Honeywell 7800 Series Manual
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Honeywell 7800 Series Manual

Relay modules
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This publication provides general checkout and troubleshooting procedures for the 7800 SERIES Relay Modules.
SYSTEM CHECKOUT
IMPORTANT
Perform all Static Checkout Procedures in the
applicable relay module installation instructions
before starting these procedures.
WARNING
Explosion Hazard.
Can cause serious injury or death.
Do not allow fuel to accumulate in the combustion
chamber for longer than a few seconds without
igniting to prevent danger of forming explosive mixture
Close manual fuel shutoff valve(s) if flame is not
burning at end of specified time.
WARNING
Electric Shock Hazard.
Can cause serious injury or death.
1.
Use extreme care while testing system. Line
voltage is present on most terminal connections
when power is on.
2.
Open master switch before removing or installing
7800 SERIES Relay Module or Keyboard Display
Module connector.
Make sure all manual fuel shutoff valve(s) are closed before
starting initial lightoff check and Pilot Turndown tests.
Do not put the system in service until you have satisfactorily
completed all applicable tests in this section and any others
recommended by the original equipment manufacturer..
Limit trial for pilot to ten seconds. Limit the attempt to light
main burner to two seconds after fuel reaches burner nozzle.
Do not exceed manufacturer nominal lightoff time.
® U.S. Registered Trademark
Copyright © 1998 Honeywell Inc. • All Rights Reserved
7800 SERIES
Relay Modules
CAUTION
Equipment Malfunction or Damage Hazard.
Each relay module type is unique. Using existing
wiring on a relay module change can cause
equipment damage.
Make wiring changes when a relay module is replaced
with a different 7800 SERIES Relay Module to
sequence burner.
IMPORTANT
1.
If the system fails to perform properly, note the
fault code, fault message, equipment status, and
sequence time on the display. Then refer to the
Troubleshooting section.
2.
Repeat all required Checkout tests after all
adjustments are made. All tests must be satisfied
with the flame detector(s) in their final position.
Equipment Recommended
S7800A Keyboard Display Module
Volt-ohmmeter (1M ohm/volt minimum sensitivity) with:
0-300 Vac capability.
0-6000 ohm capability.
0-10 Vdc capability.
Checkout Summary
Table 1 provides an overview of checkout steps performed for
each applicable system.
See Installation Instructions for location of component parts
and/or Q7800 Specifications for terminal locations.
CHECKOUT AND TEST
65-0229-1
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Summary of Contents for Honeywell 7800 Series

  • Page 1 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...

  • Page 2: Preliminary Inspection

    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 Flame Signal Measurement Initial Lightoff Check for Proved Pilot Initial Lightoff Check for...
  • Page 3 Check all burner adjustments. ALARM LED turns on. 14. If the main burner flame is not established after two 6. Let the 7800 Series Relay Module complete its cycle. attempts: 7. Open the manual fuel shutoff valve(s). Check for improper pilot size.
  • Page 4 Raise the setpoint of the operating controller. 16. Shut down the system by opening the burner switch or The 7800 Series sequence should start, and by lowering the setpoint of the operating controller. PREPURGE (if applicable) should begin.
  • Page 5 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/ (Rectifying Photocell, Infrared Detectors, Test Switch. 13. Increase the pilot flame size by increasing its fuel flow Ultraviolet Detectors) until a smooth main flame is accomplished.

  • Page 6: Ignition Spark Response Test

    0.5 Vdc. Safety shutdown occurs. 2. Opening a Lockout Interlock during PREPURGE, NOTE: The Honeywell Q624A and Q652A,B Solid State PILOT IGN, MAIN IGN or RUN period (only for Spark Generators prevent detection of ignition spark RM7800, EC/RM7840, RM7838B, EC7810, EC7820, when properly applied with C7027, C7035, C7044 or EC/RM7830, EC/RM7850).

  • Page 7: Troubleshooting

    KDM, and reset the 7800 Relay Module. on RM7800 and RM7838A,B devices; optional on all others). 2. Reset the 7800 Series Relay Module by pressing the The relay module provides 127 diagnostic messages for RESET pushbutton on the 7800 Series Relay troubleshooting the system (see Table 3).
  • Page 8 Run/Test Switch is placed in the RUN position. NOTE: Normal sequences are in bold type, while abnormal sequences are in regular type. This table is for all 7800 SERIES Relay Modules so all listed steps may not apply to the unit installed.
  • Page 9 PREPURGE until the control input closes. NOTE: Normal sequences are in bold type, while abnormal sequences are in regular type. This table is for all 7800 SERIES Relay Modules so all listed steps may not apply to the unit installed.
  • Page 10 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 Make sure the purge card is seated properly. *No Purge Card* purge card slot. Inspect the purge card and connector on the relay module for damage or contaminants.
  • Page 11 7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 11 Running Interlock powered at Check wiring to make sure that interlocks are connected *Running ILK On* improper sequence point. properly between terminals 6 and 7. Correct any errors.
  • Page 12 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 Check that flame is not present in the combustion chamber. *Flame Detected* open and no flame is expected Correct any errors.
  • Page 13 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 Start Switch held on too long. *Start Switch On* PREPURGE (RM7838A, Check wiring; verify that Start Switch is correctly connected.
  • Page 14 7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 32 Combustion Airflow Check wiring; correct any errors. *Airflow Switch* Interlock fault. Inspect the fan; make sure there is no blockage of the air intake and it is supplying air.
  • Page 15 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 Check wiring; correct any errors. *Low Fire Sw. Off* to close or stay closed. Reset and sequence the relay module.
  • Page 16 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 Make sure that flame detector and flame amplifier are *Flame Too Strong* to be valid.
  • Page 17 7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 68 Preignition Interlock fault. Check wiring; correct any errors. *Preignition ILK* Inspect the Preignition Interlock switches and make sure they work properly.
  • Page 18 7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Recommended Troubleshooting Fault 109 Negative cycle test failed, 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.
  • Page 19 7800 SERIES RELAY MODULES 65-0229—1...
  • Page 20 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.