9MainFuelValve
120 Vac, 2A pilot dutyd.
10 Ignition 120 Vac, 4.5A ignitionc.
(F)11 Flame Sensor 60 to 220 Vac, current limited.
12 to 21 Unused —
22 Shutter 120 Vac, 0.5A.

RM7895A RELAY MODULE
332-00122-01
IMPORTANT:
Flame Detection System available for use with
RM7895. To select your Plug-In Flame Signal
Amplifier and applicable Flame Detector, see Table
2 and Fig. 3 and 4.
Table 2. Flame Detection Systems (Fig. 3 and 4).
aOrder flame rod separately; see holder instructions.
bThe C7012A,C, C7027, C7035 and C7044 Flame Detectors should be used only on burners that cycle on-off at least
once every twenty-four hours. Appliances with burners that remain on continuously for twenty-four hours or longer
should use the C7012E,F Flame Detector with the R7847C Amplifier or the C7076A,D Flame Detector with the R7886A
Amplifier as the ultraviolet flame detection system.
Table 3. Sequence Timing for Normal Operation.
* STANDBY and RUN can be an infinite time period.
** PURGE will be determined by which ST7800A Purge Card is selected.
Approvals:
Underwriters Laboratories Inc. listed, File No. MP268,
guide No. MCCZ.
Factory Mutual approved, Report No. J.I.1V9A0.AF.
IRI acceptable.
Federal Communications Commission, Part 15,
Class B—Emissions.
SIL 3 Capable:
SIL 3 Capable in a properly designed Safety Instrumented
System. See form number 65-0312 for Certificate
Agreement.
Mounting: Q7800A for panel mount.
Required Components:
Plug-in Flame Signal Amplifier, see Table 2.
Plug-in Purge Timer Cards: selectable ST7800A: two sec-
onds to 30 minutes.
Q7800A Wiring Subbase.
Accessories:
203541 5-wire connector, required when Keyboard Dis-
play Module is used for remote reset; remote annuncia-
tion or report generation.
Optional:
Q7700A1014 Communication Interface Base Unit.
QS7800A1001 Communication Interface ControlBus
Module.
ZM7850A1001 Combustion System Manager™*.
203541 ControlBus 5-wire Electrical Connector.
S7810A1009 Data ControlBus™* Module.
221729A Dust Cover.
S7830A1015 Expanded Annunciator.
S7810M1003 ModBus Card.
Flame Simulators:
—203659 UV Flame Simulator.
—123514A Rectification Simulator.
S7800A1019 Keyboard Display Module.
203765 Remote Display Mounting Bracket.
203968A Remote Display Power Supply Plug-In.
S7820A1007 Remote Reset Module.
221818A Sixty-inch (1.52 meters) Extension Cable
Assembly.
221818C 120 inch (3.05 meters) Extension Cable
Assembly.
A7800A1002 Tester.
Plug-In Flame Signal Amplifiers Applicable Flame Detectors
Type Color
Self-
Checking Model
Flame
Failure
Response
Time Fuel Type Models
Rectificatio
n
Green No R7847A1041 3 sec. Gas Rectifying Flame
Rod Holdersa
C7004, C7007, C7011.
Complete Assemblies:
C7008, C7009, Q179.
Gas, oil,
coal
Ultraviolet (Purple
Peeper) C7012A,Cb.
Ultraviolet Purple R7849A1031 Gas, oil Ultraviolet
(Minipeeper) C7027, C7035, C7044b.
Device Initiate Standby Purge
Flame Establishing Period
Pilot Main
RM7895A 10 seconds * ** 4 or 10 seconds No

RM7895A RELAY MODULE
32-00122-01 4
*Registered Trademark of Honeywell International.
Fig. 1. Mounting dimensions of RM7895A Relay Module
and Q7800A Wiring Subbase in in. (mm).
Fig. 2. Rectification detectors.
POWER
BLOWER
FLAME
MAIN
ALARM
RESET
5
(127)
5 (127)]
M3529
5-1/4 (133)
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
BURNER CONTROL
R
MOUNTING FLANGE
1/2- 14 NPSM
LEADWIRES FACEPLATE
3/4-14 NPT
M1962B
3-3/4
(95)
7-7/32
(183)
5-1/8 (130)
3-7/16
(87)
5-1/4 (133)
C7012A,C,E,F
THREADED
MOUNTING
HOLES (2)
(10-32 UNF)
1 (25)
FLAME ROD
TARGET
CERAMIC
INSULATORS
IGNITION
ELECTRODE
(Q179C ONLY)
BRACKET
M1983A
3-1/8
(79)
1-21/32
(42)
1-13/32
(36)
3/8 (10)
1/2 (13)
1-1/16
(27)
25/32
(20)
25/32
(20)
2-25/32
(62)
3/32 (2) 11/16
(18)
17/32
(14)

