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..
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.
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.
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.
Table 1. Checkout Steps and Applicable 7800 Series Systems.
Checkout Step
Preliminary InspectionXXXXX
Flame Signal MeasurementXXXXX
Initial Lightoff Check for
Proved Pilot
Initial Lightoff Check for
Direct Spark Ignition
Pilot Turndown TestX
Ignition Interference TestX
Hot Refractory Saturation
Test
Hot Refractory Hold-in
Test
Ignition Spark PickupX
Response to Other
Ultraviolet Sources
Flame Signal with Hot
Combustion Chamber
Safety Shutdown TestsXXXXX
Piloted
SystemsDSI Systems
X
X
XXXX X
XXXX X
Infrared Flame
Detectors
X
Flame Rod
Systems
Ultraviolet Flame
Detectors
X
Preliminary Inspection
Perform the following inspections to avoid common problems.
Make certain that:
1. Wiring connections are correct and all terminal screws
are tight.
2. Flame detector(s) is clean, installed and positioned
properly. Consult the applicable Instructions.
3. Combination of amplifier and flame detector(s) is
correctly used. See the amplifier specifications.
4. Plug-in amplifier and purge card (if required) are
securely in place.
5. Burner is completely installed and ready to fire; consult
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 is reset (reset button) only if the Relay Module
is powered.
9. Run/Test Switch (if present) is in RUN position.
10. System is in STANDBY condition. STANDBY message
is displayed in the S7800 Keyboard Display Module.
11. All limits and interlocks are reset.
Flame Signal Measurement
See instructions provided with the amplifer.
INITIAL LIGHTOFF CHECKS
Proved Pilot Systems
Perform this check on all installations that use a pilot. It
should immediately follow the preliminary inspection.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this check.
1. Open the master switch.
2. Make sure that the manual main fuel shutoff valve(s) is
closed. Open the manual pilot shutoff valve. If the pilot
takeoff is downstream from the manual main fuel
shutoff valve(s), slightly open the manual main valve to
supply pilot gas flow. Make sure the main fuel is shut off
just upstream from the burner inlet, or disconnect power
from the automatic main fuel valve(s).
3. Close the master switch and start the system with a call
for heat by raising the setpoint of the operating
controller, see the relay module sequence. The 7800
Series Relay Module should start the INITIATE
sequence.
4. Let the sequence advance to PILOT IGN (status is
displayed on the Keyboard Display Module, if used),
PILOT LED turns on, ignition spark should occur and
the pilot should light. If the pilot ignites, the FLAME LED
is energized. Go to step 7.
5. If the pilot flame is not established in ten seconds (four
seconds if configuration jumper JR1 is clipped), safety
shutdown occurs. Let the sequence complete its cycle.
6. Push the reset pushbutton, and let the system recycle
once. If the pilot still does not ignite, make the following
ignition/pilot adjustments:
a.Open the master switch and remove the 7800
Series Relay Module from the subbase.
65-0229—1
2
7800 SERIES RELAY MODULES
b.On the subbase, jumper L1 to the ignition
terminal; refer to the appropriate wiring diagram
to determine the proper terminal. Disconnect the
leadwire to the pilot valve if it is connected to the
same terminal.
c.Close the master switch to energize only the
ignition transformer.
d.If the ignition spark is not strong and continuous,
open the master switch and adjust the ignition
electrode spark gap setting to the manufacturer
recommendation.
e.Make sure the ignition electrodes are clean.
f.Close the master switch and observe the spark.
g.After a continuous spark is obtained, open the
master switch and add a jumper on the subbase
from terminal L1 power to the pilot terminal 8 or
21. Reconnect the leadwire from the pilot valve if
it was disconnected in step b.
h.Close the master switch to energize both the
ignition transformer and the pilot valve.
i.If the pilot does not ignite and if the ignition spark
is still continuous, adjust the pressure regulator
until a pilot is established.
j.When the pilot ignites properly and stays ignited,
open the master switch and remove the jumper(s)
from the terminals of the subbase.
k.Check for adequate bleeding of the fuel line.
l.Reinstall the 7800 Series Relay Module on the
subbase, close the master switch, and then return
to step 4.
7. When pilot ignites, measure the flame signal. If the pilot
flame signal is unsteady or approaching the 1.25 Vdc
minimum value, adjust the pilot flame size or detector
sighting to provide a maximum and steady flame signal.
8. Recycle the system to recheck lightoff and pilot flame
signal.
