Honeywell 7800 SERIES User manual

1 65-0106—2
7800 SERIES RM7823A
Relay Module
■Safety features:
— Closed loop logic test.
— Dynamic AMPLI-CHECK™.
— Dynamic input check.
— Dynamic self-check logic.
— Expanded safe-start check.
— Internal hardware status monitoring.
— Tamper resistant logic.
■Access for external electrical voltage checks.
■Application flexibility with interchangeable plug-in
flame amplifiers.
■Communication interface capability.
■Dependable,long-termoperationprovidedbymicrocom-
puter technology.
■Systemanddevicediagnosticsareprovidedbyanoptional
2rowby20columnVacuumFluorescentDisplay(VFD)
located on the optional Keyboard Display Module.
■First-out expanded annunciation with 26 Light Emitting
Diodes (LEDs) for limits and interlocks (optional).
■Three (LEDs) for status information.
■LocalorremoteannunciationofRM7823Aoperationand
fault information (optional).
■Nonvolatile memory; RM7823A retains history files and
sequencing status after loss of power.
■Remote reset (optional).
■Report generation (optional).
■Shutter drive output.
■Burner controller data (optional):
— Expanded annunciator status.
— Flame signal strength.
— Hold status.
— Sequence status.
— Sequence time.
— Total hours of operation.
— Total cycles of operation.
— Fault history providing 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.
• Software revision and version of RM7823A and
optional Keyboard Display Module.
The Honeywell RM7823A is a microprocessor based
Flame Detector Relay that can be fitted with any 7800
SERIES Amplifier to provide relay action from one Spdt
relay when flame is present or not present. The RM7823A
Relay Module, Q7800 Wiring Subbase and Amplifier are
required to complete the system. Options include Keyboard
Display Module, Personal Computer Interface, DATA
CONTROLBUS MODULE™, Remote Display Module,
First-Out Expanded Annunciator and COMBUSTION
SYSTEM MANAGER™ Software.
The RM7823A is programmed to provide a level of
safety, functional capability and features beyond the capac-
ity of conventional controls.
FunctionsprovidedbytheRM7823Aincludeflamesuper-
vision, system status indication, system or self-diagnostics
and troubleshooting.
The RM7823A is a flame detector relay only. Suitable
primary control must be used to provide safe-start check,
safetylockout,loadswitchingandotherrequiredfunctionsin
flame safeguard systems.
65-0106-2
G.R. • Rev. 3-94 • ©Honeywell Inc. 1994 • Form Number 65-0106—2
CONTENTS
Specifications .................................................2
Ordering Information ..................................... 2
Principle Technical Features .......................... 7
Safety Provisions ............................................ 8
Installation ..................................................... 9
Wiring .......................................................... 10
Assembly ...................................................... 12
Operation ..................................................... 14
Checkout ...................................................... 15
Troubleshooting ........................................... 19

65-0106—2 2
RM7823A
SPECIFICATIONS • ORDERING INFORMATION
Specifications
ELECTRICAL RATINGS, see Table 1:
Voltage and Frequency: 120 Vac (+10/-15%), 50 or
60 Hz (+/- 10%). 2
Power Dissipation: 10 watts maximum.
Maximum Total Connected Load: 2000 VA.
Fusing: Total Connected Load: 20A maximum, type
FRN or equivalent.
TABLE 1—TERMINAL RATINGS.
Terminal No. Description Ratings
G Flame Sensor Ground
Earth G Earth Ground1
L2(N) Line Voltage Common
3 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz (+/- 10%).2
4 Unused
5 Unused
6 Unused
7 Unused
8 9KA Common
9 9KA1 N.O. 9.8 AFL, 58.8 ALR at 120 Vac
10 9KA2 N.C. 1A Pilot Duty at 120 Vac
F(11) Flame Sensor 60 to 220 Vac, current limited.
12 Unused
13 9KB Common
14 9KB1 N.C. 1A Pilot Duty at 120 Vac; also rated for 5V control circuits.
15 9KB2 N.O. 1A Pilot Duty at 120 Vac; also rated for 5V control circuits.
16 Unused
17 Unused
18 Unused
19 Unused
20 Unused
21 Unused
22 Shutter 120 Vac, 0.5A (RM7823A).
1The RM7823A must have an earth ground providing a connection between the subbase and the control panel or the equip-
ment.Theearthgroundwiremustbecapableofconductingthecurrenttoblowthe20Afuse(orbreaker)ineventofaninternal
short circuit. The RM7823A needs a low impedance ground connection to the equipment frame which, in turn, needs a low
impedanceconnectiontoearthground.ForagroundpathtobelowimpedanceatRFfrequencies,theconnectionmustbemade
withminimumlength conductors havingmaximumsurfaceareas. Wide strapsorbrackets rather thanleadwiresarepreferred.
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.
2Operating frequency chosen by RM7823A selection.
Ordering Information
When purchasing replacement and modernization products from your 7800 SERIES distributor, refer to the TRADELINE®Catalog for complete ordering
number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Satisfaction
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 [phone]
In Canada—Honeywell Limited/Honeywell Limitée, 740 Ellesmere Road, Scarborough, Ontario M1P 2V9 International Sales and Service Offices
inallprincipalcitiesoftheworld.ManufacturinginAustralia,Canada,Finland,France,Germany,Japan,Mexico,Netherlands,Spain,Taiwan,United
Kingdom, U.S.A.