RM7895A RELAY MODULE
532-00122-01
Fig. 3. Ultraviolet detectors.
PRINCIPAL TECHNICAL
FEATURES
The RM7895 provides all customary flame safeguard
functions while providing significant advancements in the
areas of safety, annunciation and system diagnostics.
Safety Shutdown (Lockout) Occurs
If:
1. INITIATE PERIOD
a. Purge card is not installed or is removed.
b. Purge card is bad.
c. Configuration jumpers have been changed after
200 hours of operation.
d. Ac line power errors occurred, see Operation.
e. Four minute INITIATE period has been exceeded.
2. STANDBY PERIOD
a. Flame signal is present after 40 seconds.
b. Ignition/pilot valve/intermittent pilot valve ter-
minal is energized.
c. Main valve terminal is energized.
d. Internal system fault occurred.
e. Purge card is not installed or is removed.
f. Purge card is bad.
3. PREPURGE PERIOD
a. Airflow lockout feature is enabled and the airflow
switch does not close after ten seconds or within
the specified purge card timing.
b. Flame signal is detected after 30 seconds.
c. Ignition/pilot valve/intermittent pilot valve ter-
minal is energized.
d. Main valve terminal is energized.
e. Internal system fault occurred.
f. Purge card is removed.\
g. Purge card is bad.
4. PILOT FLAME ESTABLISHING PERIOD (PFEP)
a. Airflow lockout feature is enabled and the airflow
switch opens.
b. Ignition/pilot valve terminal is not energized.
c. No flame present at end of PFEP.
d. Main valve terminal is energized.
e. Internal system fault occurred.
f. Purge card is removed.
g. Purge card is bad.
5. RUN PERIOD
a. No flame present.
b. Airflow lockout feature is enabled and the airflow
switch opens.
c. Main valve terminal is not energized.
d. Internal system fault occurred.
e. Purge card is remove.
f. Purge card is bad.
SAFETY PROVISIONS
Internal Hardware Status
Monitoring
The RM7895 checks the purge card for correct parity to
prevent purge timing shifts and circuitry failures. It also
analyzes the integrity of the configuration jumpers and
internal hardware. The POWER LED will blink every four
seconds, signifying an internal hardware check.
COLLAR WITH 1/2-14 NPSM
INTERNAL THREADS
4 (102) 8 FOOT (2.44 METER)
LEADWIRES (2)
M1943F
C7027A1064 HAS 24 FOOT (7.32 METER) LEADWIRES.
C7027A1114 HAS 44 IN. (1.118 M) LEADWIRES WITH
22 IN. (558 MM) FLEXIBLE CONDUIT.
1
2
2
3-1/2 (89)
1-1/16
(27)
1
MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL
THREADS) INSTEAD OF CLAMP TYPE CONNECTOR.
1/2-14 NPSM
INTERNAL THREADS
2
2 (51)
COLLAR WITH
1 - 1-1/2 NPSM
INTERNAL
THREADS 1
1DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL MOUNTING THREADS.
DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL MOUNTING THREADS.
C7035A1056 HAS 12 FOOT (3.66 METER) LEADWIRES.
2
3
INSERTION DEPTH
6 FOOT
[1.83 METER]
LEADWIRES (2) 3
M1945D
2-5/8 (67)
1-1/2
(38)
31/32
(25)
4-1/8 (105)
1-3/16
(30)
6 FOOT [1.83 METER]
LEADWIRES (2) MOUNTING BRACKET
3-5/8 (92)
1/2
(13) 1-27/64
(36)
3/8
(10)
7/8
(22)
9/16
(14)
M1944B

RM7895A RELAY MODULE
32-00122-01 6
Closed Loop Logic Test
The test verifies the integrity of all safety critical loads,
terminals 8, 9, 10 and 21. If the loads are not energized
properly; i.e., the main valve terminal is powered during
PREPURGE, the RM7895 will lock out on safety shutdown.
The RM7895 must react to input changes but avoid the
occurrence of nuisance shutdown events. Signal
conditioning is applied to line voltage inputs to verify
proper operation in the presence of normal electrical line
noise such as transient high voltage spikes or short
periods of line drop out. Signal conditioning is tolerant of
synchronous noise (line noise events that occur at the
same time during each line cycle).
Dynamic Input Check
All system input circuits are examined to assure that the
RM7895 is capable of recognizing the true status of
external controls, limits and interlocks. If any input fails
this test, a safety shutdown occurs and the fault will be
annunciated.
Dynamic Safety Relay Test
Checks the ability of the dynamic safety relay contact to
open and close. Verifies that the safety critical loads,
terminals 8, 9, 10 and 21, can be de-energized, as
required, by the Dynamic Self-Check logic.
Dynamic Self-Check Safety Circuit
The microcomputer tests itself and related hardware, and
at the same time, the safety relay system tests the
microcomputer operation. If a microcomputer or safety
relay failure occurs and does not allow proper execution of
the
self-check routine, safety shutdown occurs and all safety
critical loads will be de-energized.
Expanded Safe-Start Check
The conventional safe-start check, which prevents burner
startup of flame is indicated at startup, is expanded to
include a flame signal check during STANDBY, an airflow
switch check and a safety critical load check.
Off Cycle (Standby or Prepurge)
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, a system
hold occurs and startup is prevented. If the flame signal
exists at any time after the first 40 seconds of STANDBY, a
safety shutdown occurs and is annunciated. A shutter-
check amplifier and self-checking detector are energized
for the first 40 seconds during STANDBY and the last two
seconds before exiting STANDBY. If a flame exists, a safety
shutdown occurs. A standard amplifier is energized
continually through STANDBY and PREPURGE; if a flame
exists, a safety shutdown occurs.
Tamper Resistant Timing and Logic
Safety and logic timings are inaccessible and cannot be
altered or defeated.
Verified Spark Termination
The ignition terminal is monitored to assure early spark
termination (ten seconds ignition and pilot and ten
seconds pilot and main only).
First-Out Annunciation and Self-
Diagnostics
Sequence Status Lights (LEDs) provide positive visual
indication of the program sequence: POWER, PILOT,
FLAME, MAIN and ALARM. The green POWER LED blinks
every four seconds, signifying that the RM7895 hardware
is running correctly.
Optional multi-function Keyboard Display Module shows
elapsed time during PREPURGE, PILOT IGN and MAIN
IGN. As an additional troubleshooting aid, it provides
sequence timing, diagnostic information, historical
information and expanded annunciator information when
a safety shutdown or hold or normal operation occurs.
First-Out Annunciation reports the cause of a safety
shutdown or identifies the cause of a failure to start or
continue the burner control sequence with 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 43
modes of failure and detects and annunciates difficult-to-
find intermittent failures.
Self-Diagnostics add to the First-Out Annunciation by
allowing the RM7895 to distinguish between field
(external device) and internal (system related) problems.
Faults associated within the flame detection subsystem,
RM7895 or Plug-in Purge Card are isolated and reported
by the optional Keyboard Display Module. See the 7800
SERIES System Annunciation Diagnostics and
Troubleshooting, Form 65-0233.
Interlock Requirements
The following interlock input is provided:
Airflow Switch Interlock
This interlock is typically connected to an airflow switch.
The Airflow Interlock (ILK) input must close ten seconds
into PREPURGE or within the specified purge card timing;
otherwise, a recycle to the beginning of PREPURGE or
lockout will occur, depending on how the airflow switch
selectable jumper is configured (see Table 6).

