Honeywell S7800A2142 4-Line LCD User Manual

7800 SERIES

32-00110-07

S7800A2142 4-Line LCD Keyboard Display Module

PRODUCT DATA

The S7800A2142 is required to program the Valve Proving feature of selected 7800 Series devices.

The S7800A2142 KDM offers the following technical advancements to the 7800 SERIES devices:

• Compatible with installed Honeywell 7800 SERIES systems.

• When used with the new 7800 SERIES with Valve Proving Feature, the KDM allows for programming the Valve Proving Control feature and timing (Pass

APPLICATION

The S7800A2142 Keyboard Display Module (KDM) provides current system status along with ﬁrst-out annunciation and system diagnosis using a ﬁve-row by 64 column readout (Main screen shows 4 rows of text for better long-distance legibility, all other screens show 5 rows of text). The KDM provides local or remote annunciation of operation and fault information, remote reset, report generation, burner control data and diagnostic information. The KDM is part of the 7800 SERIES of microprocessorbased burner controls for gas, oil, coal or combination fuel single burner applications.

The 7800 SERIES is programmed to provide a level of safety, functional capabilities and features beyond the capacity of conventional controls.

Contents

FEATURES 2 SPECIFICATIONS 2 INSTALLATION 3 WIRING 5 TROUBLESHOOTING 10 APPENDIX A: DISPLAY SETUP 28

Code protected feature).

• When used with the new 7800 SERIES with Postpurge feature, the KDM allows for programming the Postpurge time (Pass Code protected feature).

• Allows for naming the S7830 Expanded Annunciator terminals to match your system drawings. (Displayed message only.) (Pass Code protected feature.)

• An eight line (available by scrolling) by twenty column readout set of “Call Service” (Business Card) alpha/numeric directions can be displayed instead of the standard lockout display message. (Pass Code protected feature).

• Enable ModBus communication feature.

• Conﬁgure language for English, Spanish, or French.

• On-line troubleshooting guide.

APPENDIX B: BURNER CONTROL COMMISSIONING 43 APPENDIX C: DIAGNOSTICS 48 APPENDIX D: ANNUNCIATOR TERMINAL MESSAGES 50 APPENDIX E: MODBUS FUNCTION 51

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

The Business Card (Call Service) and Expanded Annunciator can be made up using:

• Capital letters (A through Z in conﬁgured language).

• Lower case letters (a through z in conﬁgured language).

• Numbers (0 through 9).

• Symbols (!, @, #, $,%, etc.).

Programming can be done with the S7800 KDM mounted on a 7800 SERIES Relay Module or with a 13 Vdc power source connected to the KDM through the 203541 5-wire connector.

Since your Business Card (Call Service) S7800A2142 will be left at the job site, programming your personal three-number password and personal lockout message can be set up ahead of time without being connected to a 7800 SERIES device.

FEATURES

• Application ﬂexibility.

• Communication interface capability.

– Through Q7700 Network Interface Unit – Through 203541 Connector on the

ModBus data high- way.

• Dependable, long-term operation provided by microcomputer technology.

• First-out annunciation and system diagnostics provided by a 5-line by 64-character display.

• First-out expanded annunciation with 24 limit and interlock Light Emitting Diodes (LEDs).

• Local or remote annunciation of operation and fault information.

• UL NEMA Class 4 rating when p/n 204729A,C NEMA 4 cover is used.

• Remote reset.

• Report generation.

• On-line troubleshooting guide.

• Burner controller data:

– Sequence status. – Sequence time. – Hold status. – Lockout/alarm status. – Flame signal strength. – Expanded annunciator status. – Total cycles of operation. – Total hours of operation. – Fault history of six most recent faults:

• Cycles of operation at time of fault.

• Expanded annunciator data at time of fault.

• Fault message and code.

• Hours of operation at time of fault.

• Sequence status at time of fault.

• Sequence time at time of fault

– Diagnostic information:

320011007 2

• Device type.

• Flame ampliﬁer type.

• Flame failure response time (FFRT).

• Manufacturing code.

• On-Off status of all digital inputs and

• Prepurge time

• Postpurge time

• Valve Proving mode

• Valve Proving time

• Software revision and version of 7800

• Relay Module and KDM.

• Status of conﬁguration jumpers.

• Status of Run/Test Switch.

• Reset count

• Reset reason

SPECIFICATIONS

Electrical Ratings:

Voltage and Frequency: 13 Vdc peak full

wave rectiﬁed (+20%/- 15%).

Power Dissipation: 7W maximum. VA

consumption: 2 VA maximum.

Terminal Ratings:

Power: 13 Vdc peak full wave rectiﬁed.

Earth Ground.

Environmental Ratings:

Ambient Temperature Ranges: Operating: 0 °F (-18 °C) to +140 °F (+60 °C). Storage: -22 °F (-30 °C) to +158 °F (+70 °C). Humidity: 85% relative humidity

continuous, noncondensing.

NOTE: UL NEMA Class 4 rating when P/N

Vibration: 0.5G environment.

Mechanical:

Dimensions: See Fig. 1. Weight: 4 oz. (124 grams), unpacked.

Display:

5 rows by 64 columns with title and

navigation bar.

Languages:

S7800A2142 English/Spanish/French

Language display.

Approvals:

Underwriters Laboratories Inc. Listed: File

No. MP268, guide No. MCCZ.

Factory Mutual Approved: Report No.

J.I.1V9A0.AF. IRI: Acceptable.

Federal Communications Commission: Part

15, Class B emissions.

outputs.

SERIES.

204729A,C NEMA 4 Cover is used.

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

4.85

(123.3)

2.75

(69.8)

.17

(4.3)

2.63

(66.8)

.18

(4.6)

.91

(23.1)

.99

(25.1)

.22

(5.7)

.59 (15)

.32

(8.1)

3.76

(95.4)

.21

(5.4)

.78

(19.8)

.11

(2.9)

.34

(8.8)

.52

(13.2)

1.14 (29)

4.19

(106.4)

1.97 (50)

.10

(2.5)

.10

(2.4)

1.84

(46.7)

EN60730: For compliance with remote

KDM mounting require- ments, provide electrical insulation separation by insulation using double or reinforced insulation. Do this by: Optically isolating the communication or remote reset lines from the control cabinet, or provide physical separation from the communication or remote display cover assembly (part number 204729A) or other suitable enclosure that meets the IP40 class of protection.

