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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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, ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 . ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - 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 ...
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2nd Ave. 7800 Series - page 19
7800 SERIES RELA Y MODULES 19 65-0229—1 ...
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2nd Ave. 7800 Series - 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 ...
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