RM7895A RELAY MODULE
732-00122-01
INSTALLATION
WARNING
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
To prevent possible hazardous burner operation,
verification of safety requirements must be
performed each time a control is installed on a
burner.
When Installing This Product…
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a
hazardous condition.
2. Check the ratings given in the instructions and
marked on the product to make sure the product is
suitable for your application.
3. Installer must be a trained, experienced, flame
safeguard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
WARNING
Electrical Shock Hazard.
Can cause severe injury, death or property
damage.
Disconnect the power supply before beginning
installation to prevent electrical shock and
equipment damage. More than one power supply
disconnect may be involved.
1. Wiring connections for the RM7895 are unique;
therefore, refer to Fig. 5 or the correct Specifications
for proper subbase wiring.
2. Wiring must comply with all applicable codes,
ordinances and regulations.
3. Wiring, where required, must comply with NEC Class
1 (Line Voltage) wiring.
4. Loads connected to the RM7895 must not exceed
those listed on the RM7895 label or the Specifica-
tions, see Table 1.
5. Limits and interlocks must be rated to carry and
break current simultaneously to the ignition trans-
former, pilot 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.
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 flame detectors can be connected in parallel.
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 user, 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 Cana-
dian Department of Communications.
Humidity
Install the RM7895 where the relative humidity (RH) never
reaches the saturation point. The RM7895 is designed to
operate in a maximum 85 percent RH continuous,
noncondensing, moisture environment. Condensing
moisture may cause a safety shutdown.
Vibration
Do not install the RM7895 where it could be subjected to
vibration in excess of 0.5G continuous maximum
vibration.
Weather
The RM7895 is not designed to be weather tight. If
installed outdoors, the RM7895 must be protected by an
approved, weather-tight, enclosure.
Mounting Wiring Subbase
NOTE: For installation dimensions, see Fig. 1.
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 and removal of the
RM7895, Dust Cover, flame amplifier, flame
amplifier signal voltage probes, electrical signal
voltage probes and electrical field connections.

RM7895A RELAY MODULE
32-00122-01 8
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.
Fig. 4. Internal block diagram of the RM7895 (see Fig. 6 for detailed wiring instructions).
WIRING
IMPORTANT
For proper subbase wiring, refer to Fig. 5.
For proper remote wiring of the Keyboard Display
Module, refer to the Specifications for the Key-
board Display Module (form 65-0144), Communi-
cations Interface Base Unit (63-2278), Data
ControlBus™ Module (65-0091) or Extension
Cable Assembly
(65-0131).
NOTE: Part number 203541 5-Wire Connector (order
separately) is required except when using the
extension cable assembly.
WARNING
Electrical Shock Hazard.
Can cause severe injury, death or property
damage.
Disconnect the power supply before beginning
installation to prevent electrical shock or
equipment and control damage. More than one
power supply disconnect may be required.
1. For proper remote wiring of the Keyboard Display
Module, refer to the Specifications for the Keyboard
Display Module (65-0144), Communication Inter-
face Base Unit (63-2278), Data ControlBus™ Module
(65-0091) or Extension Cable Assembly (65-0131).
2. Disconnect the power supply from the main discon-
nect before beginning installation to prevent electri-
cal shock and equipment damage. More than one
disconnect may be involved.
3. All wiring must comply with applicable electrical
codes, ordinances and regulations. Wiring, where
required, must comply with NEC Class 1 (Line Volt-
age) wiring.
4. Recommended wire size and type: see Table 4.
5. Recommended grounding practices: see Table 5.
6. The Keyboard Display Module, Data ControlBus™
Module (for remote mounting or communications)
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 order of interconnection of
all the devices listed above is not important. Be
aware that modules on the closes and farthest end
of the daisy chain configuration string require a
120-ohm, 1/4 watt minimum, resistor termination
across terminals 1 and 2 of the electrical connectors,
for connections over 100 feet. Recommended wire
routing of leadwires:
CONFIGURATION
JUMPERS
MICROCOMPUTER
RESET
PUSHBUTTON
RUN/TEST
SWITCH
STATUS LEDs
PLUG-IN PURGE
TIMER CARD
SAFETY RELAY
CIRCUIT
POWER SUPPLY
OPTIONAL KEYBOARD
DISPLAY MODULE
PLUG-IN
FLAME
AMPLIFIER
RELAY
DRIVE
CIRCUIT
CONTROL
POWER
TEST
JACK
REMOTE
RESET
DDL
DDL
COMMUNICATIONS
INDICATES FEEDBACK SENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLT INPUTS
FIELD WIRING
INTERNAL WIRING
IGNITION
PILOT
MAIN VALVE
1K
RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
LIMITS CONTROLLER LOCKOUT
INTERLOCK
(INCLUDING
AIRFLOW SWITCH)
1K1 2K1 5K1
FLAME SIGNAL
TEST
PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
RS485
1
2
3
L1
(HOT)
L2
5
67
4K1
2K2
10
8
9
7K
6K
5K
4K
3K
2K
F
G
22
1
BLOWER
6K1
4
ALARM
3K1
3
L2
M5110G
1
RM7895, RM7896: 120 VAC, 50/60 HZ.
EC7895A,C: 220-240 VAC, 50/60 HZ.