Accessories:

203541 ControlBus™ 5-wire Electrical

Connector. S7810A1009 Data ControlBus™ Module. 203765 Remote Display Mounting Bracket. 221818A 60 in. (1.5 m) Extension Cable

Assembly. 221818C 120 in. (3 m) Extension Cable

Assembly. 204729A NEMA 4 Cover Assembly for

S7800A KDM. 204729C NEMA 4 Cover Assembly for

S7800A KDM with reset button. 205321B Remote Display Flush Mount Kit.

Disconnect the power supply before beginning installation to prevent electrical shock and equipment damage. More than one power supply disconnect can be involved.

When Installing This Product…

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and marked on the product to make sure the product is suitable for your application.

3. Installer must be a trained, experienced, ﬂame safeguard service technician.

4. After installation is complete, check out the product operation as provided in these instructions.

5. Be sure wiring complies with all applicable codes, ordinances and regulations.

6. See Fig. 3 for S7800A unique wiring connections.

IMPORTANT

1. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, can cause interference to radio communications. It has been tested and found to comply with the limits for a Class B computing device of Part 15 of FCC rules which are designed to provided reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area can cause interference, in which case, users, at their own expense, can be required to take whatever measures are required to correct this interference.

2. This digital apparatus does not exceed the Class B limits for radio noise for digital

Fig. 1. Approximate dimensions of S7800A2142

in. (mm).

INSTALLATION

WARNING

Electrical Shock Hazard. Can cause severe injury, death

apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications.

Humidity

Install the S7800A where the relative humidity never reaches the saturation point. The S7800 is designed to operate in a maximum 85% RH continuous, noncondensing, moisture environment.

Vibration

Do not install the S7800A where it can be subjected to vibration in excess of 0.5G continuous maximum vibration.

or property damage.

3 320011007

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Temperature

Temperatures below 32 °F (0 °C) may cause a slow screen refresh rate and ghosting. This effect will be most evident during cold start-up (display has not been operating and is in a < 32 °F (0 °C) environment). This is due to the time required for the display to warm up. The display has a heater feature which can be set to automatic/ON/OFF (refer to page 42 Heater Mode)

If the display does not fully recover within 5 minutes, then check the systems line input voltage to insure it is within speciﬁcations.

For certain RM/ EC7800xx models the display heater (used to improve display legibility in colder temperatures) will not be available and will not function regardless of what the setting is in the display module Heater Mode.

Refer to page 43 Models that do not use the Heater Function for a list of relay models that do not use the heater function.

Weather

The S7800A is not designed to be weather tight. If installed outdoors, the S7800A must be protected by an approved

weather-tight enclosure such as the 204729A or 204729C NEMA 4 Enclosure listed in Accessories.

S7800A2142 Embedded Features

See Appendix A to set up the following features:

• Call Service (Business Card) information displayed when burner system is in Lockout of the 7800 SERIES device.

• Customizing of Expanded Annunciator (S7830) message to match a given installed limit string. If ModBus Feature is required, use S7810M1003 ModBus Module.

• ModBus communication setup and enable feature: Note that this will occupy terminals 1, 2, 3 of the 203541 Connector on the KDM, which disables the Expanded Annunciator Features.

SERVICE NOTE:

The S7800A2142 can either do the Expanded Annunciator Feature or ModBus -- not both. If BOTH are required, order the S7810M1003 ModBus Module for the ModBus option.

B. The S7800A2142 KDM is also used to program the Valve Prov- ing and Postpurge feature of Select RM7800 SERIES devices. See Appendix B.

320011007 4

Mounting KDM on 7800 SERIES Relay Module.

1. Align the two interlocking ears of the KDM with the two mating slots on the 7800 SERIES Relay Module. See Fig. 2.

Fig. 2. Keyboard Display Module mounting.

2. Insert the two interlocking ears into the two mating slots and, with a hinge action, push on the lower corners of the KDM to secure it to the 7800 SERIES Relay Module.

3. Make sure the KDM is ﬁrmly in place.

Remote Mounting KDM

The KDM can be mounted either on the face of a panel door or on other remote locations. When mounting the KDM on the face of a door panel, closely follow these instructions:

1. Select the location on the door panel for ﬂush mounting.

2. Pay attention to the insertion dimensions of the two KDM screws, two interlocking ears, and the two plugin connections to allow for sufﬁcient clearance.

3. Use the KDM or Data ControlBus Module™ as a template (Fig. 28) and mark the two screw locations, interlocking ear locations and the two plug-in connector locations.

4. Drill the pilot holes for the mounting screws.

5. Cut holes in the door panel for the interlocking ears and the two plug-in connectors.

6. Mount the KDM, securing it with the two screws provided in the KDM bag assembly.

Remote Display Mounting Bracket

Use the 203765 Remote Display Mounting Bracket when mounting the KDM on a wall or remote location:

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

1. Use the 203765 Remote Display Mounting Bracket as a template to mark the four screw locations.

2. Drill the pilot holes for the four mounting screws.

3. Mount the 203765 Remote Display Mounting Bracket by securing the four no. 6 screws (M3.5 x 0.6).

4. Mount the KDM by aligning the two interlocking ears with the two mating slots on the remote mounting bracket.

5. Insert the two interlocking ears into the two mating slots.

6. Push on the lower corners of the KDM to secure it to the remote mounting bracket.

7. Make sure the KDM is ﬁrmly in place.

WIRING

WARNING

Electrical Shock Hazard. Can cause severe injury or

death.

To prevent electrical shock and equipment damage, disconnect the power supply from the main disconnect before beginning installation. More than one disconnect can be involved.

1. Refer to Fig. 3 for proper wiring.

2. Make sure all wiring complies with all

applicable electrical codes, ordinances and regulations.

3. For recommended wire size and type, see Table 1.

4. For Recommended grounding practices, see Table 2.

5. For KDM: The KDM is powered from a low voltage, energy- limited source. It can be mounted outside of a control panel if it is protected from mechanical damage.

NOTE: A 13 Vdc power supply must be

used any time more than one KDM is used. A maximum of two KDM, Data ControlBus™ Modules or S7810B Multi-Drop Switch Modules are allowed in any combination.

Application

Keyboard Display Module

Data ControlBus™ Module

Remote Reset Module

Communications Interface ControlBus Module™

13 Vdc full wave rectiﬁed transformer power input.

Table 1. Recommended Wire Size and Part Number.

