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SEQUENCE
STATUS
LEDs

RESET
PUSHBUTTON

FLAME 
SIMULATOR INPUT

FLAME CURRENT
TEST JACKS

RUN/TEST SWITCH
(RM7895C,D; 
EC7895C; 
RM7896C,D)

CAPTIVE

MOUNTING

SCREW

PLUG-IN

PURGE

CARD

DUST

COVER

RELAY

MODULE

FLAME

AMPLIFIER

M7552A

RUN/TEST SWITCH
(EC7895C; RM7895C,D; RM7896C,D)

SELECTABLE CONFIGURATION JUMPERS

M7553A

HONEYWELL

POWER

PILOT

FLAME

MAIN

ALARM

RESET

DUST
COVER

PURGE 
TIMER

WIRING 
SUBBASE

CAPTIVE 
MOUNTING 
SCREW

RUN/TEST (C,D ONLY) 
SWITCH

CONFIGURATION 
JUMPERS

RELAY 
MODULE

SEQUENCE 
STATUS 
LED PANEL

RESET 
BUTTON

FLAME
AMPLIFIER

BURNER CONTRO

L

M15122

Figure 4 - RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D Relay Module Exploded View

SECTION VII - TROUBLE SHOOTING 

continued

SETTINGS AND ADJUSTMENTS
Selectable Site-Configurable Jumpers
The relay module has three site-configurable jumper
options, see Fig. 6 and Table 7. If necessary, clip the
site-configurable jumpers with side cutters and remove
the resistors from the relay module.

SERVICE NOTE: Clipping and removing a site-
configurable jumper enhances the level of safety.

Figure 5 - Sequence Status LEDs

Figure 6 - Selectable Site-Configurable Jumpers

Table 7 - Site-Configurable Jumper Options

Jumper
Number

Description

Intact

Clipped

JR1*

Pilot Flame
Establishing Period (PFEP)

10 Seconds

4

Seconds

JR2

Flame Failure Action

Recycle

Lockout

JR3

Airflow Switch (ILK)

Recycle

Lockout

Failure

IMPORTANT: Clipping and removing a jumper after
200 hours of operation causes a nonresettable Fault
110. The relay module must then be replaced.

Summary of Contents for SDFI

Page 1: ...errupteur 3 teindre toute flamme ouverte 4 Appelez imm diatement votre fournisseur de gaz AVERTISSEMENT Une installation d ficiente de m me qu un mauvais r glage modification entretien ou maintenance...

Page 2: ...ould be checked carefully for physical damage in the presence of the carrier s representative If parts are missing or damage has occurred a claim should be filed immedi ately with the carrier All Dire...

Page 3: ...e pillow block ball bearing assemblies in the fan section It is recommended that all nuts and set screws be tightened Turn fan shaft by hand to make certain that blower does not rub against blower hou...

Page 4: ...C Location of Accessories Where applicable standard or optional accessories will be placed inside the fan section of the unit for shipment and must be removed and installed by the mechanical or electr...

Page 5: ...at thermostats especially those with mercury bulb contacts be mounted on a vibration free surface The side of building columns away from the heater or interior walls are usually the location best suit...

Page 6: ...ockwise to decrease pressure Connect test instrument to pilot flame test jack located on flame safeguard relay Set all thermostats to call for heat Set inlet ductstat if applicable above outside air t...

Page 7: ...e pilot and burner a number of times to insure smooth light off Check flame signal with burner cycling through full firing range and burner profile damper operation if applicable Unit Start Up Systems...

Page 8: ...eat switch will have to be turned off for approximately five seconds to reset the ignition control D Air Pressure Switches The high air pressure switch is checked by removing the sensing tube from the...

Page 9: ...terminal is energized RM7895C D EC7895C RM7896C D f Internal system fault occurred g Purge card is removed h Purge card is bad 5 MAIN FLAME ESTABLISHING PERIOD MFEP RM7895C D EC7895C RM7896C D a Airf...

Page 10: ...ain Flame Establishing Period MFEP a After Ignition Trials and with the presence of flame the main fuel valve terminal 9 is pow ered If a flameout occurs the relay module locks out or recycles dependi...

Page 11: ...VII TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Selectable Site Configurable Jumpers The relay module has three site configurable jumper options see Fig 6 and Table 7 If necessary clip the si...

Page 12: ...IRFLOW SWITCH FLAME DETECTOR IGN AIRFLOW SW CHECK OPERATING CONTROLS AND INTERLOCKS INITIATE ALARM ALARM STANDBY POWER POWER PILOT FLAME MAIN TIMED PURGE ALARM POWER PILOT FLAME MAIN RUN STANDBY BURNE...