RM7895A RELAY MODULE
932-00122-01
a. Do not run high voltage ignition transformer
wires in the same conduit with the flame
detector, Data ControlBus™ Module, or Remote
Reset Module wiring.
b. Do not route flame detector, Data ControlBus™
Module, 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, or Remote Reset Module
Instructions.
7. 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 KDM is used.
8. Maximum wire lengths follow:
a. RM7895—The maximum length of leadwire is
300 feet to terminal inputs (Control, Preignition
Interlock, Running/Lockout 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 1000 feet to a Remote Reset push but-
ton.
d. Data ControlBus™ Module—The maximum Data
ControlBus™ Module cable length depends on
the number of system modules connected, the
noise conditions and the cable used. The maxi-
mum length of all Data ControlBus™ Module
interconnecting wire is 4000 feet.
9. Make sure loads do not exceed the terminal ratings.
Refer to the label on the RM7895 or to the ratings in
Table 1.
Final Wiring Check
1. Check the power supply circuit. The voltage and
frequency tolerance must match those of the
RM7895. A separate power supply circuit may be
required for the RM7895. Add the required
disconnect means and overload protection.
2. Check all wiring circuits and complete the Static
Checkout, see Table 7, before installing the RM7895
on the subbase.
3. Install all electrical connectors.
4. Restore power to the panel.
Table 4. Recommended Wire Sizes and Part Numbers.
Table 5. Recommended Grounding Practices.
Application Recommended Wire Size Recommended Part Number(s)
Line voltage terminals 14, 16 or 18 AWG copper conductor,
600 volt insulation, moisture-resistant
wire.
TTW60C, THW75C, THHN90C.
Keyboard Display Module (KDM) 22 AWG two-wire twisted pair with
ground, or five wire.
Belden 8723 shielded cable or
equivalent.
Data ControlBus™ Module
Remote Reset Module 22 AWG two-wire twisted pair,
insulated for low voltage.
—
Communications Interface
ControlBus™ Module
22 AWG two-wire twisted pair with
ground.
Belden 8723 shielded cable or
equivalent.
13 Vdc full-wave rectified transformer
power input
18 AWG wire insulated for voltages and
temperatures for given application.
TTW60C, THW75C, THHN90C.
Ground Type Recommended 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 15A fuse (or breaker) in the event of an inter-
nal short circuit.
2. Use wide straps or brackets to provide minimum
length, maximum surface area ground conductors. 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 protected against corrosion on mating surfaces.
Signal ground (KDM, Data ControlBus™ Module,
Communications Interface ControlBus™ Module).
Use the shield of the signal wire to ground the device to the
signal ground terminal [3(c)] of each device. Connect the
shield at both ends of the chain to earth ground.

RM7895A RELAY MODULE
32-00122-01 10
Fig. 5. Wiring the RM7895A Relay Module.
ASSEMBLY
Mounting RM7895
NOTE: For installation dimensions, see Fig. 1.
Relay Module Mounting
1. Mount the RM7895 vertically (see Fig. 7) or mount
horizontally with the knife blade terminals pointing
downward. When mounted on the Q7800A, the
RM7895 must be in an electrical enclosure. See Fig.
6.
2. Select the location in an electrical enclosure. Be sure
to allow adequate clearance for servicing, installa-
tion and removal of the RM7895, Dust Cover, flame
amplifier, flame amplifier signal probes, electrical
signal voltage probes and electrical connections.
M3536B
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
AIR FLOW INTERLOCK
MASTER
SWITCH
IGNITION
MAIN FUEL VALVE(S)
BURNER
CONTROLLER/LIMITS
BURNER MOTOR
(BLOWER)
120V ALARM
INTERRUPTED
PILOT/IGNITION
RECTIFYING FLAME
ROD
FLAME DETECTOR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
C7012A,C, ULTRAVIOLET
FLAME DETECTOR
120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT WIRE TO ANY UNUSED TERMINALS.
FOR DIRECT SPARK IGNITION
(OIL OR GAS)
IGNITION
TRANSFORMER
MAIN VALVE
L1
(HOT)
L2 1
OR
OR
BLUE
BLUE
WHITE
YELLOW
L2
WHITE
WHITE
BLACK
BLACK
L1
L2
8
10
L2
Q7800
2
1
2

RM7895A RELAY MODULE
11 32-00122-01
a. Allow an additional two inches below the
RM7895 for the flame amplifier mounting.
b. Allow an optional three-inch minimum to both
sides of the RM7895 for electrical signal voltage
probes.
3. Make sure no subbase wiring is projecting beyond
the terminal blocks. Tuck wiring in against the back
of the subbase so it does not interfere with the knife
blade terminals or bifurcated contacts.
4. Mount the RM7895 by aligning the four L-shaped
corner guides and knife blade terminals with the
bifurcated contacts on the wiring subbase and tight-
ening the two screws securely without deforming the
plastic.
IMPORTANT:
Install the RM7895 with a plug-in motion rather
than a hinge action.
Installing ST7800 Purge Card
1. Remove the Dust Cover, Keyboard Display Module,
Data ControlBus™ Module, or Extension Cable
Assembly.
2. Remove the current ST7800 from the RM7895 by
pulling upward on the plastic support cover, see Fig.
7.
3. Make sure the ST7800A selected has the desired
timing.
4. Insert the Purge Card into the opening of the
RM7895. (Again, see Fig. 7.)
5. Reinstall the Dust Cover, Keyboard Display Module,
Data ControlBus™ Module, or Extension Cable
Assembly onto the RM7895 and restore power to the
device.
6. Run the burner system through at least one com-
plete cycle to verify that the system is operating as
desired.
Mounting Dust Cover
1. Align the two interlocking ears of the Dust Cover with
the two mating slots on the RM7895, see Fig. 8.
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
RM7895.
3. Be sure the Dust Cover is firmly in place.
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 RM7895. Ensure the
amplifier nameplate faces away from the relay mod-
ule. See Fig. 9.
3. Push in the amplifier until the circuit board is fully
inserted into the receptacle and then push the
amplifier toward the RM7895 retaining clasp.
4. Verify the amplifier is firmly in place.
5. Restore power.
Perform all required checkout tests.
Installing the Flame Detector
NOTE: Table 2 and Fig. 10 list the flame detection
systems available for use with theRM7895. Make
sure the correct combination of amplifier and
flame detector(s) is used.
Proper flame detection installation is the basis of a safe
and reliable flame safeguard installation. Refer to the
instructions packed with the flame detector and the
equipment manufacturer instructions.
Keep the flame signal leadwires as short as possible from
the flame detector to the wiring subbase. Capacitance
increases with leadwire length, reducing the signal
strength. The maximum permissible leadwire length
depends on the type of flame detector, leadwire and
conduit. The ultimate limiting factor in the flame detector
leadwire is the flame signal, see Table 8.
Fig. 6. Electrical panel installation.
Fig. 7. ST7800 Purge Card installation.