Recommend-

ed Wire Size

22 AWG twowire twisted pair with ground, or ﬁve-wire. 22 AWG twowire twisted pair with ground, or ﬁve-wire. 22 AWG twowire twisted pair, insulated for low voltage.

22 AWG two-wire twisted pair with ground.

18 AWG wire, insulated for voltages and temperatures for given applications.

Ground Type Recommended Practice

Signal ground (KDM, Data ControlBus™ Module, Communications Interface ControlBus Module™).

Table 2. Recommended Grounding Practices.

Use the shield of the signal wire to ground the device to the signal ground terminals [3(c)] of each device. Connect the shield at both ends of the daisy chain to ground.

6. Recommended wire routing: a. ControlBus:

(1) Do not route the ControlBus cable

in conduits that carry line voltage circuits.

(2) Avoid routing the ControlBus cable

close to ignition transformer leadwires.

(3) Route the ControlBus cable outside

of conduit if properly supported and protected from damage.

b. Remote Reset:

(1) Do not run high voltage ignition

transformer wires in the same conduit with the Remote Reset wiring.

(2) Do not route Remote Reset wires in

conduit with line voltage circuits.

Recommended

Part Num-

ber

Belden 8723 shielded cable or equivalent. Belden 8723 shielded cable or equivalent.

—

Belden 8723 shielded cable or equivalent.

TTW60C, THW75C, THHN90C

7. Maximum wire lengths: (a) KDM: The maximum length

interconnecting wire is 4000 ft (1219m).

5 320011007

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

S7810 DATA CONTROLBUS MODULEª

A CABINET DOOR.

(b) Remote Reset leadwires: The

maximum length wire is 1000 ft

(MOUNTED ON 7800 SERIES RELAY MODULE)

(300m) to a Remote Reset pushbutton.

8. Install all electrical connectors.

9. Restore power to the panel.

KDM Display

The ﬁrst line of the KDM display provides current status of the burner sequence (STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE), timing information (PURGE, PILOT IGN, MAIN IGN and POSTPURGE) in minutes and seconds, hold information (PURGE HOLD), and lockout information (Lockout, Fault Code, Message and Sequence). The second line will display selectable or preemptive messages. A selectable message supplies information for ﬂame strength, system status indication, system or self-diagnostics and troubleshooting. A preemptive message has parentheses around the message and supplies a detailed message to support the sequence status information. A preemptive message can also be a lockout message. A preemptive message replaces a selectable message to support the sequence status information. The 7800 SERIES Relay Module LED provide positive visual indication of the Relay Module sequence. The LED is energized simultaneously with the correct sequence description.

THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

OHM TERMINATING RESISTORS ARE REQUIRED FOR CONNECTIONS OVER 100 FEET. CABLE SHIELD MUST BE TERMINATED TO EARTH GROUND AT BOTH ENDS. IF SHIELDED CABLE IS NOT USED, TWISTED PAIR WIRE MUST BE USED.

WHEN CONNECTING THE KEYBOARD DISPLAY MODULE DATA CONTROLBUS MODULEª, OR REMOTE RESET MODULE EXTERNAL FROM THE CONTROL CABINET, APPROPRIAT E MEASURES MUST BE TAKEN TO MEET EN60730 SAFETY LOW VOLTAGE REQUIREMENTS (SEE APPROVALS).

221818A OR C EXTENSION CAN BE USED IN PLACE OF THE S7810 DATA CONTROLBUS MODULEª IF DISPLAY IS TO

Fig. 3. Wiring Keyboard Display Module for remote

mounting.

C (GND)

2345

120 OHM RESISTOR

2345

C (GND)

7800 REMOTE KEYBOARD DISPLAY MODULE

RESET

+13 VDC

RESET

+13 VDC

MOMENTARY PUSH BUTTON SWITCH

M5285C

320011007 6

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

C (GND)

MOMENTARY PUSHBUTTON SWITCH

+13 VDC

RESET

MOMENTARY PUSHBUTTON SWITCH

+13 VDC

RESET

RM78xx SERIES DEVICE WITH S7800 SERIES 5 OR GREATER DISPLAY.

PC/PLCGND

MULTI-DROP RS-485 COMMUNICATION BUS. UP TO 31 S7800 SERIES 5 OR GREATER DISPLAYS CAN BE CONNECTED TO A SINGLE BUS

WITHOUT AN RS-485 REPEATER. UP TO 99 MODBUS™ (SUBNETWORKS) CAN BE CONNECTED TO A BUS WITH RS-485 REPEATERS. WHEN USING AN RS-485 REPEATER, THE REPEATER MUST BE INSTALLED EVERY 30TH MODULE.

THE SUBNETWORKS MUST BE WIRED IN A DAISY CHAIN CONFIGURATION. RECOMMEND THAT THE PC/PLC BE AT ONE END OF THE

DAISY CHAIN.

MODBUS™ COMMUNICATION BUS TERMINATION RESISTORS:

A. WITHOUT RS-485 REPEATER: MODULES AT THE CLOSEST AND FARTHEST END OF THE DAISY CHAIN REQUIRE TERMINATION RESISTORS. INSTALL A 120 OHM, 1/4 WATT RESISTOR BETWEEN TERMINALS A AND B OF THE PC/PLC (IF INSTALLED AT ONE END THE DAISY CHAIN). INSTALL A 120 OHM, 1/4 WATT RESISTOR BETWEEN TERMINALS 7 AND 8 OF THE LAST S7810M MODBUS™ MODULE IN THE DAISY CHAIN.

B. WITH RS-485 REPEATER: WHEN AN RS-485 REATER IS USED, TWO DAISY CHAIN CONFIGURATIONS ARE EFFECTIVELY FORMED. MODULES AT THE CLOSEST AND FARTHEST ENDS OF EACH DAISY CHAIN REQUIRE TERMINATION RESISTORS. INSTALL A 120 OHM, 1/4 WATT RESISTOR BETWEEN TERMINALS A AND B OF THE PC/PLC (IF INSTALLED AT THE END OF THE DAISY CHAIN. INSTALL A 120 OHM, 1/4 WATT RESISTOR BETWEEN INPUT TERMINALS DATA+ AND DATA- OF THE RS-485 REPEATER. INSTALL A 120 OHM, 1/4 WATT RESISTOR BETWEEN TERMINALS 7 AND 8 OF THE LAST S7810M MODBUS™ MODULE IN THE ADDITIONAL DAISY CHAIN.