3 65-0106—2
RM7823A
SPECIFICATIONS
TABLE 2—FLAME DETECTION SYSTEMS .
Plug-in Flame Signal Amplifiers Applicable Flame Detectors
Flame
Failure
Self- Response
Type Color Checking Model Time Fuel Type Models
Rectification Green No R7847A .8 or 3 sec Gas Rectifying C7004, C7007, C7011.
Flame Rod Complete Assemblies:
HoldersdC7008, C7009, Q179.
No R7847A .8 or 3 sec Oil Rectifying C7003, C7010,
Photocell C7013, C7014.
No R7847A 3 sec Gas, oil, Ultraviolet C7012A,C.a
coal (Purple Peeper)
Dynamic R7847Bc.8 or 3 sec Gas Rectifying C7004, C7007, C7011.
AMPLI- Flame Rod Complete Assemblies:
CHECK™ HoldersdC7008, C7009, Q179.
Dynamic R7847Bc.8 or 3 sec Oil Rectifying C7003, C7010,
AMPLI- PhotocelleC7013, C7014.
CHECK™
Dynamic R7847Bc3 sec Gas, oil, Ultraviolet C7012A,C.a
AMPLI- coal (Purple Peeper)
CHECK™
Dynamic R7847Cb3 sec Gas, oil, Ultraviolet C7012E,F.
Self-Check coal (Purple Peeper)
Infrared Red No R7848A 3 sec Gas, oil, Infrared C7015.
coal (Lead Sulfide)
Dynamic R7848Bc3 sec Gas, oil Infrared C7015.
AMPLI- coal (Lead Sulfide)
CHECK™
Ultraviolet Purple No R7849A .8 or 3 sec Gas, oil Ultraviolet C7027, C7035, C7044.a
(Minipeeper)
Dynamic R7849Bc.8 or 3 sec Gas, oil Ultrviolet C7027, C7035, C7044.a
AMPLI- (Minipeeper)
CHECK™
Blue Dynamic R7886Ab3 sec Gas, oil, Ultraviolet C7076.
Self-Check coal (Adjustable
Sensitivity)
WEIGHT: RM7823A with Dust Cover: 1 pound 13 ounces,
unpacked.
IMPORTANT: Flame Detection System available for use
with RM7823A. To select your Plug-in Flame Signal
AmplifierandapplicableFlameDetector,seeTable2and
Figs. 3-5.
ENVIRONMENTAL RATINGS:
Ambient Temperature:
Operating: -40°F to 140°F.
Storage: -40°F to 150°F.
Humidity: 85% RH continuous, noncondensing.
Vibration: 0.5G environment.
DIMENSIONS: Refer to Figs. 1 and 2.
aThe 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.
bCircuitry 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.
cCircuitry tests the flame signal amplifier at least 12 times a minute during burner operation and shuts down the burner if
the amplifier fails.
dOrder flame rod separately; see holder Instructions.
eUse only Honeywell Photocell, part no. 38316.

65-0106—2 4
RM7823A
SPECIFICATIONS
APPROVAL BODIES:
Underwriters Laboratories Inc. listed: file no. MP268,
guide no. MCCZ.
Canadian Standards Association certified: LR9S329-3.
Factory Mutual approved: OX4A5.AF.
IRI acceptable.
Federal Communications Commission: Part 15, Class B
Emissions.
MOUNTING: Q7800A for panel mount or Q7800B for
wall or burner mount.
REQUIRED COMPONENTS:
Plug-in Flame Signal Amplifier, see Table 2.
Q7800A1005 (panel mount) or Q7800B1003 (wall
mount).
ACCESSORIES:
Optional:
COMBUSTIONSYSTEMMANAGER™—partno.
ZM7850A1001.
Communication Interface Base Unit—part no.
Q7700A1014.
Fig. 1—Mounting dimensions of RM7823A Relay Module and Q7800A. Subbase in in. [mm].
POWER
FLAME
ALARM
RESET
5
[127]
5 [127]
M2649
5 [133]
1
4
BURNER CONTROL
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
Communication Interface ControlBus Module—part
no. QS7800A1001.
ControlBus 5-Wire Electrical Connector—part no.
203541.
Keyboard Display Module—part no. S7800A1001.
DATA CONTROLBUS MODULE™—part no.
S7810A1009.
Remote Reset Module—part no. S7820A1007.
Expanded Annunciator—part no. S7830A1005.
Flame Simulators:
— part no. 203659 UV Flame Simulator.
— part no. 123514A Rectification Simulator.
RemoteDisplayMountingBracket—partno.203765.
Remote Display Power Supply (13 Vdc):
— part no. 203968A Plug-in.
— part no. 203969A Screw Terminal.
Tester—part no. A7800A1002.
Replacement Parts:
Dust Cover—part no. 221729A.
Electrical Access Slot Cover—part no. 221779.

5 65-0106—2
RM7823A
SPECIFICATIONS
MOUNTING FLANGE
7 [183]
7
32
3
[87]
7
16
3
[95]
3
4
5
[130]
1
8
5 [133]
1
4
1/2–14 NPSM
LEADWIRES FACEPLATE
3/4–14 NPT OR
1–11-1/2 NPT
M1962
THREADED
MOUNTING
HOLES (2)–
10-32 UNF
[13]
1
2
1 [25]
FLAME ROD
[18]
11
16
3
8[10]
[2]
3
32
[20]
25
32 [20]
25
32 [14]
17
32
TARGET
2 [62]
25
32
1
[27]
1
16
1
[36]
13
32
1
[42]
21
32
3
[79]
1
8
CERAMIC
INSULATORS
IGNITION
ELECTRODE
(Q179C ONLY)
BRACKET M1983
Q179 C7012A,C,E,F
Fig. 2—Mounting dimensions of RM7823A Relay Module and Q7800B Subbase in in. [mm].
Fig. 3—Rectification detectors.
POWER
FLAME
ALARM
RESET
5
[127]
5 [127]
M2650
6 [155]
3
32
BURNER CONTROL
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
1 [32]
1
4
1
[45]
3
4
[21]
13
16 1 [35]
3
8
1 [33]
5
16 5
16 [8]1 [32]
1
4
2
[51]
C7013A C7014A
M1847

65-0106—2 6
RM7823A
SPECIFICATIONS
C7035
[22]
7
8
3 [92]
5
8
1
2[13]
9
16 [14]
1 [36]
27
64
[10]
3
8
MOUNTING BRACKET
6 FOOT [1.83 METER]
LEADWIRES (2)
M1944A
C7044
C7027
1
[27]
1
16
COLLAR WITH 1/2-14 NPSM
INTERNAL THREADS
4 [102]
3 [89]
1
2
6 FOOT [1.83 METER]
LEADWIRES (2)
M1943A
MODEL AVAILABLE WITH 24 FOOT [7.32 METER] LEADWIRES.
MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL
THREADS
)
INSTEAD OF CLAMP TYPE CONNECTOR.
1
2
1
2
Fig. 4—Ultraviolet detectors.
C7076A
1
[38]
1
231
32
[25]
1/2-14 NPSM
INTERNAL THREADS
4 [105]
1
8
2
1
[30]
3
16
2 [51]
COLLAR WITH
1–11-1/2 NPSM
INTERNAL
THREADS 1
1DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL THREADS.
DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL THREADS.
MODEL AVAILABLE WITH 12 FOOT [3.66 METER] LEADWIRES.
2 [67]
5
8
2
3
INSERTION DEPTH
6 FOOT
[1.83 METER]
LEADWIRES (2) 3
M1945A
4 [123]
4
[102]
27
32
1 [27]
1
16
2 [57]
1
4
4 [102]
2
[57]
1
4
10 [261]
9
32
2
[58]
5
16 7 [188]
13
32
7 [194]
2 [68]
11
16 5
8
1
[41]
19
32
[19]
3
4
[23]
29
32
3/8 INCH NPT
1 INCH NPT
7/8 [22] OPENING
FOR 1/2-INCH CONDUIT
ALLOW 9 INCHES [228 MILLIMETERS]
CLEARANCE TO SWING OUT THE DETECTOR
FOR LENS CLEANING OR SERVICING.
1
M5083A

