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2nd Ave. 7800 Series manual

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  • Page 1

    ® U.S. Registered Trademark Copyright © 1998 Honeywell Inc. • All Rights Reserved CHECKOUT AND TEST 65-0229-1 7800 SERIES Relay Modules This publication provides gener al checkout and troub leshooting procedures for the 7800 SERIES Rela y Modules. SYSTEM CHECKOUT IMPORT ANT P erform all Static Check out Procedures in the applicable rela y modul[...]

  • Page 2

    2 7800 SERIES RELA Y MODULES 65-0229—1 T able 1. Chec kout Steps and Applicable 7800 Series Systems. Checkout Step Piloted Systems DSI Systems Infrared Flame Detectors Flame Rod Systems Ultraviolet Flame Detectors Preliminary Inspection X X X X X Flame Signal Measurement X X X X X Initial Lightoff Check for Proved Pilot X Initial Lightoff Check f[...]

  • Page 3

    7800 SERIES RELA Y MODULES 3 65-0229—1 b . On the subbase, jumper L1 to the ignition ter minal; ref er to the appropriate wir ing diagr am to deter mine the proper terminal. Disconnect the leadwire to the pilot valv e if it is connected to the same ter minal. c. Close the master switch to energiz e only the ignition transf or mer . d. If the igni[...]

  • Page 4

    4 7800 SERIES RELA Y MODULES 65-0229—1 12. W ait about three minutes. Close the master s witch, open the manual fuel shutoff v alve(s), and tr y to light off the burner again. The first attempt may be required to purge the lines and bring sufficient fuel to the burner . 13. If the first stage burner flame is not established within f our seconds, [...]

  • Page 5

    7800 SERIES RELA Y MODULES 5 65-0229—1 12. Close the master switch to recycle the b ur ner and stop the sequence in the PILOT period b y using the Run/ T est Switch. 13. Increase the pilot flame size by increasing its fuel flo w until a smooth main flame is accomplished. 14. Reposition the flame scanner sight tube or use orifices until the pilot [...]

  • Page 6

    6 7800 SERIES RELA Y MODULES 65-0229—1 IGNITION SP ARK RESPONSE TEST (ALL UL TRA VIOLET DETECT ORS) T est to mak e cer tain that the ignition spar k is not actuating the FLAME LED: 1. Close the pilot and main burner manual fuel shut-off valv e(s). 2. Star t the b ur ner and use the Run/T est Switch (if av ailable) to stop the sequence in the PILO[...]

  • Page 7

    7800 SERIES RELA Y MODULES 7 65-0229—1 6. Loss of flame during RUN. a. Open the main fuel manual shutoff valv e(s) and open manual pilot shutoff valv e(s). b . Depress the RESET button. c. Star t the system. Star t-up should be normal and the main b ur ner should light nor mally . d. After the sequence is in the nor mal R UN period for at least t[...]

  • Page 8

    8 7800 SERIES RELA Y MODULES 65-0229—1 Table 2. Keyboard Display Module Sequence and Status Hold Messages. Sequence Status INITIATE mm:ss The Keyboard Display Module (KDM) indicates the burner status, INITIATE, a stabilization period for the relay module to check for any fluctuations in ac line voltage inputs or control inputs on power up or duri[...]

  • Page 9

    7800 SERIES RELA Y MODULES 9 65-0229—1 T able 2. Keyboar d Display Module Sequence and Status Hold Messages (continued). Sequence Status If the relay module is in a PURGE HOLD status, the following conditions could exist (continued) : PURGE HOLD: T18 (Low Fire Switch Jumpered) The KDM indicates the burner status and that the Low Fire Switch is ju[...]

  • Page 10

    10 7800 SERIES RELA Y MODULES 65-0229—1 T able 3. Hold and F ault Message Summary . Fault Code System Failure Recommended Troubleshooting Fault 1 *No Purge Card* No card is plugged into the purge card slot. 1 . Make sure the purge card is seated properly. 2 . Inspect the purge card and connector on the relay module for damage or contaminants. 3 .[...]

  • Page 11

    7800 SERIES RELA Y MODULES 11 65-0229—1 T ab le 3. Hold and F ault Message Summary (continued). (continued) Fault Code System Failure Recommended Troubleshooting Fault 11 *Running ILK On* Running Interlock powered at improper sequence point. 1 . Check wiring to make sure that interlocks are connected properly between terminals 6 and 7. Correct an[...]

  • Page 12

    12 7800 SERIES RELA Y MODULES 65-0229—1 T able 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 18 *Flame Detected* Flame sensed when shutter is open and no flame is expected during PREPURGE. 1 . Check that flame is not present in the combustion chamber. Correct any errors. 2 . Make sure t[...]

  • Page 13

    7800 SERIES RELA Y MODULES 13 65-0229—1 T ab le 3. Hold and F ault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 27 *Start Switch On* Start Switch was on during PREPURGE (RM7838A, RM7838B only). 1 . Start Switch held on too long. 2 . Check wiring; verify that Start Switch is correctly connected. 3 . Make[...]

  • Page 14

    14 7800 SERIES RELA Y MODULES 65-0229—1 T able 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 32 *Airflow Switch* Combustion Airflow Interlock fault. 1 . Check wiring; correct any errors. 2 . Inspect the fan; make sure there is no blockage of the air intake and it is supplying air. 3 . M[...]

  • Page 15

    7800 SERIES RELA Y MODULES 15 65-0229—1 T ab le 3. Hold and F ault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 45 *Low Fire Sw. Off* Low Fire Interlock switch failure to close or stay closed. 1 . Check wiring; correct any errors. 2 . Reset and sequence the relay module. 3 . Use either the manual motor [...]

  • Page 16

    16 7800 SERIES RELA Y MODULES 65-0229—1 T able 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 51 *Flame Too Strong* Flame signal value is too high to be valid. 1 . Make sure that flame detector and flame amplifier are compatible. 2 . Remove the flame amplifier and inspect the connections[...]

  • Page 17

    7800 SERIES RELA Y MODULES 17 65-0229—1 T ab le 3. Hold and F ault Message Summary (continued). (continued) Fault Code System Failure Recommended Troubleshooting Fault 68 *Preignition ILK* Preignition Interlock fault. 1 . Check wiring; correct any errors. 2 . Inspect the Preignition Interlock switches and make sure they work properly. 3 . Check f[...]

  • Page 18

    18 7800 SERIES RELA Y MODULES 65-0229—1 T able 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 109 *Call Service* Negative cycle test failed, earth ground absent or line voltage phasing improper. 1 . Make sure a good earth ground connection exists at the installation site and all earth gr[...]

  • Page 19

    7800 SERIES RELA Y MODULES 19 65-0229—1[...]

  • Page 20

    20 7800 SERIES RELA Y MODULES 65-0229—1 65-0229—1 G.R. Re v . 4-98 Home and Building Control Honeywell Limited-Honeywell Limitée 155 Gordon Baker Road North York, Ontario M2H 3N7 Home and Building Control Honeywell Inc. Honeywell Plaza P.O. Box 524 Minneapolis MN 55408-0524 Printed in U.S.A. on recycled paper containing at least 10% post-consu[...]