Page 13: ...ITIATE ALARM ALARM STANDBY POWER POWER PILOT FLAME MAIN TIMED PURGE ALARM POWER PILOT FLAME MAIN ALARM POWER PILOT FLAME MAIN RUN STANDBY BURNER START MAIN VALVE LIMITS AND BURNER CONTROLLER CLOSED 10...

Page 14: ...he appliance nameplate for high pressure The gas control full rate outlet pressure should match this rating 4 With main burner operating check the gas control flow rate using the meter clocking method...

Page 15: ...at or controller above room tempera ture to call for heat 3 Watch for ignition spark or for glow at hot surface igniter either immediately or following prepurge See IP module specifications 4 Time the...

Page 16: ...quired gas pressure 3 No gas through pilot regulator with inlet gas pressure ok 4 No gas through pilot solenoid 1 Check power source 2 Check and replace 3 Close or connect customer interlock 4 Switch...

Page 17: ...in main flame check wiring and flame rod 1 Place in Run position see technical cut sheet on flame safeguard relay 5 Type of gas natural LP supplied different from factory required type Note component...

Page 18: ...ing down the reset button 7 Correct problem Reset both switches 8 Check for power and replace if necessary 1 Low or no voltage 2 Fuse s blown 3 Customer interlock not closed or connected 4 Fan Off On...

Page 19: ...ng or replace if necessary 12 Clean or replace regulator 13 Check vent lines or replace limiters 14 Adjust setting on modulating valve or gas valve 1 See following troubleshooting guide for Maxitrol s...

Page 20: ...20 TROUBLESHOOTING GUIDE P 001004 P 001003...

Page 21: ...Inspect for loose or broken wires between amplifier terminals 1 2 and TD114 terminals 1 3 3 Connect test resistor as described in Preliminary Circuit Analysis in Section IX Follow procedures outlined...

Page 22: ...tor as described in Preliminary Circuit Analysis Turn TD114 selector dial so heater goes through its entire modulating range 3 Temporarily wire each TD114 TS114 and MR212 externally and observe heater...

Page 23: ...If on high fire control can do no more Heater unable to furnish additional heat to raise temperature 1 Replace automatic control valve 2 Correct wiring I Incorrect Discharge Air Temperature J Burned...

Page 24: ...ult Install replacement amplifier 1 Adjust to proper low fire 2 If greater than 1 5 negative pressure check equipment for clogged filters and other inlet air restrictions For other solutions consult f...

Page 25: ...read 6000 ohms 1000 T244 If TS244 TD244 are used meter should read 4500 ohms 1000 TS244 and 2100 ohms 150 TD244 3 Follow procedures outline in Preliminary Circuit Analysis in Section IX 1 Compare sen...

Page 26: ...l circuit 1 Incorrect maximum discharge air temper ature setting A1044 2 Incorrect minimum discharge air temper ature setting A1044 3 Insufficient burner capacity 4 Incorrect space temperature calibra...

Page 27: ...warranty A Maintenance Schedule 1 Weekly a Check that fan belts are tight and sheaves are aligned The fan belts can be checked every 30 days after the first 60 days of new belt run in CAUTION Do not...

Page 28: ...seals and a high operating temperature suggest too much grease Frequency of Lubrication Frequency of lubrication depends upon operating conditions The bearing operating temperature is the best index...

Page 29: ...ompare the force you have applied with the values given in the table below If the force is between the values for normal tension and 1 1 2 times normal tension the belt tension should be satisfactory...

Page 30: ...specific mixing plate or plates involved must be replaced c Put system back into operation and view burner while cycling through full firing range This will give a visual check for blocked burner port...

Page 31: ...inuous low fire 2 Remove cap B and loosen lock screw C Turn D to desired low fire adjustment Clockwise rotation reduces minimum flow rate 3 Tighten screw C replace cap B and reconnect wire to amplifie...

Page 32: ...ructed the problem can be isolated to the electron ics and this may once again be reviewed in the check list After test remove the test resistor and reconnect the Discharge Air Sensor to terminals 3 a...

Page 33: ...igure 1 except have TS144 connected in place of jumper Set A1044 MIN temperature selector at least 10 F above outdoor temperature Set A1044 MAX temperature selector at mid range Heater is now under co...

Page 34: ...s generated by the heater may create hazard ous concentration of carbon monoxide nitrogen dioxide and other combustion products in the heated space If gas fork trucks or other fossil fuel powered equi...

Page 35: ...35...

Page 36: ...4830 Transport Drive Dallas TX 75247 Phone 214 638 6010 Fax 214 905 0806 www sterlinghvac com HVAC PRODUCTS...

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