7 65-0106—2
C7076D
7 [198]
13
16
2
[64]
1
2
15/16 [24] DIA.
6
[158]
7
32
6
[168]
19
32
2 [51]
1 [25]
1 INCH NPT
15/16–18 UNC
(2 EACH)
2
[55]
5
32 1
[47]
27
32
11 [300]
13
16
5 [147]
13
16
5
[147]
13
16
M5084
1
[32]
1
4
2 [70]
3
4
APERTURE
BUSHING WITH
MAGNIFYING LENS COLLAR, 3/4-14 NPSM
INTERNAL THREADS
3/4-14
NPSM 3/4-14 NPSM
INTERNAL
THREADS
1
[32]
1
4
1 [27]
1
16
1 [41]
5
8
HEAT BLOCKCELL MOUNT
M1982A
2 LEADS IN A
48 INCH [1.2 METER]
FLEXIBLE CONDUIT
C7015
Fig. 4—Ultraviolet detectors (Continued).
Fig. 5—Infrared Detector.
RM7823A
SPECIFICATIONS • PRINCIPLE TECHNICAL FEATURE
The RM7823A provides flame switch functions while
providingongoing internallogictests. Safety shutdownwill
occur if the RM7823A fails any internal system test.
The RM7832A is a Flame Switch that has components
monitoredbyacomputer.ItisnecessaryforaRESETbutton
toputthecomputerinsyncwithreal-timebutisnotintended
for safety lockout on loss of flame.
Pressing RESET will put the RM7823A back into its
STANDBY position, ready to respond to a flame sighting
condition.
RM7823A outputs are accomplished with one spdt re-
lay.
PrincipalTechnical Feature

65-0106—2 8
Safety Provisions
INTERNAL HARDWARE STATUS MONITORING
The RM7823A analyzes the integrity of the internal
hardware. The POWER LED will blink every four seconds,
signifying an internal hardware check.
CLOSED LOOP LOGIC TEST
TheRM7823Amustreacttoinputchangesbutavoidthe
occurrenceofnuisance shutdownevents.Signalcondition-
ing is applied to line voltage inputs to verify proper opera-
tion 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 AMPLI-CHECK™
Dynamic AMPLI-CHECK™ circuitry tests the flame
signal amplifier during operation and shuts down the
RM7823A if the flame amplifier fails.
DYNAMIC FLAME AMPLIFIER AND
SHUTTER CHECK
Self-checking circuitry tests all electronic components in
theflamedetectionsystemandamplifier12timesperminute
and shuts down the RM7823A if the detection system fails.
DYNAMIC SELF-CHECK SAFETY CIRCUIT
The microcomputer tests itself and related hardware, and
atthesametime, the safetyrelaysystemteststhe microcom-
puter operation. If a microcomputer or safety relay failure
occursanddoes notallowproperexecution of theself-check
routine, safety shutdown occurs and all internal relays will
be de-energized.
FLAME SIGNAL CHECK
The flame detection subsystem (flame detector and
amplifier) is monitored at all times when power is applied
totheRM7823A.Ashutter-checkamplifierandself-check-
ing detector check for a possible runaway detector or
amplifiercomponentfailure.Ifthissituationexists,asafety
shutdownoccurs.AnAMPLI-CHECK™Amplifierchecks
for any possible amplifier component failure. If a failure
exists, a safety shutdown occurs. A standard amplifier is
energized continually.
TAMPER RESISTANT TIMING AND LOGIC
Safety and logic timings are inaccessible and cannot be
altered or defeated.
RM7823A
SAFETY PROVISIONS
FIRST-OUT ANNUNCIATION AND
SELF-DIAGNOSTICS
Sequence Status Lights (LEDs) provide positive visual
indication of the RM7823A status: POWER, FLAME, and
ALARM. The green POWER LED blinks every four sec-
onds, signifying that the RM7823A hardware is running
correctly.
OptionalMulti-FunctionKeyboardDisplayModuleflame
signal strength. As an additional troubleshooting aid, it
provides hours of operation, diagnostic information, histori-
calinformationandexpandedannunciatorinformationwhen
a safety shutdown or hold or normal operation occurs.
First-out Annunciation reports or identifies the cause of
an alarm with an English text and numbered code via the
optionalKeyboardDisplayModule.Itmonitorspowerinput
circuits and the flame signal amplifier. The system distin-
guishes 23 modes of failure.
Self-Diagnostics add to the first-out annunciation by
allowing the RM7823A to distinguish internal (system
related)problems.Faultsassociatedwithintheflamedetec-
tion subsystem or RM7823A are isolated and reported by
the optional Keyboard Display Module. See 7800 SERIES
System Annunciation Diagnostics and Troubleshooting,
form 65-0118.
INITIATE
The RM7823A will enter an INITIATE sequence if the
Relay Module verifies voltage fluctuations of +10/-15% or
frequency fluctuations of +/- 10% during the time power is
appliedto thedevice.The RM7823Awillhold(fiveseconds
minimumtofourminutesmaximum)toallowfluctuationsto
stablilize before entering an INITIATE sequence that lasts
for ten seconds. If fluctuations return during INITIATE, the
RM7823A will return to the hold condition and will be
displayed on the optional VFD. If the condition is not
corrected and the hold condition exists for four minutes, the
RM7823A will lockout. Causes for hold conditions in the
INITIATE sequence are:
• AC line dropout is detected.
• Brownouts caused by a low line voltage.
• AC line noise that can prevent a sufficient reading of
the line voltage inputs.
• AClinefrequencyerrorcausedbyusinga60Hzdevice
on a 50 Hz line or vice versa.