RM7895A RELAY MODULE
32-00122-01 12
Fig. 8. Dust Cover mounting. Fig. 9. Flame Signal amplifier mounting.
Fig. 10. Flame detector wiring.
OPERATION
Sequence of Operation
The RM7895 has the following operating sequences, see
Fig. 11. Sequence status LEDs are shown in Fig. 12.
INITIATE
The RM7895 enters the INITIATE sequence when the
Relay Module is powered. The RM7895 can also enter the
INITIATE sequence if the Relay Module verifies voltage
fluctuations of +10/-15% or frequency fluctuations of
±10% during any part of the operating sequence. The
INITIATE sequence lasts for ten seconds unless the
voltage or frequency tolerances are not met. When the
tolerances are not met, a hold condition will be initiated
and will be displayed on the optional KDM for at least five
seconds. When the tolerances are met, the INITIATE
sequence will restart. If the condition is not corrected and
the hold condition exists for four minutes, the RM7895
will lockout. Causes for hold conditions in the INITIATE
sequence are:
• AC line dropout is detected.
• AC line frequency error caused by using a 60 Hz
device
on a 50 Hz line, or vice versa (devices with a date code
prior to 9804).
• AC line noise that can prevent a sufficient reading of
the
line voltage inputs.
• Brownouts caused by a low line voltage.
The INITIATE sequence also delays the burner motor
starter from being energized and de-energized from an
intermittent AC line input or control input.
M3514B
BLUE
WHITE
F
G
ULTRAVIOLET (C7027/C7035/C7044)
BLUE
YELLOW
BLACK
BLACK
F
G
L1
L2
SOLID STATE ULTRAVIOLET
(C7012A,C)
1
2
G
F
X
X
FLAME ROD
1FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL
AND THE WHITE MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE.
REVERSING THE LEADS EVEN MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL
AND THE YELLOW MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE.
REVERSING THE LEADS EVEN MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
2

RM7895A RELAY MODULE
13 32-00122-01
STANDBY
The RM7895 is ready to start an operating sequence when
the operating control input determines a call for heat is
present. The burner switch, limits, operating limit control
and all microcomputer monitored circuits must be in the
correct state for the RM7895 to continue into the
PREPURGE sequence.
NORMAL START-UP
PREPURGE
The RM7895 provides a selectable PREPURGE timing
from two seconds to 30 minutes with power applied and
the RM7895 operating control indicating a call for heat.
1. Airflow Interlock, burner switch and all microcom-
puter monitored circuits must be in the correct oper-
ating state.
2. The blower motor output, terminal 4, is powered to
start the PREPURGE sequence.
3. The Airflow Interlock input must close ten seconds in
PREPURGE or within the specified purge card tim-
ing; otherwise, a recycle to the beginning of PRE-
PURGE or lockout will occur depending on how the
airflow switch selectable jumper is configured.
IGNITION TRIALS
1. Pilot Flame Establishing Period (PFEP):
a. The pilot valve and ignition transformer,
terminals 8 and 10, are energized. The RM7895A
has an intermittent pilot valve, terminal 8.
b. If 10 second PFEP is chosen, main valve,
terminal 9, is turned on as soon as flame is
sensed. Ignition, terminal 10, is de-energized as
soon as the main valve is energized. The pilot
valve remains energized (intermittent pilot). The
control will lockout if a flame is not sensed within
ten seconds.
c. If four second PFEP is chosen, ignition, terminal
10, stays on, even if flame is sensed. Main valve,
terminal 9, is energized at the end of the four
second PFEP, assuming flame is proven. The
pilot valve remains energized (intermittent pilot).
RUN
The RM7895 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.
See Table 9 for further details of Hold conditions.
Fig. 11. RM7895A sequence.
POWER
00
LED
DISPLAY
OPERATING
CONTROLS
AND
INTERLOCKS
BURNER
FLAME
SIGNAL
INITIATE
POWER
STANDBY
POWER
PREPURGE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
4 OR 10 SEC
PILOT
FLAME
MAIN
POWER
RUN
FLAME
MAIN
POWER
STANDBY
00 00
BURNER/BLOWER MOTOR
IGN.
IGN./PILOT
LIMITS AND BURNER CONTROLLER CLOSED
AIRFLOW INTERLOCK CLOSED
SAFE START CHECK FLAME
PROVING
TO
TO
M3537
MAIN VALVE
IGNITION IS DEENERGIZED AS SOON AS MAIN VALVE IS ENERGIZED, IF 10 SECOND
PFEP IS CHOSEN.
MAIN VALVE IS TURNED ON AS SOON AS FLAME IS SENSED IF 10 SECOND PFEP IS
CHOSEN.
1
1
PILOT
TIMED
PURGE
ALARM ALARMALARM
SSC
2
2
L1 6
10
4
8
9
76