LOCAL RS-485 COMMUNICATIONS BUS. THE DEVICES ON THIS BUS MUST BE WIRED IN A DAISY CHAIN CONFIGURATION. THE ORDER OF

INTERCONNECTION IS NOT IMPORTANT. THE MODULES ON THE CLOSEST AND FARTHEST ENDS OF THE DAISY CHAIN REQUIRE A 120 OHM, 1/4 WATT TERMINATION RESISTOR BETWEEN TERMINALS 1 AND 2 OR A AND B.

THREE WIRE SHIELDED CABLE (BELDEN 8723 SHIELDED OR EQUIVALENT) IS RECOMMENDED AND SHOULD BE GROUNDED AS

FOLLOWS: IF NO INTERFERENCE IS PRESENT, OR TO REDUCE CAPA CITIVE INTERFERENCE, THE SHIELD SHOULD BE GROUNDED AT ONE END. WHEN GROUNDING ONLY ONE END OF THE THE SHIELD, THE SHIELD END CLOSEST TO THE S7810M MODBUS™ MODULE SHOULD BE ATTACHED TO EARTH GROUND. TO REDUCE INDUCTIVE INTERFERENCE (RF INTERFERENCE), THE SHIELD SHOULD BE GROUNDED AT BOTH ENDS.

TERMINAL NUMBERS ARE ON 203541 5-WIRE CONNECTOR (SUPPLIED WITH REMOTE MOUNTING BRACKET).

RS-485 BUS

M24190

Fig. 4. Wiring for ModBusTM Feature.

NOTE: LED has been replaced by block characters visible on the MB address setup menu.

7 320011007

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

KEYBOARD

4 LINES

LINE WITH

doesn’t make sense for the button action, selecting the button is ignored.

BUTTONS

Fig. 5. S7800 Keyboard Display Module

Keyboard Functions

The keyboard contains six push-buttons that are used to navigate on each page and between pages on the display module (see Fig. 6). These buttons generally have the following functions:

• Up arrow - move up on a page or increment a value for an input control

• Down arrow - move down on a page or decrement a value for an input control

• Left arrow - move to the left on a page (tab left) or go to a previous page

• Right arrow - move to the right on a page (tab right) or go to the next page when applicable

• OK - approve/accept the highlighted item or go to the next page when applicable

• Home - go to the Home (Main Status) page

When the burner control module is in a Lockout condition the “Home” button navigates to the Lockout page instead of the Home page to display the lockout.

These buttons are acted on when they are pressed and released. In some cases a button can be pressed and held, i.e., not released, for repeated execution of the button (arrow buttons). Buttons are active on some pages only when the action for the button makes sense for the position of the input focus on the page. If the input focus

Fig. 6. Keyboard buttons.

Page Structure

The Home and Lockout pages display text using a larger font size than all other pages so that information on them can be more easily viewed from distances farther away from the display module (see Fig. 7 and Fig.

8).

Up to 4-5 lines of text are displayed (dependent on font size) at a time on the page. When the page has more than 4 lines of text to display a scroll bar is present on the right-hand side of the page to indicate this situation. The “Up arrow” and “Down arrow” buttons are used to scroll up and down the lines of the page. Each line is highlighted with a white background to indicate that it currently has input focus for any button actions. The scroll bar adjusts to give a relative position of the current view with respect to all lines that the page can display.

When a line has a right arrow symbol positioned on the righthand side it indicates that this line can navigate to another page, “Next page”, related to the subject of the line when that line has input focus. A “Right arrow” or “OK” button can be pressed when the focus is on this line to navigate to the next page.

Fig. 7. Home page

320011007 8

SCROLL BAR

RIGHT ARROW SYMBOL INDICATES “NEXT” PAGE IS AN OPTION

INPUT FOCUS

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

4 LINES

TION

BAR

W INPUT

GO TO LOCKOUT DETAIL

Fig. 8. Lockout page

For pages other than Home and Lockout a smaller font size is used to display the text and pages have a format like the one shown in Fig. 9.

TITLE BAR

MAIN BODY

NAVIGA

Fig. 9. Page structure

The top line of the page is a title that describes the context or purpose of the page (see Fig. 9).The bottom line of the page is a navigation bar which indicates the more important button actions that can be performed for the current input focus (see Fig. 10). The middle or main body of the page contains the lines that show information or allow for user input. Up to 5 lines of text may be displayed in the main body. Solid lines separate the title and navigation bar from the main body.

INPUT FOCUS

Home Page

The Home page is the main status page that displays primary status of the burner control operation (see Fig. 11). This page is intended to be the primary one displayed most often when the user is not speciﬁcally looking for other information or conﬁguring the display. The following information is displayed by default:

• Burner control sequence or lockout state

• Flame signal strength

• Total cycles count

• Total run-time hours count

• Annunciator connection status

• Remote command status

The burner control sequence state may be displayed in one or two lines due to the length of the text. In case of two lines the remaining lines are pushed down to make room for the second line.

This page also permits navigation to the following pages:

• Lockout message (when burner control is in a lockout condition)

• Fault history

• Burner control diagnostic status

• Annunciator diagnostic status (when annunciator is connected)

• Burner control commissioning (supported models only)

• Display menu

MAY BE 1 OR 2 LINES (SEQUENCE STATE)

NE FOCUS

Fig. 10. Input focus

An item on a page that has input focus is usually highlighted with an inverse look (black text on white background) to distinguish it from the rest of the page. The arrow buttons move the input focus to another selectable item if another one exists on the page (some pages may only have a single focus item).

For pages that allow user input (see Fig.

10) the input value is edited on the page and then is acknowledged or conﬁrmed at another tab position on the page (“Yes” tab

Fig. 11. Home page status

An additional status line can be displayed between the burner control sequence line(s) and the ﬂame signal strength line when conﬁgured (see “Selected Status Message” on page 30). Fig. 12 shows an example with the T6 terminal (“Demand”) status displayed.

in the above example). This conﬁrmation action permits the user to cancel the editing and not commit to the change or to accept the edited value.

Fig. 12. Home page status

9 320011007

GO TO FAULT HISTORY GO TO BURNER DIAGNOSTICS

GO TO COMISSIONING (ONLY SOME MODELS)

GO TO DISPLAY

OPTIONAL SELECTED STATUS

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

The lines are scrollable using the up and down arrows. For lines that navigate to another page the right arrow or OK button is pressed when the line has input focus (highlighted) to go to the new page.