9 65-0106—2
Installation
MICROCOMPUTER
RESET
PUSHBUTTON
STATUS
LEDs
POWER SUPPLY
PLUG-IN
FLAME
AMPLIFIER
RELAY
DRIVE
CIRCUIT
CONTROL
POWER
TEST
JACK
FIELD WIRING
INTERNAL WIRING
NC
COMMON
NO
NC
A1
120 Vac FLAME SIGNAL
TEST
PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
OUTPUTS SHOWN ARE WHEN THE
DEVICE DOES
NOT SEE FLAME.
L1
(HOT) L2
3
A2
B1
10
8
9
14
F
G
22
1
COMMON13
NO15
L2
OPTIONAL KEYBOARD
DISPLAY MODULE
REMOTE
RESET
DDL
DDL
COMMUNICATIONS
RS485
123
1
M9259
9K
B2
9K
2
2
RM7823A
INSTALLATION
!WARNING
FIRE OR EXPLOSION HAZARD CAN
CAUSE PROPERTY DAMAGE, SEVERE
INJURY, OR DEATH
Verification of safety requirements must be per-
formed each time a control is installed on a burner
to prevent possible hazardous burner operation.
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 on
the product to make sure the product is suitable for your
application.
3. Installer must be a trained, experienced flame safe-
guard service technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
!CAUTION
1. Disconnect the power supply before begin-
ninginstallationtopreventelectricalshockand
equipment damage. More than one power sup-
ply disconnect may be involved.
2. Wiring connections for the RM7823A 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 (Line Voltage) wiring.
5. Loads connected to the RM7823A must not
exceed those listed on the RM7823A label or
the Specifications, see Table 1.
6. Allexternaltimersmustbelistedorcomponent
recognizedbyauthoritieswhohavejurisdiction
forthespecificpurpose forwhich theyare used.
Fig. 6—Internal block diagram of the RM7823A (see Fig. 7 for detailed wiring instructions).

65-0106—2 10
RM7823A
INSTALLATION • WIRING
Wiring
1. Refer to Fig. 7 for proper subbase wiring. For proper
wiring of optional Keyboard Display Module mounted
remotely, DATA CONTROLBUS MODULE™, Remote
Reset Module or Communication Interface Base Unit, refer
to Specifications, form no. 65-0090, 65-0091, 65-0095 or
63-2278, respectively.
2. Disconnect the power supply from the main discon-
nect before beginning installation to prevent electrical
shock and equipment damage. More than one disconnect
may be involved.
3. Allwiringmustcomplywithallappropriateelectrical
codes, ordinances and regulations. Wiring, where required,
must comply with NEC Class 1 (Line Voltage) wiring.
4. Recommendedwiresizeandtype:useno.14,16,or18
copper conductor (TTW60C or THW75C or THHN90C),
600 volt insulation wire for all line voltage terminals. For
high temperature installations, use wire selected for a tem-
perature rating above the maximum operating temperature.
All leadwires must be moisture resistant.
5. Recommended grounding practices:
a. Use the earth ground to provide a connection be-
tween the subbase and the control panel or the
equipment.Theearthground wire mustbecapable
of conducting the current to blow the 20A fuse
(or breaker) in event of an internal short circuit.
The RM7823A needs a low impedance ground
connection to the equipment frame which, in
turn, needs a low impedance connection to earth
ground. For a ground path to be low impedance at
RF frequencies, the connection must be made with
minimum length conductors that have a maximum
surface area. Wide straps or brackets are preferred
rather than leadwires. Be careful to verify that me-
chanically tightened joints along the ground path,
such as pipe or conduit threads or surfaces held
togetherwithfasteners,arefreeof nonconductive
coatings and are protected against corrosion on
mating surfaces.
b. Ground the earth ground terminal with wire as
shortas practical for each RM7823A that must be
grounded to the metal control panel. Each ground
wire must be capable of carrying a fault current
equal to the rating of the protective fuse (20A). A
number 14 copper conductor is adequate but
wide straps or brackets are preferred rather than
leadwires.
6. Recommended wire routing for flame detector
leadwires:
a. Do not run high voltage ignition transformer
wiresinthesameconduitwiththeflamedetection
wiring.
b. Do not route scanner wires in a conduit with line
voltage circuits.
VIBRATION
Do not install the RM7823A where it could be subjected
to excessive vibration, 0.5G continuous maximum.
WEATHER
The RM7823A is not designed to be weather tight. If
installed outdoors, the RM7823A must be protected by a
weather-tight, NEMA 4 enclosure.
MOUNTING WIRING SUBBASE
NOTE: For installation dimensions, see Figs. 1 or 2.
1. Mountthesubbaseinanypositionexcepthorizontally
with the bifurcated contacts pointing down. The standard
vertical position is recommended. Any other position de-
creases 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, installa-
tion,accessandremovaloftheRM7823A,DustCover,flame
amplifier, flame amplifier signal voltage probes, electrical
signal voltage probes and electrical field connections.
3. For surface mounting, use the back of the subbase
as a template to mark the four screw locations. Drill the
pilot holes.
4. Insert the mounting screws using the four no. 6
screws and securely tighten.
IMPORTANT:
1. Do not connect more than two C7012E,F or
C7076A,D Ultraviolet Flame Detectors (with self-
checking shutter) in parallel to the same terminals.
2. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in
accordance with the instructions, may cause interfer-
ence to radio communications. It has been tested and
foundtocomply withthelimitsfor a ClassBcomput-
ing device of part 15 of FCC rules, which are de-
signed to provide reasonable protection against such
interference when operated in a commercial environ-
ment. Operation of this equipment in a residential
area may cause interference; in which case, the users
attheirownexpensemayberequiredtotakewhatever
measures are required to correct this interference.
3. This digital apparatus does not exceed the Class B
limitsforradionoiseofdigitalapparatussetoutinthe
Radio Interference Regulations of the Canadian De-
partment of Communications.
HUMIDITY
Install the RM7823A where the relative humidity never
reaches the saturation point. The RM7823A is designed to
operate in a maximum 85% RH continuous, noncondensing
moisture environment. Condensing moisture may cause a
safety shutdown.

