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7800 SERIES
Relay Modules
CHECKOUT AND TEST
This publication provides general checkout and troubleshooting procedures for the 7800 SERIES Relay Modules.
SYSTEM CHECKOUT
CAUTION
Equipment Malfunction or Damage Hazard.
IMPORTANT
Each relay module type is unique. Using existing
Perform all Static Checkout Procedures in the
wiring on a relay module change can cause
applicable relay module installation instructions
equipment damage.
before starting these procedures.
Make wiring changes when a relay m
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7800 SERIES RELAY MODULES Table 1. Checkout Steps and Applicable 7800 Series Systems. Piloted Infrared Flame Flame Rod Ultraviolet Flame Checkout Step Systems DSI Systems Detectors Systems Detectors Preliminary Inspection X X X X X Flame Signal Measurement X X X X X Initial Lightoff Check for X Proved Pilot Initial Lightoff Check for X Direct Spark Ignition Pilot Turndown Test X Ignition Interference Test X Hot Refractory Saturation X Test Hot Refractory Hold-in X XXX X Test Ignition Spark Picku
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7800 SERIES RELAY MODULES b. On the subbase, jumper L1 to the ignition 17. Shut down the system by opening the burner switch or terminal; refer to the appropriate wiring diagram by lowering the setpoint of the operating controller. to determine the proper terminal. Disconnect the Make sure the main flame goes out. There may be a leadwire to the pilot valve if it is connected to the delay due to gas trapped between the valve(s) and same terminal. burner. Make sure all automatic fuel valve(s) clos
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7800 SERIES RELAY MODULES 12. Wait about three minutes. Close the master switch, If using AMPLI-CHECK™ or self-checking amplifier and 1M open the manual fuel shutoff valve(s), and try to light off ohm/volt meter, the flame signal fluctuates every time the the burner again. The first attempt may be required to amplifier does a self-check or a shutter check. purge the lines and bring sufficient fuel to the burner. 13. If the first stage burner flame is not established within NOTE: Low fuel pressur
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7800 SERIES RELAY MODULES 12. Close the master switch to recycle the burner and stop Hot Refractory Hold-in Test the sequence in the PILOT period by using the Run/ Test Switch. (Rectifying Photocell, Infrared Detectors, 13. Increase the pilot flame size by increasing its fuel flow Ultraviolet Detectors) until a smooth main flame is accomplished. 14. Reposition the flame scanner sight tube or use orifices This condition can delay response to flame failure and also until the pilot flame signal vol
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7800 SERIES RELAY MODULES 9. If the detector is relocated or resighted, or the amplifier IGNITION SPARK RESPONSE TEST is replaced, repeat all required Checkout tests. (ALL ULTRAVIOLET DETECTORS) Test to make certain that the ignition spark is not actuating SAFETY SHUTDOWN TESTS the FLAME LED: 1. Close the pilot and main burner manual fuel shut-off (ALL INSTALLATIONS) valve(s). 2. Start the burner and use the Run/Test Switch (if Perform these tests at the end of Checkout, after all other availabl
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7800 SERIES RELAY MODULES 6. Loss of flame during RUN. The KDM displays a sequence status message indicating: a. Open the main fuel manual shutoff valve(s) and STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN and open manual pilot shutoff valve(s). POSTPURGE. The selectable messages also provide visual b. Depress the RESET button. indication of current status and historical status of the c. Start the system. Start-up should be normal and equipment such as: Flame Signal, Total Cycles, Total Hours, the ma
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7800 SERIES RELAY MODULES Table 2. Keyboard Display Module Sequence and Status Hold Messages. Sequence Status INITIATE mm:ss The Keyboard Display Module (KDM) indicates the burner status, INITIATE, a stabilization period for the relay module to check for any fluctuations in ac line voltage inputs or control inputs on power up or during normal operation. The timing of the INITIATE period is either two seconds or ten seconds, depending on the model, before entering STANDBY. If the relay module is