TROUBLESHOOTING

After the KDM is installed, return the 7800 SERIES to normal operation, restore power and run the system through at least one complete automatic cycle. For complete Troubleshooting and System Checkout information, see form 65-0229.

7800 SERIES System Diagnostics

Troubleshooting control system equipment failures is made easier with the 7800 SERIES self-diagnostics and ﬁrst-out annunciation. The S7800 provides visual annunciation by displaying a fault code and fault or hold message on the display.

Self-diagnostics of the 7800 SERIES enables it to detect and annunciate both external and internal system problems. Internal faults and external faults such as interlock failures, ﬂame failures and false ﬂame signals are annunciated by the KDM via the 7800 SERIES Relay Module.

The KDM displays a sequence status message indicating STANDBY, PREPURGE, PREIGNITION, SAFETY 1, PILOT IGN, PILOT STAB., MAIN IGN, RUN or POSTPURGE, as appropriate. The selectable messages also provide visual indication of current status and historical status of the equipment, such as: Flame Signal, Total Cycles, Total Hours, Fault History, Diagnostic Information and Expanded Annunciator terminal status (if used). With this information, most problems can be diagnosed without extensive trial-and-error testing.

Table 3 provides the sequence and status hold messages. These messages along with the fault messages (Table 5) can be viewed on-line in the KDM.

320011007 10

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Sequence Status

The Keyboard Display Module (KDM) indicates the burner status, INITIATE, a stabilization period for the relay module to check for any ﬂuctuations in ac line

INITIATE mm:ss

voltage inputs or control inputs on power up or during normal operation. The timing of the INITIATE period is either two seconds or ten seconds, depending on the model, before entering STANDBY.

If the relay module is in an INITIATE HOLD status, the following conditions could exist:

The KDM indicates the burner status and that it is waiting for excess line noise

INITIATE HOLD: (AC Frequency/ Noise)

to clear up, which prevents sufﬁcient reading of the line voltage inputs. The burner sequence does not advance into STANDBY until the excess line noise ceases or a line frequency error occurs; this is caused by using a 60 Hz device on a 50 Hz line, or vice versa on devices with a date code earlier than 9804, is

corrected. INITIATE HOLD: (AC Line Dropout)

The KDM indicates the burner status and that ac line power has momentarily

dropped out. The burner sequence does not advance into STANDBY until the ac

line voltage has stabilized throughout the INITIATE sequence.

The KDM indicates the burner status and that line frequency is faster than the INITIATE HOLD: (AC Frequency)

expected value. The burner sequence does not advance into STANDBY until the

line frequency returns to the proper value; this is perhaps caused by using a 60

Hz device on a 50 Hz line for devices with a date code earlier than 9804.

INITIATE HOLD: (Low Line Voltage)

The KDM indicates the burner status and that low line voltage (10% lower

than rated voltage) has occurred. The burner sequence does not advance

into STANDBY until the line voltage is at a sufﬁcient level for proper operating

parameters.

The KDM indicates the burner status, STANDBY. The burner can be placed in

STANDBY by opening the burner switch or if the operating controller indicates

STANDBY

its setpoint is satisﬁed. If a demand is present for burner operation, the burner

sequence does not advance from STANDBY to PURGE until the recycle limits

close. If an Expanded Annunciator is connected, the display messages are

enhanced. If the relay module is in a STANDBY HOLD status, the following conditions could exist:

STANDBY HOLD: F/G (Flame Detected)

STANDBY HOLD: T20(Pre-Ignition Interlock)

STANDBY HOLD: T7(Lockout Interlock)

STANDBY HOLD: T7 (Running Interlock) EC/ RM7850

The KDM indicates the burner status and that a ﬂame is detected. A demand

is present for burner operation. The sequence does not advance to PREPURGE

until the ﬂame signal clears. If the ﬂame signal does not clear within 40 sec-

onds, the relay module locks out.

The KDM indicates the burner status and that the Pre-Ignition Interlock is not

closed. A demand is present for burner operation, but the burner sequence does

not advance to PREPURGE until the Pre-Ignition Interlock proves closed. If this

time exceeds a 30 second hold, the relay module locks out.

The KDM indicates the burner status and that the Lockout Interlock is closed.

A demand is present for burner operation, but the burner sequence does not

advance to PREPURGE until the Lockout Interlock proves open. If this time

exceeds the 120 second hold, the relay module locks out.

The KDM indicates the burner status and that the Running Interlock is closed.

A demand is present for burner operation, but the burner sequence does not

advance to PREPURGE until the Running Interlock proves open. If this time

exceeds the 120 second hold, the relay module locks out.

The KDM indicates the burner status, PURGE, which is the period of time the PURGE

blower motor is running before the Ignition period. The timing of the PURGE

period is selectable. If the relay module is in a PURGE HOLD status, the following conditions could exist: PURGE HOLD: T19 (High Fire Switch)

PURGE DELAY: T19 (High Fire Switch Jumpered)

PURGE HOLD: TEST (Run/Test Switch)

11 320011007

The KDM indicates the burner status and that the High Fire Switch is not closed.

The ﬁring rate motor is driving to its PURGE rate position. If this time exceeds

four minutes and ﬁfteen seconds, the relay module locks out.

The KDM indicates the burner status and that the High Fire Switch is jumpered.

The High Fire Switch is bypassed, welded or otherwise prematurely closed. The

system automatically adds 30 seconds to allow the ﬁring rate motor additional

drive time to reach or near the open damper position before starting the PURGE

sequence.

The KDM indicates the burner status and that the Run/Test Switch is in the

TEST position. The sequence does not continue until the Run/Test Switch is

placed in the RUN position.

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Sequence Status

PURGE HOLD: T18 (Low Fire Switch Jumpered)

PURGE HOLD: F/G(Flame Detected)

PURGE HOLD: T18 (Low Fire Switch)

PURGE HOLD: T7 (Running Interlock)

PILOT IGN mm:ss

The KDM indicates the burner status and that the Low Fire Switch is jumpered.

The Low Fire Switch is bypassed, welded or otherwise prematurely closed. The

system automatically adds 30 seconds to allow the ﬁring rate motor addition-

al drive time to reach or near the closed damper position before starting the

ignition sequence.

The KDM indicates the burner status and that a ﬂame is detected. The burner

sequence does not advance through PREPURGE because a ﬂame is detected

as being present. The sequence holds waiting for the ﬂame signal to clear. If the

time exceeds 30 seconds, the relay module locks out.