11 65-0106—2
c. Enclose scanner wires without armor cable in
metal cable or conduit.
d. Follow directions given in the flame detector
Instructions.
7. Maximum wire lengths:
a. For the RM7823A, the maximum length of
leadwire to the terminal inputs is 300 feet.
b. For the Flame Detector leadwires, the maximum
flame sensor leadwire length is limited by the
flame signal strength.
8. Make sure loads do not exceed the terminal ratings.
Refer to the label on the RM7823A or to the ratings in the
Specifications, see Table 1.
9. Check the power supply circuit. The voltage and
frequency tolerance must match those of the RM7823A. Do
notconnecttheRM7823Atoapowersupply circuit that can
have line voltage variations like on-off switching of heavy
loads.Aseparatepowersupplycircuitmayberequiredforthe
RM7823Awiththerequireddisconnectmeansandoverload
protection added.
10. Check all wiring circuits and complete the Static
Checkout,seeTable4, before installing the RM7823Aon
the subbase.
11. Install all electrical connectors.
12. Restore power to the panel.
RM7823A
INSTALLATION
Fig. 7—Wiring the RM7823A
M5153
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
MASTER
SWITCH
NORMALLY
CLOSED
NORMALLY
OPEN
COMMON
RECTIFYING FLAME
ROD, RECTIFYING
PHOTOCELL,
OR INFRARED
(LEAD SULFIDE)
FLAME DETECTOR
C7027A, C7035A, OR
C7044A ULTRAVIOLET
FLAME DETECTOR
C7012A,C,E,F OR
C7076A ULTRAVIOLET
FLAME DETECTOR
120V, 60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DO NOT CONNECT ANY WIRES TO UNUSED TERMINALS.
OUTPUTS SHOWN ARE WHEN THE DEVICE DOES NOT SEE FLAME.
L1
(HOT)
L2 1
OR
OR
BLUE
BLUE
WHITE
YELLOW
L2
WHITE
WHITE
BLACK
BLACK L1
L2
1
Q7800
2
2
NORMALLY
CLOSED
NORMALLY
OPEN
COMMON
3
3
3

65-0106—2 12
Fig. 8—Electrical panel installation.
Fig. 10—Dust Cover mounting.
RM7823A
ASSEMBLY
Assembly
MOUNTING RM7823A
NOTE: For installation dimensions, see Figs. 1 or 2.
RELAY MODULE MOUNTING
1. Mount the RM7823A vertically, see Figs. 8 or 9, or
mount horizontally with the knife blade terminals pointing
downward. When mounted on the Q7800A, the RM7823A
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 RM7823A, Dust Cover, flame amplifier,
flame amplifier signal voltage probes, electrical signal volt-
age probes and electrical connections.
a. Allowan additionaltwoinchesbelowthe RM7823A
for the flame amplifier mounting.
b. Allowan optionalthreeinchesminimumto bothsides
of the RM7823A for electrical signal voltage probes.
3. Makesurenosubbasewiringisprojectingbeyondthe
terminal blocks. Tuck wiring in against the back of the
subbase so it does not interfere with the knife blade termi-
nals or bifurcated contacts.
4. Mount the RM7823A by aligning the four L shaped
corner guides and knife blade terminals with the bifurcated
contactsonthewiringsubbaseandtighteningthetwoscrews
securely without deforming the plastic.
Fig. 9—Wall or burner installation.
MOUNTING DUST COVER
1. AlignthetwointerlockingearsoftheDustCoverwith
the two mating slots on the RM7823A, see Fig. 10.
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 RM7823A.
3. Be sure the Dust Cover is firmly in place.
INSTALLING PLUG-IN FLAME SIGNAL
AMPLIFIER
1. Disconnectthe power supply before beginning instal-
lation to prevent electrical shock and equipment damage.
More than one disconnect may be involved.
2. Align the amplifier circuit board edge connector with
thekeyedreceptacleontheRM7823A.Ensuretheamplifier
nameplate faces away from the Relay Module, see Fig. 11.
3. Push in the amplifier until the circuit board is fully
inserted into the receptacle and then push the amplifier
toward the RM7823A retaining clasp.
4. Verify the amplifier is firmly in place.
5. Perform all required checkout tests.

13 65-0106—2
Fig. 11—Flame signal amplifier mounting.
RM7823A
ASSEMBLY
INSTALLING THE FLAME DETECTOR
NOTE: Table 2 and Fig. 12 list the flame detection systems
available for use with the RM7823A. Make sure the
correct combination of amplifier and flame detector(s)
is used.
Proper flame detector installation is the basis for a reliable
installation. Refer to the Instructions packed with the flame
detector and the equipment manufacturer instructions.
Keeptheflamesignalleadwires as short as possiblefrom
the flame detector to the wiring subbase. Capacitance in-
creases with leadwire length, reducing the signal strength.
The maximum permissible leadwire length depends on the
type of flame detector, leadwire and conduit. The ultimate
limiting factor in the flame detector leadwire is the flame
signal, see Table 5.
Fig. 12—Flame detector wiring.
BLUE
YELLOW
WHITE
WHITE
BLACK
BLACK
F
G
22
L2
L1
L2
BLUE
WHITE
F
G
WHITE
BROWN
F
G
INFRARED (C7015)
ULTRAVIOLET (C7027/C7035/C7044)
SOLID STATE SELF-CHECKING
ULTRAVIOLET (C7012E,F)
BLUE
YELLOW
BLACK
BLACK
F
G
L1
L2
SOLID STATE
ULTRAVIOLET (C7012A,C)
1
22
F G
4
5
3
L2
C7076A,D ULTRAVIOLET DETECTOR
522
6
SHUTTER
G
SHUTTER
F
1
8
2
7
7800 SERIES
L1
L2
3a 3b
REMOTE
SENSOR
2b
2a
EARTH
GROUND
C7076A
OR
C7076D
TERMINAL
BLOCK
L2 (COMMON)
L1 (HOT)
G
F
X
X
FLAME ROD
G
F
X
X
PHOTOCELL
M1969B
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