RM7895A RELAY MODULE
32-00122-01 14
Fig. 12. Sequence status LEDs.
SELECTABLE SITE-CONFIGURABLE
JUMPERS
The RM7895 has three site-configurable jumper options,
see Fig. 14 and Table 6. The site-configurable jumpers
should be clipped with side cutters and the resistors
removed from the Relay Module.
SERVICE NOTE: Clipping and removing a site-
configurable
jumper enhances the level of safety.
IMPORTANT:
Clipping and removing a site-configurable jumper
after 200 hours of operation results in a hard lock-
out (code 110).
Fig. 13. Selectable site-configurable jumpers.
Table 6. Selectable site-configurable jumper status.
Static Checkout
WARNING
Electric Shock Hazard.
Can cause severe injury, death or property
damage.
1. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
2. Open the master switch before installing or
removing a jumper on the subbase.
1. Before continuing to the next test, be sure to remove
the test jumper(s) used in the previous tests.
2. Replace all limits and interlocks not operating prop-
erly. Do not bypass limits and interlocks.
3. Close all manual fuel shutoff valve(s) before starting
these tests.
After checking all wiring, perform this checkout before
installing the RM7895 on the subbase. These tests verify
that the Q7800 Wiring Subbase is wired correctly, and that
the external controllers, limits, interlocks, actuators,
valves, transformers, motors and other devices are
operating properly.
IMPORTANT
Do not perform a dielectric test with the RM7895
installed. Internal surge protectors will break down
and conduct a current. This could cause the
RM7895 to fail the dielectric test or possibly
destroy the internal lightning and high current
transient protection components.
Equipment Recommended
1. Voltmeter (1 megohm/volt minimum sensitivity) set
on the 0-300 Vac scale.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
(305 mm) long, with insulated alligator clips at both
ends.
General Instructions
1. Perform all applicable tests listed in Static Checkout,
Table 5, in the order listed.
2. MAKE SURE THAT ALL MANUAL FUEL SHUT-OFF
VALVE(S) ARE CLOSED.
3. Raise the set point of the operating controller to
simulate a call for heat.
4. For each test, open the master switch and install the
jumper wire(s) between the subbase wiring termi-
nals listed in the Test Jumpers column of Table 7.
5. Close the master switch before observing operation.
6. Read the voltage between the subbase wiring termi-
nals listed in the Voltmeter column of Table 7.
CAPTIVE
MOUNTING
SCREW
PLUG-IN
PURGE
CARD
DUST
COVER
RELAY
MODULE
FLAME
AMPLIFIER
FLAME
CURRENT
TEST JACKS
FLAME
SIMULATOR
INPUT
RESET
PUSH
BUTTON
SEQUENCE
STATUS
LEDs M10590
SELECTABLE CONFIGURATION JUMPERS
M10591
Configuration
Jumper Intact
Clipped and
Removed
JR1 10 sec. limit. 4 sec.
JR2 Recycle Lockout
JR3 Recycle Lockout

RM7895A RELAY MODULE
15 32-00122-01
7. If there is no voltage or the operation is abnormal,
check the circuits and external devices as described
in the last column.
8. Check all wiring for correct connections, tight termi-
nal screws, correct wire, and proper wiring tech-
niques. Replace all damaged or incorrectly sized
wires.
9. Replace faulty controllers, limits, interlocks, actua-
tors, valves, transformers, motors and other devices
as required.
10. Obtain normal operation for each required test
before continuing the checkout.
11. After completing each test, be sure to remove the
test jumper(s).
Table 7. Static Checkout.
Test
No.
Test
Jumper
s
Voltmete
r Normal Operation
If Operation is Abnormal, Check the
Items Listed Below
WARNING
Explosion Hazard.
Can cause serious injury, death or property damage.
Make sure all manual fuel shutoff valves are closed.
IMPORTANT:
Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if
required).
1 None 5-L2 Line voltage at terminal 5. 1. Master switch.
2. Power connected to the master
switch.
3. Overload protection (fuse, circuit
breaker) has not opened the power
line.
2 None 6-L2 Line voltage at terminal 6. 1. Limits.
2. Burner controller.
34-57-L2 1. Burner motor (fan or blower) starts.
2. Line voltage at terminal 7 within 10
seconds.
1. Burner motor circuit.
a. Manual switch of burner motor.
b. Burner motor power supply,
overload protection and starter.
c. Burner motor.
4 5-10 — Ignition spark (if ignition transformer is
connected to terminal 10).
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
55-8— 1. Ignition spark (if ignition transformer is
connected to terminal 8.
2. Automatic pilot valve opens (if connected
to terminal 8.
NOTE: Refer to wiring diagram of system
being tested.
1. Watch for spark or listen for buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
2. Listen for click or feel head of valve
for activation.
a. Actuator, if used.
b. Pilot valve.
6 5-9 — Automatic fuel valve(s) open(s).
If using direct spark ignition, check the first
stage fuel valve(s) instead of the pilot valve.
Same as test no. 6. If using direct spark
ignition, check the first stage fuel valve(s)
instead of the pilot valve.
7 5-3 — Alarm, if used, turns on. 1. Alarm
Final
CAUTION
Equipment Damage Hazard.
Can cause serious equipment damage.
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.