The KDM indicates the burner status and that the Low Fire Switch is not closed.

The ﬁring rate motor is driving to its Low Fire position in preparation for Ignition

Trials. If this time exceeds four minutes and ﬁfteen seconds, the relay module

locks out.

The KDM indicates the burner status and that the Running Interlock is not

closed. The sequence does not advance to ignition until the Running Interlock

proves closed. If this time exceeds 30 seconds, the relay module locks out.

The KDM indicates the burner status, PILOT IGN, and the timing of the PILOT

IGN trial begins, in seconds. During this period, the relay module permits the

pilot valve to open and the pilot ﬂame to establish. If the relay module is in a PILOT HOLD status, the following conditions could exist: PILOT HOLD: TEST (Run/Test Switch)

The KDM indicates the burner status, PILOT IGN, and that the Run/Test Switch

is in the TEST position. The sequence does not continue until the Run/Test

Switch is placed in the RUN position.

The KDM indicates the burner status, MAIN IGN, and the timing of the MAIN MAIN IGN mm:ss

IGN trial begins, in seconds. During this period, the relay module permits the

main valve to open and the main ﬂame to establish.

The KDM indicates the burner status, RUN, which is the period of time after the RUN

Ignition Trials and before the operating controller setpoint is reached. During

this time, the burner is ﬁring under control of the ﬁring rate control. If the relay module is in a RUN HOLD status, the following condition could exist: RUN LOWFIRE: TEST (Run/Test Switch)

POSTPURGE mm:ss

Waiting for connection...

The KDM indicates the burner status and that the Run/Test Switch is in the

TEST position. Normal modulation or operation does not continue until the

Run/Test Switch is placed in the RUN position.

The KDM indicates the burner status, POSTPURGE, which is the period of time

after the RUN period when the blower motor continues to run. The timing of the

POSTPURGE period is ﬁfteen seconds.

The KDM has power but is waiting to receive a signal from the relay module to

continue operation.

The KDM indicates the burner status, RESET/ALARM TEST. This condition inRESET/ALARM TEST

dicates that the reset button is pressed. If it is held for more than four seconds,

the alarm output is energized. The alarm output is de-energized when the reset

button is released. Additional Sequence Status Information When An Expanded Annunciator is Connected to the Relay Module: BURNER OFF: T6 (Burner Switch)

The KDM indicates the Burner Switch is not closed. The burner sequence does

not advance to PREPURGE until the Burner Switch closes.

The KDM indicates the burner status, STANDBY, and that the Operating Control STANDBY

is not closed. The burner sequence does not advance to PREPURGE until the

Operating Control closes. STANDBY HOLD: T6 (EA Hold Message)

STANDBY HOLD: T6 (Circuit Fault)

Table 3. Keyboard Display Module Sequence and Status Hold Messages .

The KDM indicates the burner status, STANDBY, and that a limit is not closed.

The burner sequence does not advance to PREPURGE until one or all limits

close downstream from the Operating Control.

The KDM indicates the burner status, STANDBY, and that the control input is not

closed. The burner sequence does not advance to PREPURGE until the control

input closes.

320011007 12

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

The S7800 provides diagnostic information to aid the service mechanic in obtaining information when troubleshooting the system. See Table 4 for information on accessing historical and diagnostic selectable messages. Information available in the Diagnostic Information includes Device Type, Software Revision, Manufacturing Code, Flame Ampliﬁer Type, Flame Failure Response Time (FFRT), Selectable Jumper Conﬁguration Status, Run/ Test Switch Status and Terminal Status.

Information from the above table and Table 5 are viewable in the display module. The troubleshooting guide can be accessed from the Display Menu (see Fig. 13). A menu is displayed that permits access to these different sections of the guide:

• Introduction

• Faults

• Sequence and Status Hold messages

Fig. 13. Troubleshooting guide menu

The Introduction section contains brief troubleshooting tips and is presented in a scrollable paragraph form for reading using the up and down arrow buttons (see Fig. 14). The navigation bar contains the following commands that can be selected using the right and left arrow buttons:

• “Faults” – go to Troubleshooting guide Faults section

• “Exit” – exit Introduction section and return back to Troubleshooting guide menu

• “Sequence” – go to Troubleshooting guide Sequence/Status Hold section

Pressing the OK button executes the command with the current input focus.

Fig. 14. Troubleshooting guide introduction

The Faults section presents a description and recommended actions for each fault that the burner control module may have (see Fig. 15). The information is presented for a single fault code and when more lines are needed to display the information than can ﬁt on the page, the up and down arrow buttons are used to scroll through the lines.

Fig. 15. Troubleshooting guide faults section

The Faults section can be accessed starting at the beginning (see Fig. 15) or by going directly to a speciﬁc fault code (see Fig. 16).

Fig. 16. Troubleshooting guide direct fault access

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7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

The Faults navigation bar contains the following commands that can be selected using the right and left arrow buttons:

• “Prev fault” – go to previous fault code

• “Exit” - exit Faults section and return back to Troubleshooting guide menu

• “Next fault” – go to next fault code Pressing the OK button executes the command with the current input focus.

The Sequence and Status Hold section explains the meaning of different sequence state and status hold messages that can display for a burner control on the display module (see Fig. 17). The up and down arrow buttons are used to scroll the lines of the explanation.

Fig. 17. Troubleshooting guide sequence section

The Sequence/Status Hold navigation bar (see Fig. 18) contains the following commands that can be selected using the right and left arrow buttons:

• “Prev sequence” – go to previous sequence/status hold message

• “Exit” - exit Sequence/Status Hold section and return back to Troubleshooting guide menu

• “Next sequence” – go to next sequence/status hold message

Pressing the OK button executes the command with the current input focus.

Fig. 18. Troubleshooting guide sequence section (continued)

Historical Information Index

The S7800 displays historical information for the six most recent lockouts. Each of the six lockout records retains the cycle when the fault occurred, a fault code, a fault message, and burner status when the fault occurred. The fault history can be accessed from either the Home or Display Menu pages (see Fig. 19).

Fig. 19. Fault history menu

The fault history is displayed in order from most recent lockout, #1, on the ﬁrst line to the oldest lockout on the last line. The up and down arrow buttons are used to scroll to the lockout desired and the right arrow or OK button is pressed to view the fault information (see Fig. 20) for that lockout.