65-0106—2 14
RM7823A
OPERATION
Operation
TABLE 3—LED SEQUENCE STATUS
DISPLAY INFORMATION.
Burner Sequence LEDs Energized
STANDBY POWER, FLAME and ALARM
RUN POWER, FLAMEand ALARM
RESET/ALARM POWER, FLAME and ALARM
TEST
See Table 6 for further details of Hold conditions.
Fig. 13—Sequence status LEDs.
Sequence of Operation
The RM7823A has the following operating sequences,
see Fig. 13 and Table 3.
STANDBY
The RM7823A is ready to respond to sighting of aflame
or flame simulating condition. The green POWER LED will
blink every four seconds, signifying the RM7823A is
doing internal hardware checks.
RUN
The RM7823A pulls in the two internal spdt relays and
turnsontheFLAMELEDwhenaflameorflamesimulating
condition exists. The RM7823A is now in RUN.
STATIC CHECKOUT
CAUTION
1. Use extreme care while testing the system. Line
voltage is present on most terminal connections
when power is on.
2. Open the master switch before installing or re-
moving a jumper on the subbase.
After checking all wiring, perform this checkout before
installing the RM7823A on the subbase. These tests verify
that the Q7800 Wiring Subbase is wired correctly.
NOTE:DonotperformadielectrictestwiththeRM7823A
installed. Internal surge protectors will break down and
conductacurrent.ThiscouldcausetheRM7823Atofail
the dielectric test or possibly destroy the internal light-
ning and high current transient protection components.
EQUIPMENT REQUIRED
1. Voltmeter (20 kohm/volt minimum sensitivity) set on
the 0-300 Vac scale.
2. Two jumper wires, no. 14 wire, insulated, 12 inches
(304.8 mm) long, with insulated alligator clips at both ends.
GENERAL INSTRUCTIONS
1. Perform all applicable tests listed in Static Checkout,
Table 4, in the order listed.
2. For each test, open the master switch and install the
jumperwire(s) between the subbase wiring terminals listed
in the Test Jumpers column of Table 4.
3. Close the master switch before observing operation.
4. Read the voltage between the subbase wiring termi-
nals listed in the Voltmeter column of Table 4.
5. If there is no voltage or the operation is abnormal,
check the circuits and external devices as described in the
last column.
6. Check all wiring for correct connections, tight termi-
nal screws, correct wire, and proper wiring techniques.
Replace all damaged or incorrectly sized wires.
7. Replacefaultycontrollers,limits,interlocks,actuators,
valves, transformers, motors and other devices as required.
8. Obtain normal operation for each required test before
continuing the checkout.
9. Aftercompletingeachtest,besuretoremovethetest
jumper(s).
!
CAPTIVE
MOUNTING
SCREW
DUST
COVER
RELAY
MODULE
FLAME
AMPLIFIER
RESET PUSHBUTTON
SEQUENCE
STATUS
LEDS
M7889

15 65-0106—2
Checkout
WARNING
Do not allow fuel to accumulate in the combus-
tion chamber.Iffuel isallowed toenter thecham-
berforlongerthanafewsecondswithoutigniting,
an explosive mixture could result. It is recom-
mended that you limit the trial for pilot to ten
seconds, and limit the attempt to light the main
burner to two seconds from the time the fuel has
reached the burner nozzle. In any case, do not
exceed the nominal lightoff time specified by the
equipment manufacturer. Close the manual fuel
shutoff valve(s) if the flame is not burning at the
end of the specified time.
CAUTION
1. Useextreme carewhiletesting thesystem.Line
voltageispresenton most terminalconnections
when power is on.
2. Open the master switch before removing or
installing the RM7823A.
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 the system in service until you have
satisfactorily completed all applicable tests in
this section and any others required by the
equipment manufacturer.
CAUTION
If an RM7823A is replaced with a higher func-
tioning 7800 SERIES Relay Module, the burner
willnotsequenceunlesswiringchangesaremade.
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 adjust-
ments are made. ALL tests must be satisfied with the
flame detector(s) in its FINAL position.
EQUIPMENT REQUIRED
Volt-ohmmeter (20 kohm/volt minimum sensitivity):
• 0-300 Vac capability.
• 0-6000 ohm capability.
• 0-10 Vdc capability.
CHECKOUT SUMMARY
Perform the following checks as directed by the equip-
ment manufacturer:
• Initiallightoffcheckforprovedpilot—allinstallations
using a pilot.
• Initial lightoff check for direct spark ignition of oil—
all burners using DSI.
• Pilot turndown test—all installations using a pilot.
Perform the following tests that apply:
• Preliminary inspection—all installations.
!
!
!
RM7823A
OPERATION • CHECKOUT
TABLE 4—STATIC CHECKOUT.
Test Test
No. Jumpers Voltmeter Normal Operation If Abnormal Check
1 — L2-3 LINE VOLTAGE 1. Master switch.
2. Power connected to the master Switch
2 8 - 9 — Load operation 1. Load connections to terminals 8 and 9.
without flame
sighting.
3 8 - 10 Load operation 1. Load connections to terminals 8 and 10.
when flame detected.
4 13 - 14 — Load operation 1. Load connections to terminals 13 and 14.
without flame
sighting.
5 13 - 15 — Load operation 1. Load connections to terminals 13 and 15.
when flame detected.
FINAL ALL CAUTION
After completing these tests, open the; master switch and remove all test jumpers
from the subbase terminals. Also remove bypass jumpers from limits if used.
!

65-0106—2 16
• Flame signal measurement—all installations.
• Hot refractory saturation test—all installations using
Infrared (lead sulfide) Flame Detectors.
• Hot refractory hold-in test—all installations.
• Ignition interference test—all installations using
flame rods.
• Ignition spark pick-up—all installations using Ultra-
violet Flame Detectors.
• Response to other ultraviolet sources—all installa-
tions using Ultraviolet Flame Detectors.
• Flame signal with hot combustion chamber—all
installations.
• Safety shutdown tests—all installations.
See Fig. 14 for location of component parts and see
Fig. 7 or Q7800 Specifications for terminal locations.
PRELIMINARY INSPECTION
Perform the following inspections along with proce-
dures specified by the equipment manufacturer to avoid
common problems. Make certain that:
1. Wiring connections are correct and all the terminal
screws are tight.
2. Flame detector(s) is clean, installed and positioned
properly. Consult the applicable Instructions.
3. Correct combination of amplifier and flame detec-
tor(s) is used. See Table 2 in the Specifications.
4. Plug-in amplifier is 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 pushbutton)
only if the RM7823A is powered, see Figs. 1 and 2.
9. Systemis intheSTANDBYcondition.POWER LED
is energized.
10. All limits and interlocks are reset.
RM7823A
CHECKOUT
TABLE 5—FLAME SIGNAL.
Minimum
Acceptable Maximum
Flame Flame Signal Steady Dc Expected
Detector Amplifier VoltageaDc Voltage
Flame Rod R7847A,Bc1.25 Vdc 5.0 Vdc at the
Photocell Keyboard Display
C7012A,C Module
C7012E,F R7847Cb
C7015A R7848A,Bcor
C7027A R7849A,Bc
C7035A 5.0 Vdc at a
C7044A volt-ohmmeter
C7076A,D R7886A
aThis 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.
bThe 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).
cThe flame amplifiers are AMPLI-CHECK™ type.
Fig. 14—Flame signal measurement.
FLAME SIGNAL MEASUREMENT
Measurethe flamesignalattheappropriate timesdefined
inthefollowingcheckouttests.Readtheflamesignalvoltsdc
at the flame amplifier test jacks + and—(Com).
1. Usea20kohm/voltmeterwitha0to10Vdccapability.
2. Set the 20 kohm/voltmeter 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.
4. Allowafewsecondsforthemeterreadingtostabilize.
5. If using AMPLI-CHECK™ or shutter check amplifi-
ers, read the average stable voltage, disregarding the peaks
caused by the self-checking operation.
6. ThemeterreadingmustbeasspecifiedinTable5after
all tests are completed and all adjustments are made.
NEGATIVE (-)
METER LEAD
POSITIVE (+)
METER LEAD 20K OHM/
VOLT METER
M7554