RM7895A RELAY MODULE
32-00122-01 16
CHECKOUT
WARNING
Fire or Explosion Hazard.
Can cause serious injury, death or property
damage.
Do not allow fuel to accumulate in the combustion
chamber. If fuel is allowed to enter the combustion
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 two seconds from the time the fuel has
reached the burner nozzle. In any case, do not
exceed the nominal lightoff time specified by the
equipment manufacturer. Close the manual fuel
shutoff valves if the flame is not burning at the end
of the specified time.
WARNING
Electrical Shock Hazard.
Can cause serious injury or death.
1. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
2. Open the master switch before removing or
installing the RM7895.
3. Make sure all manual fuel shutoff valves are
closed before starting the initial lightoff check
and the Pilot Turndown tests.
4. Do not put system in service until you have
satisfactorily completed all applicable tests in
this section and any others required by the
equipment manufacturer.
CAUTION
Equipment Damage Hazard.
Can damage equipment or cause improper
operation.
If an RM7895 is replaced with a lower or higher
functioning 7800 SERIES Relay Module, the
burner will not sequence unless wiring changes are
made.
IMPORTANT
1. If the system fails to perform properly, refer to
7800 SERIES System Annunciation Diagnostics
and Troubleshooting, form 65-0233.
2. Repeat ALL required Checkout tests after all
adjustments are made. ALL tests must be satisfied
with the flame detector(s) in the FINAL position.
Equipment Recommended
Volt-ohmmeter (1 Mohm/volt minimum sensitivity) with:
• 0-300 Vac capability.
• 0-6000 ohm capability.
• 0-10 Vdc capability.
Checkout Summary
• Preliminary inspection—all installations.
• Flame signal measurement—all installations.
• Initial lightoff check for proved pilot—all installations
using
a pilot.
• Initial lightoff check for direct spark ignition of oil—all
burners using DSI.
• Pilot turndown test—all installations using a pilot.
• Hot refractory hold-in test—all installations.
• Ignition interference test—all installations using
flame rods.
• Ignition spark pickup—all installations using
Ultraviolet
Flame Detectors.
• Response to other ultraviolet sources—all
installations
using Ultraviolet Flame Detectors.
• Flame signal with hot combustion chamber—all
installations.
• Safety shutdown tests—all installations.
See Fig. 1 for location of component parts and see Fig. 5 or
Q7800 Specifications for terminal locations.
Preliminary Inspection
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 (are) clean, installed and
positioned properly. Consult the applicable
Instructions.
3. Correct combination of flame amplifier and flame
detector(s) is used. See Table 2 in the Specifications
section.
4. Plug-in amplifier and purge card are securely in
place.
5. Burner is completely installed and ready to fire; con-
sult 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).
8. Lockout switch is reset (push in reset push button)
only if the RM7895 is powered, see Fig. 1.
9. System is in the STANDBY condition. POWER LED is
energized.
10. All limits and interlocks are reset.
Flame Signal Measurement (Fig. 17 and Table 8).

RM7895A RELAY MODULE
17 32-00122-01
Table 8. Flame Signal.
aThis minimum or a stronger signal should easily be obtained if the detector is correctly installed and positioned to prop-
erly sense the flame. This voltage must be obtained before completing checkout.
Fig. 14. Flame signal measurement.
Measure the flame signal at the appropriate times defined
in the following checkout tests. Read the flame signal volts
dc at the flame amplifier test jacks + and - (Com).
1. Use a 1 Megohm/volt meter with a 0 to 10 Vdc
capability.
2. Set the meter to the 0 to 10 Vdc range.
3. Insert the positive (red) probe into the + jack of the
flame amplifier. Insert the negative (black) probe
into the - (Com) jack of the flame amplifier. See Fig.
14.
4. Allow a few seconds for the meter reading to stabi-
lize.
5. The meter reading must be as specified in Table 8
after all tests are completed and all adjustments are
made.
As an option, the flame signal can be checked by using the
optional Keyboard Display Module.
If the signal is unstable or less than the minimum
acceptable voltage, check the flame detector installation
and circuitry.
1. Check the supply voltages at terminals 5 (L1) and
L2(N). Make sure the master switch is closed,
connections are correct, and the power supply is of
the correct voltage and frequency and is sinusoidal.
2. Check the detector wiring for defects including:
Incorrect connections.
• Wrong type of wire.
• Deteriorated wire.
• Open circuits.
• Short circuits.
• Leakage paths caused by moisture, soot or
accumulated
dirt.
3. For flame rod, make sure:
• Ground area is large enough.
• Flame rod is properly located in the flame.
• Temperature at the flame rod insulator is no greater
than
500°F (260°C).
4. For all optical detectors, clean the detector viewing
window and inside of the sight pipe as applicable.
5. 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.
• Add a shield or screen to reflect radiated heat.
• Add cooling (refer to sight pipe ventilation in the
detector
instructions).
6. Make sure that the flame adjustment is not too lean.
7. Make sure that the detector is properly sighting the
flame.
8. If necessary, resight or reposition the detector.
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 valves
are closed. Open the manual pilot shutoff valve. If
the pilot takeoff is downstream from the manual
main fuel shutoff valve(s), very slightly open the
manual main valve to supply pilot gas flow. Make
sure the main fuel is shutoff just upstream from the
burner inlet, or disconnect power from the automatic
main fuel valves.
Flame Detector
Acceptable Flame Signal
Amplifier
Minimum Maximum
Steady dc VoltageaExpected dc Voltage
Flame Rod
C7012A,C
R7847A 1.25 Vdc 5.0 Vdc at the Keyboard
Display Module
or
5.0 Vdc at a 1 Megohm/volt
meter.
C7027A
C7035A
C7044A
R7849A
1 MEGOHM/VOLT
METER
M20281
POSIIVE (+)
METER LEAD
NEGATIVE (–)
METER LEAD