320011007 14

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Fig. 20. Fault history record

The fault record is scrollable using the up and down arrow buttons to see all lines of the information. The fault description can take 1 or 2 lines to display and is presented on the line(s) below the fault code line. Below the sequence time line is displayed the sequence state that the burner control was in at the time of the fault. This state description may take 1 or 2 lines to display also.

The left arrow button can be pressed to exit this fault record and go back to the Fault history menu (previous page).

The title bar displays which fault history record is displayed and indicates that the Troubleshooting guide can be navigated to using the “Next page” (right arrow) button (see Fig. 21).

GO TO TROUBLESHOOTING GUIDE

Fig. 21. Troubleshooting guide from fault history record

When the “Exit” command in the troubleshooting guide has input focus and the OK button is pressed control returns back to the fault history record.

Step Operation Press Display Comments

Press hi buttons to access

1. Diagnostic Information.

Press u button to access Diag-

2. nostic Information.

t u

STANDBY Diagnostic Information>

Use the Down/Up arrow buttons to access the "Diagnostic information" line. Use the right arrow or OK button to access the Diagnostic Information. Push the Down/Up arrow

Continue display of Diagnostic

3. Information.

Device RM7800<

buttons to scroll through the burner control diagnostic status.

Continue through remaining

diagnostic information display

— — —

following step 3 as required.

Another display can be

Press the t arrow button to

5. return to the Home page

t u

STANDBY Diagnostic Information>

selected or discontinue accessing Diagnostic Information review.

Table 4. Accessing Historical and Diagnostic Selectable Messages.

SERVICE NOTE: If the Keyboard Display Module screen is scrambled, remove and reinstall

the Keyboard Display Module and reset the 7800 SERIES Relay Module.

SERVICE NOTE: Reset the 7800 SERIES Relay Module by pressing the reset push button

on the relay module or pressing a remote reset push button wired through the Keyboard Display Module, Data ControlBus™ Module or Remote Reset Module. A power-up reset will cause an electrical reset of the 7800 SERIES Relay Module but will not reset a lockout condition.

Lockout Messages

When the 7800 SERIES is locked out, a standard lockout message is displayed unless the Call for Service feature is enabled. When the Call for Service feature is enabled a custom lockout message is displayed instead. The standard lockout message (see Fig. 22) is automatically displayed when the lockout initially occurs unless the user happens to be

15 320011007

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

ANNUNCIATED

editing a parameter on a page. In this case the lockout message waits until the user is done editing and exits the page.

FAULT CODE

DESCRIPTION

STATE AT TIME OF FAULT

GO TO LOCKOUT DETAIL

Fig. 22. Lockout message

Up to 4 lines are displayed in the standard lockout message. The top line shows the numeric fault code that determined the lockout. A description of this fault is shown on the second line and possibly on the third line if the description requires two lines to display it (only one line needed in the above example). On the next line(s) the burner control sequence state at the time of the lockout is displayed. The sequence state may need 1 or 2 lines to display (Fig. 22 required two lines). Since a maximum of 4 lines are displayed in this message, in the case when both the fault description and sequence state each need 2 lines to display their text, the second line of the sequence state is dropped to make room.

FAULT CODE

ANNUNCIATED DESCRIPTION

Fig. 23. Annunciated lockout message

When an annunciator is connected to the burner control system it may annunciate the lockout to provide more detailed information regarding the lockout. In this case the fault code is annunciated with a fault code letter and the fault description identiﬁes more speciﬁcally the cause of the fault (see Fig. 23 for an example).

On the top line of the message the input focus is on a ﬂashing “Detail” tab that permits the user to view more details about the lockout. Pressing the “Right arrow” or “OK” button navigates to a Lockout Detail page (see the following ﬁgure) that provides the following information:

• Fault code

• Fault description

• Cycle count at the time of the fault

• Run-time hours at the time of the fault

• Sequence time at the time of the fault

• Operation sequence state at the time of the fault

Fig. 24. Lockout detail

The information may take more lines to display than can ﬁt on the 5 main body lines. In this case the a scroll bar is displayed, and the up and down arrow buttons can be used to scroll to view all lines.

A ﬂashing “Troubleshoot” tab is displayed in the title bar that has input focus to indicate that the troubleshooting guide can be navigated to display what is recommended for this fault (see Fig. 25).

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7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

LOCKOUT

Fig. 25. Troubleshooting guide

When the Call for Service feature is enabled a custom message up to 8 lines is displayed instead of the standard lockout message (see Fig. 26 for an example). Only 4 lines of the custom message are displayed at a time; the ﬁrst 4 lines are displayed for 2 seconds, followed by the remaining lines for 2 seconds. The page alternates between these two sets of lines continuously. If the custom message is 4 lines or less, no alternation is needed.

GO TO LOCKOUT DETAIL

Fig. 26. Call for Service lockout message

The ﬁrst or top line of the message is not custom and is the same as the top line in the standard lockout message. This line permits the user to navigate to the Lockout Detail page.

The lockout message (standard or custom) displays continuously while the lockout condition persists. The user may elect to exit the message to view other pages by pressing the “Left arrow” or “Home” button which navigates to the Home page. The lockout condition is displayed on the Home page (see Fig. 27) which permits the user to re-display the lockout message. Pressing the “Right arrow” button when the lockout fault code line has input focus causes the lockout message to be re-displayed.

C0NDITION

GO TO LOCKOUT MESSAGE

Fig. 27. Lockout indication on Home page

The following table describes the possible faults a burner control may have and the recommended action.

Fault Code System Failure

Make sure the purge card is seated properly. Inspect the purge card and connector on the relay module for

damage or contaminants. Fault 1 *No Purge Card*

No card is plugged into the purge card slot.

Reset and sequence the relay module.

If the fault code reappears, replace the purge card.

Reset and sequence the relay module.

f the fault persists, replace the relay module.

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7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Fault Code System Failure

Fault 2 *AC Frequen/ Noise* Fault 3 *AC Line Dropout* Fault 4 *AC Frequency* Fault 5*Low Line Voltage*

Excess noise or device running on slow AC.

AC line dropout detected.

Device running on fast AC.

Low AC line detected.

Check the relay module and display module connections.

Reset and sequence the relay module.

Check the relay module power supply and make sure that

both frequency and voltage meet the speciﬁcations.

Check the backup power supply, as appropriate.

Make sure the purge card is seated properly.

Inspect the purge card and connector on the relay module for Fault 6 *Purge Card Error*

Purge card timing changed since card was initially read.

damage or contaminants.

Reset and sequence the relay module.