17 65-0106—2
3. Check for correct spacing on the ignition electrode:
a. 6,000V systems—1/16 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
havetobechangedtoanultravioletorinfraredflamedetec-tion
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
shouldnotbemorethan0.5VdcandtheFLAMELEDshould
not turn on.
3. If the flame signal is higher than 0.5 Vdc and the
FLAME LED does come on, consult the equipment Op-
erating 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:TheHoneywell Q624ASolidStateSpark Generator
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
(All Ultraviolet Detectors)
Under certain conditions, an ultraviolet detector will
respondtootherultravioletsourcesasifitissensingaflame.
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,checktheFlameFailureResponseTime(FFRT)
and conduct Safety Shutdown Tests under all operating
conditions.
HOT REFRACTORY SATURATION TEST
(All Infrared Detectors)
Test to be sure that radiation from hot refractory does
not mask the flickering radiation of the flame itself.
Start the burner and monitor the flame signal during
the warm-up period. A decrease in signal strength as the
refractory heats up indicates hot refractory saturation. If
saturation is extreme, the flame signal will drop below
1.25 Vdc and the system will shut down as though a flame
failure has occurred.
RM7823A
CHECKOUT
Asanoption,theflamesignalcanbecheckedbyusingthe
optional Keyboard Display Module.
If the signal is unstable or less than the minimum
acceptable voltage, check the flame detector installation
and circuitry:
1. Checkthesupply voltages atterminals3(L1) and L2
(N).Make surethemaster switchisclosed,connectionsare
correct, and the power supply is of the correct voltage and
frequency.
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 accu-
mulated dirt.
3. For a flame rod, make sure:
• Ground area is large enough.
• Flame rod is properly located in the flame.
• Temperatureattheflamerodinsulatorisnogreater
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:
• Addaheatblocktostopconductedheattravelingup
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.
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
increasestheflamesignal,itcouldcausetheFLAMELEDto
come on when the true flame signal is below the minimum
acceptable value.
Start the burner and measure the flame signal with both
ignitionandpilot(ormainburner)on,andthenwithonlythe
pilot (or main burner) on. Any significant difference
(greater than .5 Vdc) indicates ignition interference.
TO ELIMINATE IGNITION INTERFERENCE
1. Make sure there is enough ground area.
2. Besuretheignitionelectrodeandthe flame rod are on
opposite sides of the ground area.

65-0106—2 18
RM7823A
CHECKOUT
If hot refractory saturation occurs, the condition must be
corrected.Addanorificeplateinfrontofthecelltorestrictthe
viewing area. You can also try to lengthen the sight pipe or
decreasethepipesize(diameter).Continueadjustmentsuntil
you eliminate hot refractory saturation.
HOT REFRACTORY HOLD-IN TEST
(Rectifying Photocell or All Infrared Detectors)
Test to be sure hot refractory will not delay the flame
detection system response to a flameout. This condition can
delayresponsetoflamefailureandalsocanpreventasystem
restart as long as hot refractory is detected.
Tocheckrectifyingphotocellsforhotrefractoryhold-in,
operate the burner until the refractory reaches its maximum
temperature.Thenterminatethefiringcycle.Donotopenthe
master switch. Visually observe when the burner flame or
FLAME LED goes out. If this takes longer than .8 or 3
seconds (depending on the FFRT of the amplifier), the
photocell is sensing hot refractory. This condition must be
corrected as described in the last paragraph of this test.
Infrared (lead sulfide) detectors can respond to infrared
raysemittedbyahotrefractory,evenwhentherefractoryhas
visibly ceased to glow. Infrared radiation from a hot refrac-
tory is steady, but radiation from a flame has a flickering
characteristic. The infrared detection system responds only
to flickering infrared radiation; it can reject a steady signal
fromhotrefractory.Therefractorysteadysignalcanbemade
tofluctuate ifitis reflected,bentorblockedby smokeorfuel
mistwithinthecombustionchamber.Becarefulwhenapply-
ing an infrared system to verify its response to flame only.
To check infrared (lead sulfide) detectors for hot refrac-
toryhold-in,operatetheburneruntiltherefractoryreachesits
maximum temperature. If the installation has a multi-fuel
burner, burn the heaviest fuel that is most likely to reflect,
bend or obscure the hot refractory steady infrared radiation.
Whenthemaximumrefractorytemperatureisreached,close
allmanualfuelshutoffvalve(s)oropentheelectricalcircuits
of all automatic fuel valve(s). Visually observe when the
burner flame or FLAME LED goes out. If this takes longer
than three seconds, the infrared detector is sensing hot
refractory. Immediately terminate the firing cycle. Do not
open the master switch.
NOTE: Some burners continue to purge their oil lines be-
tween the valve(s) and nozzle(s) even though the fuel
valve(s) is closed. Terminating the firing cycle (instead
of opening the master switch) will allow purging of the
combustion chamber. This will reduce a buildup of fuel
vapors in the combustion chamber caused by oil line
purging.
If the detector is sensing hot refractory, the condition
mustbe corrected.Addanorificeplateinfront ofthecellto
restrict the viewing area of the detector. If this does not
correct the problem, resight the detector at a cooler, more
distant part of the combustion chamber. While resighting
the detector, be aware that it must also properly sight the
flame. When using an infrared detector, you can also try
lengthening the sight pipe or decreasing the pipe size
(diameter).Fordetails,refertothedetectorInstructionsand
the equipment Operating Manual. Continue adjustments
until hot refractory hold-in is eliminated.
FLAME SIGNAL WITH HOT COMBUSTION
CHAMBER (All Installations)
After all initial start-up tests and burner adjustments are
completed,operatethe burneruntilthe combustion chamber
isatthemaximumexpectedtemperature.Observetheequip-
ment 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.
Also check the FFRT. Lower the set point of the operat-
ing controller and observe the time it takes for the burner
flame to go out. This should be within .8 or 3 seconds
maximum depending on the amplifier selected.
Ifthe flamesignalis tooloworunsteady,check theflame
detectortemperature.Relocatethedetectorifthetemperature
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 re-
placed, 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.
1. 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. Start the system. Startup should be normal and the
burner(s) should light normally.
c. After the system sequence is in the normal RUN
periodforatleasttenseconds,closethemanualfuel
shutoff valve(s) to extinguish the burner flame.
d. The flame signal should drop below 1.25 Vdc
within .8 or 3 seconds (depending on the FFRT of
the amplifier) after the main flame goes out.
e. The loads should switch and respond as the equip-
ment manufacturer has specified.
IMPORTANT:
1. If the RM7823A fails to shut down on these tests, take
correctiveaction(refertoTroubleshooting,RM7823A
SystemDiagnostics,andreturntothebeginningofall
Checkout tests).
2. When all Checkout tests have been completed, reset
all switches to original states.