RM7895A RELAY MODULE
32-00122-01 18
3. Close the master switch and start the system with a
call for heat by raising the set point of the operating
controller, see Fig. 11 or 13. The primary sequence
should start the ten-second INITIATE sequence.
4. Let the sequence advance through PREPURGE.
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 schedule. Consult the equipment
operating manual for further information.
6. Push the reset push button and let the system recy-
cle once. If the pilot still does not ignite, make the
following ignition/pilot adjustments.
a. Open the master switch and remove the RM7895
from the subbase.
b. On the subbase, jumper terminal 5 to ignition
terminal 8 or 10; 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 igni-
tion 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
recommendations.
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 5 (L1) 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.
i. If the pilot does not ignite and if the ignition
spark is still continuous, adjust the pressure reg-
ulator 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 5-8 or 5-10 of the sub-
base.
k. Check for adequate bleeding of the fuel line.
l. Reinstall the RM7895 on the subbase and close
the master switch, then return to step 4.
7. When the pilot ignites, measure the flame signal. If
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 IGN 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).
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 reattempt 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 adequate 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 through 14 to establish the main
burner flame; then proceed to step 16.
16. With the sequence in RUN, make burner adjust-
ments for flame stability and BTU input ratings.
17. Shut down the system by opening the burner switch
or by lowering the set point of the operating control-
ler. 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 all automatic fuel valves
close.
18. Restart the system by closing the burner switch
and/or raising the set point of the operating control-
ler. Observe that the pilot is established during
PILOT IGN and the main burner flame is established
during MAIN IGN within the normal lightoff time.
19. Measure the flame signal. Continue to check for the
proper signal, see Table 7, through the RUN period.
20. Run the burner through another sequence, observ-
ing the flame signal for:
a. Pilot flame alone (unless using direct spark igni-
tion).
b. Pilot and main flame together.
c. Main flame alone (unless monitoring an inter-
mittent pilot).
21. Also observe the time it takes to light the main flame.
Ignition of the main flame should be smooth.
22. Return the system to normal operation.
23. Make sure all readings are in 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.
Initial Lightoff Check for Direct
Spark Ignition
This check applies for gas and oil burners that do not use 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 normal checkout of the fuel supply
and equipment as recommended by the equipment
manufacturer.

RM7895A RELAY MODULE
19 32-00122-01
3. Close all manual main fuel shutoff valves. Check
that the automatic fuel valves 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 set point of the operating
controller, see Fig. 11. The primary sequence should
start the ten-second INITIATE sequence.
5. Let the sequence advance through PREPURGE.
Ignition spark should occur after the PREPURGE
period. Listen for the click of the first stage fuel
solenoid valve(s).
6. Let the program sequence complete its cycle.
7. Open the manual fuel shutoff valve(s).
8. Reset the Lockout Switch and recycle the primary
sequence through PREPURGE.
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.
12. Wait about three minutes. Close the master switch,
open the manual fuel shutoff valve(s), and try again
to lightoff 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 8 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.
16. Shut down the system by opening the burner switch
or by lowering the set point of the operating
controller. Make sure the burner flame goes out and
make sure 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) has opened and check the
lightoff as follows. Otherwise, proceed to step 19.
a. Open the manual second stage fuel valve(s).
b. Restart the system by raising the set point 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 set point
of the operating controller. Make sure the burner
flame goes out and all automatic fuel valves
close. Proceed to step 19.
19. Restart the system by closing the burner switch
and/or raising the set point of the operating control-
ler. Observe that the burner flame is established
during PILOT IGN, within the normal lightoff time
specified by the equipment manufacturer.
20. Measure the flame signal. Continue to check for the
proper signal, see Table 8, through the RUN period.
Any pulsating or unsteady readings will require
further attention.
21. Make sure all readings are in the required ranges
before proceeding.
NOTE: Upon completing these tests, open the master
switch and remove all test jumpers from the sub-
base terminals, limits/control or switches.
22. Return the system to normal operation.
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 it will detect the smallest
acceptable pilot flame.
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 mea-
sure the 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 set point of the operating
controller. The primary sequence should start and
PREPURGE should begin.
NOTE: INTERMITTENT PILOT MODELS should continue
with step 6.
6. INTERMITTENT PILOT MODELS—After the
sequence has entered the normal burner run period,
turn the pilot gas pressure down very slowly, reading
the manometer (or gauge) as the pressure drops.
Stop immediately when the FLAME LED goes out.
Note the pressure at this point.
a. If the Flame Failure Action jumper is not clipped:
allow the RM7895A to recycle through PRE-
PURGE. If the Flame Failure Action jumper is
clipped: push the reset push button and allow
the RM7895A to recycle through PREPURGE.
b. As the control attempts to relight the pilot, turn
the pilot gas pressure back up slowly until the
FLAME LED comes on. This step must be com-
pleted within 4 or 10 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 gas
pressure just above the reading noted in step 6
above.)
NOTE: Step d requires two people, one to open the man-
ual main fuel valve(s) and one to watch for igni-
tion.

RM7895A RELAY MODULE
32-00122-01 20
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. Return to step 6.
Ignition Interference Test (All
Flame Rods)
Test to be sure that a false signal from a spark ignition
system is not superimposed on the flame signal.
Ignition interference can subtract from (decrease) or add
to (increase) the flame signal. If it decreases the flame
signal enough, it will cause a safety 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 0.5 Vdc) indicates ignition interference.
To Eliminate Ignition Interference
1. Be sure there is enough ground area.
2. Be sure the ignition electrode and the flame rod are
on opposite sides of the ground area.
3. Check for correct spacing on the ignition electrode:
a. 6,000V systems—1/6 to 3/32 in. (1.6 to 2.4 mm).
b. 10,000V systems—1/8 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, the system may
have to be changed to an ultraviolet or infrared
flame detection system.
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 IGN
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.
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 Solid State Spark Genera-
tor will prevent detection of ignition spark when
properly applied with the C7027, C7035, or
C7044 Minipeeper Ultraviolet Flame Detectors.
The Q624A is only for use with gas pilots.
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
operation, check the Flame Failure Response Time (FFRT)
and conduct Safety Shutdown tests under all operating
conditions.
Flame Signal with Hot Combustion
Chamber (All Installations)
After 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, 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 FFRT of the Flame Amplifier. Lower the set point
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. If the
response time is still too slow, replace the Plug-in Flame
Signal Amplifier. 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 have been completed. If used, the external alarm
should turn on. Press the RM7895 reset push button to
restart the system.
1. Close the Airflow Interlock during PREPURGE,
PILOT IGN, MAIN IGN or RUN period.
a. Safety shutdown will occur if Airflow ILK Switch
Failure configuration jumper (JR3) is clipped.
2. Detect flame 40 seconds after entry to STANDBY.
Detect flame 30 seconds during measured PRE-
PURGE time.