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7800 SERIES RELAY MODULES Table 2. Keyboard Display Module Sequence and Status Hold Messages (continued). Sequence Status If the relay module is in a PURGE HOLD status, the following conditions could exist (continued): PURGE HOLD: T18 The KDM indicates the burner status and that the Low Fire Switch is jumpered. The Low Fire (Low Fire Switch Switch is bypassed, welded or otherwise prematurely closed. The system automatically adds 30 Jumpered) seconds to allow the firing rate motor additional driv
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary. Fault Code System Failure Recommended Troubleshooting Fault 1 No card is plugged into the 1. Make sure the purge card is seated properly. *No Purge Card* purge card slot. 2. Inspect the purge card and connector on the relay module for damage or contaminants. 3. Reset and sequence the relay module. 4. If the fault code reappears, replace the purge card. 5. Reset and sequence the relay module. 6. If the fault persists, replace th
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 11 Running Interlock powered at 1. Check wiring to make sure that interlocks are connected *Running ILK On* improper sequence point. properly between terminals 6 and 7. Correct any errors. 2. Reset and sequence the relay module. 3. If the fault persists, measure the voltage between terminals 6 and G (ground), then terminals 7 and G. If there is line supply vo
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 18 Flame sensed when shutter is 1. Check that flame is not present in the combustion chamber. *Flame Detected* open and no flame is expected Correct any errors. during PREPURGE. 2. Make sure that the flame amplifier and flame detector are compatible. 3. Check the wiring and correct any errors. Make sure F and G wires are in individual conduits and protected f
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 27 Start Switch was on during 1. Start Switch held on too long. *Start Switch On* PREPURGE (RM7838A, 2. Check wiring; verify that Start Switch is correctly connected. RM7838B only). 3. Make sure that the Start Switch is functioning properly and that the switch contacts are free of contaminants. 4. Reset and sequence the relay module to PREPURGE; set the Run/T
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 32 Combustion Airflow 1. Check wiring; correct any errors. *Airflow Switch* Interlock fault. 2. Inspect the fan; make sure there is no blockage of the air intake and it is supplying air. 3. Make sure the Airflow Interlock Switches are working properly and all switch contacts are free of contaminants. 4. Reset and sequence the relay module to PREPURGE. Place t
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 45 Low Fire Interlock switch failure 1. Check wiring; correct any errors. *Low Fire Sw. Off* to close or stay closed. 2. Reset and sequence the relay module. 3. Use either the manual motor position to drive the motor to the Low Fire position, or use the Run/Test Switch option, if available. Sequence to Run, drive to Low Fire and place in the Test position. Ad
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 51 Flame signal value is too high 1. Make sure that flame detector and flame amplifier are *Flame Too Strong* to be valid. compatible. 2. Remove the flame amplifier and inspect the connections. Reset the flame amplifier. 3. Reset and sequence the relay module. 4. Check the flame detector sighting position, reset and cycle. 5. Verify that no ignition noise i
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 68 Preignition Interlock fault. 1. Check wiring; correct any errors. *Preignition ILK* 2. Inspect the Preignition Interlock switches and make sure they work properly. 3. Check fuel valve operation. Valve must close within five seconds. 4. Reset and sequence the relay module. 5. During STANDBY or PREPURGE, measure the voltage between terminal 17 and G (ground)
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 109 Negative cycle test failed, 1. Make sure a good earth ground connection exists at the *Call Service* earth ground absent or line installation site and all earth ground connections are complete voltage phasing improper. and correct. 2. Make sure the relay module and all loads operate at the same line voltage phase. 3. Reset and sequence the relay module. 4
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7800 SERIES RELAY MODULES 19 65-0229—1
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7800 SERIES RELAY MODULES Home and Building Control Home and Building Control Honeywell Inc. Honeywell Limited-Honeywell Limitée Honeywell Plaza 155 Gordon Baker Road P.O. Box 524 North York, Ontario Minneapolis MN 55408-0524 M2H 3N7 Printed in U.S.A. on recycled paper containing at least 10% 65-0229—1 G.R. Rev. 4-98 www.honeywell.com 65-0229—1 post-consumer paper fibers. 20
