Honeywell 7800 Series Manual

5 (1)
7800 SERIES
Relay Modules
CHECKOUT AND TEST
This publication provides general checkout and troubleshooting procedures for the 7800 SERIES Relay Modules.
SYSTEM CHECKOUT
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.
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.
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
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Table 1. Checkout Steps and Applicable 7800 Series Systems.
Checkout Step
Preliminary Inspection X X X X X
Flame Signal Measurement X X X X X
Initial Lightoff Check for
Proved Pilot
Initial Lightoff Check for
Direct Spark Ignition Pilot Turndown Test X
Ignition Interference Test X
Hot Refractory Saturation
Test
Hot Refractory Hold-in
Test
Ignition Spark Pickup X
Response to Other Ultraviolet Sources
Flame Signal with Hot Combustion Chamber
Safety Shutdown Tests X X X X X
Piloted
Systems DSI 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.
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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.
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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.
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.
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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
.
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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.
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