9. When the MAIN LED turns on, make sure the automatic
main fuel valve is open; then smoothly open the manual
main fuel shutoff valve(s) and watch for main burner
flame ignition. When the main burner flame is
established, go to step 16.
10. If the main burner flame is not established within five
seconds or the normal lightoff time as specified by the
equipment manufacturer, close the manual main fuel
shutoff valve(s).
11. Recycle the system to recheck the lightoff and pilot
flame signal.
12. Smoothly open the manual fuel shutoff valve(s) and try
lightoff again. (The first re-attempt may have been
required to purge the lines and bring sufficient fuel to
the burner.)
13. If the main burner flame is not established within five
seconds or the normal lightoff time specified by the
equipment manufacturer, close the manual main fuel
shutoff valves(s). Check all burner adjustments.
14. If the main burner flame is not established after two
attempts:
A. Check for improper pilot size.
B. Check for excess combustion air at low fire.
C. Check for adequate low fire fuel flow.
D. Check for proper gas supply pressure.
E. Check for proper valve operation.
F.Check for proper pilot flame positioning.
15. Repeat steps 8 and 9 to establish the main burner
flame; then go to step 16.
16. With the sequence in RUN, make burner adjustments
for flame stability and Btu input rating.
17. Shut down the system by opening the burner switch or
by lowering the setpoint of the operating controller.
Make sure the main flame goes out. There may be a
delay due to gas trapped between the valve(s) and
burner. Make sure all automatic fuel valve(s) close.
18. Restart the system by closing the burner switch and/or
raising the setpoint of the operating controller. Observe
that the pilot is established during PILOT IGN and the
main burner flame is established during MAIN IGN
within the normal lightoff time.
19. Measure the flame signal. Continue to check for the
proper signal through the RUN period. Check the signal
at both High and Low Firing Rate positions and while
modulating, if applicable.
20. Run the burner through another sequence, observing
the flame signal for:
a.Pilot flame alone.
b.Pilot and main flame together.
c.Main flame alone (unless monitoring an
intermittent pilot). Also observe the time it takes
to light the main flame. Ignition of main flame
should be smooth.
21. Make sure all readings are in the required ranges
before proceeding.
22. Return the system to normal operation.
NOTE: After completing these tests, open the master switch
and remove all test jumpers from the subbase
terminals, limits/controls or switches.
Direct Spark Ignition Systems
This check applies to gas and oil burners not using a pilot. It
should immediately follow the preliminary inspection. Refer to
the appropriate sample block diagram of field wiring for the
ignition transformer and fuel valve(s) hookup.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this check.
1. Open the master switch.
2. Complete the normal ready-to-fire checkout of the fuel
supply and equipment as recommended by the
equipment manufacturer.
3. Close all manual main fuel shutoff valve(s). Check that
the automatic fuel valve(s) is closed. Make sure fuel is
not entering the combustion chamber.
4. Close the master switch and start the system with a call
for heat by raising the setpoint of the operating
controller; see the relay module sequencing. The
program sequence should start the INITIATE sequence.
5. Let the sequence advance through PREPURGE (if
applicable). Ignition spark should occur when the PILOT
LED turns on. Listen for the click of the first stage fuel
solenoid valve(s). The relay module locks out and the
ALARM LED turns on.
6. Let the 7800 Series Relay Module complete its cycle.
7. Open the manual fuel shutoff valve(s).
8. Push the reset button and the relay module recycles the
program sequence through PREPURGE (if applicable).
9. When the PILOT LED turns on, make sure that the first
stage burner flame is established. If it is, go to step 15.
10. If the first stage burner flame is not established within
four seconds, or within the normal lightoff time specified
by the equipment manufacturer, close the manual fuel
shutoff valve(s), and open the master switch.
11. Check all burner adjustments.
3
65-0229—1
7800 SERIES RELAY MODULES
12. Wait about three minutes. Close the master switch,
open the manual fuel shutoff valve(s), and try 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
four seconds, or within the normal lightoff time specified
by the equipment manufacturer, close the manual fuel
shutoff valve(s), and open the master switch.
14. If necessary, repeat steps 11 through 13 to establish
the first stage burner flame. Then go to step 15.
15. When the first stage burner flame is established, the
sequence advances to RUN. Make burner adjustments
for flame stability and input rating. If a second stage is
used, go to step 18.
16. Shut down the system by opening the burner switch or
by lowering the setpoint of the operating controller.
Make sure the burner flame goes out and all automatic
fuel valves close.