19 65-0106—2
RM7823A
TROUBLESHOOTING
Troubleshooting
(continued)
RM7823A SYSTEM DIAGNOSTICS
Troubleshooting control system equipment failures is
easier with the RM7823A self-diagnostics. The RM7823A
provides visual annunciation of internal faults (detection
system failure with AMPLI-CHECK or Shutter Check sys-
tems) by displaying the ALARM LED.
Self-diagnostics of the RM7823A enable it to detect and
annunciateinternalsystemproblemswithanALARMLED.
The RM7823A provides diagnostic information (acces-
sible by the optional Keyboard Display Module) to aid the
service mechanic to obtain information when troubleshoot-
ing the system, see Table 6.
The optional Keyboard Display Module displays se-
quence status messages indicating: STANDBY and RUN.
The selectable messages also provide visual indication, cur-
rent status and historical status of the equipment such as:
Flame Signal, Total Cycles, Total Hours, Fault History,
Diagnostic Information and Expanded Annunciator Termi-
nalStatus(ifused).Withthisinformation,mostproblemscan
be diagnosed without extensive trial and error testing. Infor-
mationavailable intheDiagnosticInformationfile includes:
Device Type, Device Suffix, Software Revision, Manufac-
turing Code, Flame Amplifier Type, and Flame Failure
Response Time.
DIAGNOSTIC INFORMATION INDEX
TheRM7823AwiththeoptionalKeyboardDisplayMod-
ulecanmonitoranddisplayflamesignalstrengthattheVFD,
seeS7800A1001KeyboardDisplayModuleSpecifications.
!
HISTORICAL INFORMATION INDEX
The RM7823A has nonvolatile memory that allows the
Relay Module to retain historical information for the six
mostrecentlockouts.Eachofthesixlockoutfilesretainsthe
cycle when the fault occurred, the hour of operation when
the fault occurred, and the fault message when the fault
occurred. The Historical Information can be viewed by the
optional S7800A1001 Keyboard Display Module.
SERVICE NOTE: A Lockout condition or restart of a
RM7823A can be accomplished by pressing the reset
pushbutton on the RM7823A, or by pressing a remote
reset pushbutton wired through an optional Keyboard
DisplayModule,DATACONTROLBUSMODULE™
or Remote Reset Module. A power-up reset will cause
an electrical reset of the RM7823A but will not reset a
lockout condition.
SERVICE NOTE: Remove the access slot covers on the
sides of the Q7800A,B to check voltages.
CAUTION
Reinstallaccessslotcoversonthe Q7800A,BSub-
base after performing voltage checks.
SERVICE NOTE: Maximum ambient operating tem-
perature of a C7012E,F Series 1 through 6 will be
reducedto125°Fbecauseofthe dutycycleoperationof
the RM7823A Relay Module.
TABLE 6—SEQUENCE AND STATUS HOLD INFORMATION.
Sequence Information
NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type.
STANDBY TheLEDindicatesthesystemstatus,POWER.TheRM7823Aremains
in STANDBY until a flame or flame simulating condition is present.
If the RM7823A is in a HOLD status, the following conditions could exist:
RUN The LEDs indicate the system status, POWER, and FLAME, which is
the period of time flame is detected by the RM7823A. During this
time, the burner is firing under the control of the operating controller.
INITIATE The LED indicates the burner status, POWER, which is a stabilization
periodfortheRM7823AtocheckforanyfluctuationsinAClinevoltage
inputs during normal operation. The minimum timing of INITIATE
period is ten seconds but if the problem exists for four minutes the
Alarm LED will be turned on.
If the RM7823A is in a HOLD status, the following conditions could exist:
INITIATE HOLD: (AC Frequency/Noise) The LED indicates the burner status, POWER, and that it is waiting for
excesslinenoisetoclearup.TheRM7823Asequencewillnotadvance
into RUN until the excess line noise, which prevents sufficient reading
of the line voltage inputs, ceases or a line frequency error (perhaps
caused by using a 60 Hz device on a 50 Hz line, or vice versa) is
corrected.

65-0106—2 20
QUALITY IS
KEY
RM7823A
TROUBLESHOOTING
TABLE 6—SEQUENCE AND STATUS HOLD INFORMATION (Continued)
Sequence Information
NOTE: Normal sequences are in bold type, while abnormal sequences are not in bold type.
INITIATE HOLD: (AC Line Dropout) TheLED indicatesthesystem status, POWER,andthat ACLinepower
has momentarily dropped out. The RM7823A sequence will return to
STANDBY until the AC Line voltage has stabilized throughout the
INITIATE sequence.
INITIATE HOLD: (AC Frequency) The LED indicates the system status, POWER, and that line frequency
is faster than the expected value. The RM7823A sequence will not
advance into RUN until the line frequency returns to the proper value
(perhaps caused by using a 60 Hz device on a 50 Hz line).
INITIATE HOLD: (Low Line Voltage) The LED indicates the system status, POWER, and that low line
voltage has occurred. The RM7823A sequence will not advance into
RUN until the line voltage is at a sufficient level for proper operating
parameters.
RESET/ALARM TEST The LED indicates the burner status, POWER and ALARM. This
condition indicates that the reset pushbutton is pressed.
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