2nd Ave. Honeywell Relay Modules 7800 Series - Manual (Page 4)

4
7800 SERIES RELAY MODULES
65-0229—1
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 locks 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.