17. If used, remove the bypass jumpers from the low fuel
pressure limit and subbase.
18. If a second stage is used, make sure the automatic
second stage fuel valve(s) opened. Check the lightoff as
follows (or go to step 19):
a.Open the manual second stage fuel valve(s).
b.Restart the system by raising the setpoint of the
operating controller.
c.When the first stage burner flame is established,
watch for the automatic second stage fuel
valve(s) to open. Observe that the second stage
lights off properly.
d.Make burner adjustments for flame stability and
input rating.
e.Shut down the system by lowering the setpoint of
the operating controller. Make sure the burner
flame goes out and all automatic fuel valves
close.
f.Go to step 19.
19. Restart the system by closing the burner switch and/or
raising the setpoint of the operating controller. Observe
that the burner flame is established during PILOT IGN,
within the normal lightoff time specified by the
equipment manufacturer .
20. Measure the flame signal. Continue to check for the
proper signal through the RUN period. Check the signal
at both high and low firing rate positions and while
modulating. Any pulsating or unsteady readings require
further attention.
21. Make sure all readings are in the required ranges
before proceeding.
NOTE: On completing these tests, open the master
switch and remove all test jumpers from the
subbase terminals, limits/controls or switches.
22. Return the system to normal operation.
PILOT TURNDOWN TEST (ALL
INSTALLATIONS USING A PILOT)
Perform this check on all installations that use a pilot. The
purpose of this test is to verify that the main burner can be lit
by the smallest pilot flame that can hold in the flame amplifier
and energize the FLAME LED. Clean the flame detector(s) to
make sure that it detects the smallest acceptable pilot flame.
If using AMPLI-CHECK™ or self-checking amplifier and 1M
ohm/volt meter, the flame signal fluctuates every time the
amplifier does a self-check or a shutter check.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this test.
1. Open the master switch.
2. Close the manual main fuel shutoff valve(s).
3. Connect a manometer (or pressure gauge) to measure
pilot gas pressure during the turndown test.
4. Open the manual pilot shutoff valve(s).
5. Close the master switch and start the system with a call
for heat. Raise the setpoint of the operating controller.
The 7800 Series sequence should start, and
PREPURGE (if applicable) should begin.
6. After the PILOT LED turns on in interrupted pilot
applications, set the Run/Test Switch to the TEST
position to stop the sequence. The FLAME LED comes
on when the pilot ignites.
NOTE: If the sequence does not stop, reset the
system and make sure you set the Run/Test
Switch to TEST within the first eight seconds
of the PILOT IGN sequence.
IMPORTANT
You have 0.8 second or three seconds, depending
on PFEP selected, to position the Run/Test Switch to
the TEST position to stop the sequence after the
start of the PILOT IGN period.
7. Turn down the pilot pressure very slowly, reading the
manometer (or pressure gauge) as it drops. Stop
instantly when the FLAME LED goes out. Note the
pressure. The pilot is at the minimum turndown position.
Immediately turn up the pilot pressure until the FLAME
LED comes on again or the flame signal increases to
1.25 Vdc.
NOTE: If there is no flame for fifteen seconds with the
RUN/TEST switch in the TEST position, the
relay module loc ks out.
8. Repeat step 7 to verify the pilot gas pressure reading at
the exact point the FLAME LED light goes out.
9. Increase the pilot pressure immediately until the
FLAME LED comes on, and then turn it down slowly to
obtain a pressure reading just above the dropout point
or until the flame signal increases to 1.25 Vdc.
10. Set the Run/Test Switch in the RUN position (if used)
and let the sequence proceed. When the MAIN LED
turns on, make sure the automatic main fuel valve(s)
opens; then smoothly open the manual main fuel
shutoff valve(s) (or any other manually-opened safety
shutoff valve(s), if used) and watch for main burner
ignition. If the main burner flame is established, go to
step 18.
NOTE: This step requires two people, one to open the
manual valve(s) and one to watch for ignition.
11. If the main burner flame is not established within five
seconds, or within the normal lightoff time specified by
the equipment manufacturer, close the manual main
fuel shutoff valve(s) and open the master switch. If the
lightoff is rough, the pilot flame size is too small.
65-0229—1
4
7800 SERIES RELAY MODULES
12. Close the master switch to recycle the burner and stop
the sequence in the PILOT period by using the Run/
Test Switch.
13. Increase the pilot flame size by increasing its fuel flow
until a smooth main flame is accomplished.
14. Reposition the flame scanner sight tube or use orifices
until the pilot flame signal voltage is in the range of 1.25
to 1.50 Vdc.
15. When the main burner lights reliably with the pilot at
turndown, disconnect the manometer (or pressure
gauge) and turn up the pilot gas flow to that
recommended by the equipment manufacturer.
16. If used, remove the bypass jumpers from the subbase
terminals, limits/controls, or switches.
17. Run the system through another cycle to check for
normal operation.
18. Return the system to normal operation.
IGNITION INTERFERENCE TEST
(ALL FLAME RODS)
Ignition interference can subtract from (decrease) or add to
(increase) the flame signal. If it decreases the flame signal
enough, it causes a safety shutdown. If it increases the flame
signal, it could cause the FLAME LED to come on when the
true flame signal is below the minimum acceptable value.
Start the burner and measure the flame signal with both
ignition and pilot (or main burner) on, and then with only the
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. Be sure the ignition electrode and the flame rod are on
opposite sides of the ground area.
3. Check for correct spacing on the ignition electrode:
a.6000V 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, consider changing
the system to an ultraviolet flame detection system.
Hot Refractory Saturation Test
(All Infrared Detectors)
Start the burner and monitor the flame signal during the
warmup period. A decrease in signal strength as the
refractory heats up indicates hot refractory saturation. If
saturation is extreme, the flame signal drops below 1.25 Vdc
and the system shuts down as though a flame failure
occurred.
If hot refractory saturation occurs, the condition must be
corrected. Add an orifice plate in front of the cell to restrict the
viewing area, lengthen the sight pipe or decrease the pipe
size (diameter). Continue adjustments until hot refractory
saturation is eliminated.
Hot Refractory Hold-in Test
(Rectifying Photocell, Infrared Detectors,
Ultraviolet Detectors)
This condition can delay response to flame failure and also
can prevent a system restart if hot refractory is detected.
Infrared (lead sulfide) detectors can respond to infrared rays
emitted by a hot refractory, even when the refractory has
visibly ceased to glow. Infrared radiation from a hot refractory
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 from
hot refractory. The refractory steady signal can be made to
fluctuate if it is reflected, bent or blocked by smoke or fuel
mist within the combustion chamber. Be careful when
applying an infrared system to verify its response to flame
only.
The ultraviolet detector can respond to hot refractory above
2300°F (1371°C).
1. Operate the burner until the refractory reaches its
maximum temperature (Infrared Only).
If the installation has a multi-fuel burner, burn the
heavier fuel that is most likely to reflect, bend or
obscure the hot refractory steady infrared radiation
2. When the maximum refractory temperature is reached,
close all manual fuel shutoff valves, or open the
electrical circuits of all automatic fuel valves.
3. Visually observe when the burner flame or FLAME LED
goes out. If this takes more than three seconds, the
infrared detector is sensing hot refractory.
4. Immediately terminate the firing cycle. Lower the
setpoint to the operating controller, or set the Fuel
Selector Switch to OFF.
NOTE: Some burners continue to purge oil lines
between the valves and nozzles even though
the fuel valves are closed. Terminating the
firing cycle (instead of opening the master
switch) allows purging the combustion
chamber. This reduces a buildup of fuel vapors
in the combustion chamber caused by oil line
purging.
5. If the detector is sensing hot refractory, correct the
condition by one or more of the following procedures:
a.Add an orifice plate in front of the cell to restrict
the viewing area of the detector.
b.Resight the detector at a cooler, more distant part
of the combustion chamber. Make sure the
detector properly sights the flame.
c.Try lengthening the sight pipe or decreasing the
pipe size (diameter).
For details, refer to the detector Instructions and the
equipment Operating Manual. Continue adjustments until hot
refractory hold-in is eliminated.
Do not open the master switch
.
5
65-0229—1
7800 SERIES RELAY MODULES
IGNITION SPARK RESPONSE TEST
(ALL ULTRAVIOLET DETECTORS)
Test to make certain that the ignition spark is not actuating
the FLAME LED:
1. Close the pilot and main burner manual fuel shut-off
valve(s).
2. Start the burner and use the Run/Test Switch (if
available) to stop the sequence in the PILOT IGN
period. Ignition spark should occur, but the flame signal
should not be more than 0.5 Vdc.
3. If the flame signal is higher than 0.5 Vdc and the
FLAME LED does come on, consult the equipment
operating manual and resight the detector farther 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: The Honeywell Q624A and Q652A,B Solid State
Spark Generators prevent detection of ignition spark
when properly applied with C7027, C7035, C7044 or
C7061 Ultraviolet Flame Detectors. The Q624A and
Q652B are only for use with gas pilots; the Q652A is
only for oil applications.
Response To Other Ultraviolet Sources
Some sources of artificial light (such as incandescent or
fluorescent bulbs, mercury sodium vapor lamps and daylight)
produce small amounts of ultraviolet radiation. Under certain
conditions, an ultraviolet detector responds to these sources
as if it is sensing a flame. To check for proper detector
operation, check the Flame Failure Response Time (FFRT)
and conduct Safety Shutdown Tests under all operating
conditions.
Flame Signal With Hot Combustion Chamber
(All Installations)
1. With all initial start-up tests and burner adjustments
completed, operate the burner until the combustion
chamber is at the maximum expected temperature.
2. Observe the equipment manufacturer warm-up
instructions.
3. Recycle the burner under these hot conditions and
measure the flame signal. Check the pilot alone, the
main burner flame alone, and both together (unless
monitoring only the pilot flame when using an
intermittent pilot, or only the main burner flame when
using DSI). Check the signal at both High and Low
Firing Rate positions and while modulating, if
applicable.
4. Check the FFRT of the flame amplifier and relay
module.
5. Lower the setpoint of the operating controller and
observe the time it takes for the burner flame to go out.
This should be within the maximum FFRT.
6. If the flame signal is too low or unsteady, check the
flame detector temperature. Relocate the detector if the
temperature is too high.
7. If necessary, realign the sighting to obtain the proper
signal and response time.
8. If the response time is still too slow, replace the Plug-in
Flame Signal Amplifier.
SAFETY SHUTDOWN TESTS
(ALL INSTALLATIONS)
Perform these tests at the end of Checkout, after all other
tests are completed. If used, the external alarm should turn
on. Press the RESET pushbutton on the relay module to
restart the system.
9. If the detector is relocated or resighted, or the amplifier
is replaced, repeat all required Checkout tests.
1. Opening a Preignition Interlock during the STANDBY or
PREPURGE period (only for RM7800, EC/RM7840,
RM7838B, EC7810, EC7820, EC/RM7830, EC/
RM7850).
a.*Preignition ILK* fault is displayed on the
Keyboard Display Module. Fault code 10 or 33 is
displayed to denote the fault.
b.Safety shutdown occurs.
2. Opening a Lockout Interlock during PREPURGE,
PILOT IGN, MAIN IGN or RUN period (only for
RM7800, EC/RM7840, RM7838B, EC7810, EC7820,
EC/RM7830, EC/RM7850).
a.*Lockout ILK* fault is displayed on the Keyboard
Display Module. Fault code 11 or 12 or 21 or 29 is
displayed to denote the fault.
b.Safety shutdown occurs.
3. Detection of flame 40 seconds after entry to STANDBY
from RUN, fault code 9. Detection of flame from ten
seconds up to 30 seconds into PREPURGE time.
a.Simulate a flame to cause the flame signal
voltage level to be at least 1.25 Vdc for 40
seconds after entry to STANDBY from RUN and
also simulate a flame signal for 10 seconds to
30 seconds for PREPURGE.
b.*Flame Detected* fault is displayed on the
Keyboard Display Module. Fault code 9 or 15 or
18 is displayed to denote the fault.
c.Safety shutdown occurs.
4. Failure to ignite pilot.
a.Close pilot and main fuel manual shutoff valve(s).
b.Cycle burner on.
c.Automatic pilot valve(s) should be energized but
the pilot cannot ignite.
d.*Pilot Flame Fail* fault is displayed on the
Keyboard Display Module. Fault code 28 is
displayed four or ten seconds, depending on the
jumper configuration selection for Pilot Flame
Establishing Period (PFEP) after the pilot valve(s)
is energized to denote the fault.
e.Safety shutdown occurs.
5. Failure to ignite main (only interrupted pilot application).
a.Open the manual pilot valve(s); leave the main
fuel manual shutoff valve(s) closed.
b.Depress the RESET button.
c.Start the system.
d.The pilot should ignite and the flame signal
should be at least 1.25 Vdc but the main burner
cannot light.
e.The flame signal should drop below 1.25 Vdc
within the FFRT of the amplifier and the relay
module after the interrupted pilot goes out.
f.*Main Flame Ign.* fault is displayed on the
Keyboard Display Module. Fault code 19 is
displayed to denote the fault.
g.Safety shutdown occurs.
65-0229—1
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