If the fault code reappears, replace the purge card.

Reset and sequence the relay module.

If the fault persists, replace the relay module. Fault 7 *Flame Ampliﬁer*

Flame sensed when ﬂame not present.

Check wiring and correct any errors. Make sure that ﬂame

sensor wires are in separate conduits. Check for noise cou-

pling into the ﬂame detector leadwires.

Make sure that ﬂame detector and ﬂame ampliﬁer are com-

patible.

Fault 8 *Flame Amp/ Shutter*

Flame sensed when no signal expected during shutter-check or Ampli-Check versions.

Remove the ﬂame ampliﬁer and inspect connections. Reseat

the ampliﬁer.

Reset and sequence the relay module.

If the code reappears, replace the ampliﬁer and/or the ﬂame

detector.

If the fault persists, replace the relay module.

Check that ﬂame is not present in the combustion chamber;

correct any errors.

Check wiring and correct any errors. Make sure that ﬂame

Fault 9 *Flame Detected*

Flame sensed when shutter open and no ﬂame is expected during STANDBY.

sensor wires are in separate conduits. Check for noise cou-

pling into ﬂame detector leadwires.

Remove the ﬂame ampliﬁer and inspect its connections.

Reseat the ampliﬁer. Reset and sequence the relay module.

If the code reappears, replace the ampliﬁer and/or the ﬂame

detector.

If the fault persists, replace the relay module.

Check wiring and correct any errors.

Fault 10 *Pre-Ignition ILK*

Pre-Ignition Interlock fault during STANDBY *(EC/RM7800, 7840, 7838B only).

Check Pre-Ignition Interlock switches to assure proper func-

tioning.

Check fuel valve operation.

Reset and sequence the relay module; monitor the Pre-Igni-

tion Interlock status.

If the code persists, replace the relay module.

Check wiring to make sure that interlocks are connected

properly between terminals 6 and 7. Correct any errors.

Reset and sequence the relay module.

If the fault persists, measure the voltage between terminals 6

and G (ground), then terminals 7 and G. If there is line supply

Fault 11 *Running ILK On*

Running Interlock powered at improper sequence point.

voltage present at terminal 6 when the controller is off, the

controller switch may be bad or is jumpered.

If steps 1 through 3 are correct and there is line supply volt-

age present at terminal 7 when the controller is closed and

the fault persists, check for a welded or jumpered Running

Interlock, Lockout Interlock, or Airﬂow Switch. Correct any

errors.

If steps 1 through 4 are correct and the fault persists, replace

the relay module.

320011007 18

Fault Code System Failure

Fault 12 *Lockout ILK On* Fault 13 *Airﬂow Sw. On*

Fault 14 *High Fire Sw.*

Fault 15 *Flame Detected*

Fault 16 *Flame-Out Timer*

Fault 17 *Main Flame Failure*

Fault 18 *Flame Detected*

Lockout Interlock powered at improper point in sequence. Combustion airﬂow interlock fault during STANDBY.

High Fire Interlock Switch failure to close during PREPURGE.

Flame sensed when no ﬂame is expected during STANDBY.

No ﬂame detected during Pilot Flame Establishing Period.

Main ﬂame failure during RUN after ﬂame is established and on for at least 10 seconds.

Flame sensed when shutter is open and no ﬂame is expected during PREPURGE.

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Check wiring and correct any errors.

Reset and sequence the relay module.

Use either the manual motor potentiometer to drive the motor

to the High Fire position or use the Run/Test Switch option, if

available. Sequence to Prepurge drive to High Fire and place

in the Test position. Adjust the High Fire Switch while in this

state to make sure that it closes properly.

Measure the voltage between terminal 19 and G (ground)

while in the Prepurge drive to High Fire state. Line supply

voltage should be present. If not, the switch adjustment is

incorrect and/or the switch is defective and needs replacing.

Reset and sequence the relay module. If line supply voltage

was present between the High Fire Switch and terminal 19,

and the fault still persists, replace the relay module.

Check that the ﬂame is not present in the combustion cham-

ber; correct any errors.

Make sure that the ﬂame ampliﬁer and ﬂame detector are

compatible.

Check wiring and correct any errors.

Remove the ﬂame ampliﬁer and inspect the connections.

Reseat the ampliﬁer.

Reset and sequence the relay module.

If the code reappears, replace the ampliﬁer and/or the ﬂame

detector.

If the fault persists, replace the relay module.

Measure the ﬂame signal. If one exists, make sure it meets

speciﬁcations.

Make any necessary burner adjustments using manufacturer

instructions. Make sure that the ﬂame ampliﬁer and ﬂame

detector are compatible.

If the code reappears, replace the ampliﬁer and/or the ﬂame

detector.

If the fault persists, replace the relay module.

Inspect the main fuel valve(s) and connection(s).

Make sure that the fuel pressure is high enough to supply fuel

to the combustion chamber.

Check the ﬂame detector sighting for adequate ﬂame signal

throughout the burner ﬁring rate.

Check that ﬂame is not present in the combustion chamber.

Correct any errors.

Make sure that the ﬂame ampliﬁer and ﬂame detector are

compatible.

Check the wiring and correct any errors. Make sure F and

G wires are in individual conduits and protected from stray

noise pickup.

Remove the ﬂame ampliﬁer and inspect the connectors.

Reseat the ﬂame ampliﬁer.

Reset and sequence the relay module.

If the code reappears, replace the ﬂame ampliﬁer and/or the

ﬂame detector.

If the fault persists, replace the relay module.

19 320011007

7800 SERIESS7800A2142 4Line LCD Keyboard Display Module

Fault Code System Failure

Fault 19 *Main Flame Ignition*

Flame was lost during MFEP or the ﬁrst 10 seconds of the RUN state.

Inspect the main fuel valve(s) and connection(s).

Make sure that the fuel pressure is high enough to supply fuel

to the combustion chamber.

Make sure the ﬂame detector is positioned to obtain the

required ﬂame signal strength; reset and recycle.

Check wiring and correct any errors.

Reset and sequence the relay module.

Use either the manual motor potentiometer to drive the motor

to the Low Fire position or use the Run/Test Switch option, if

available. Sequence to Prepurge drive to Low Fire and place in

Fault 20 *Low Fire Switch Off*

Low Fire Interlock switch failure to close during PREPURGE.

the Test position. Adjust the Low Fire Switch to make sure that

it closes properly.

Measure the voltage between terminal 18 and G (ground)

while in the Prepurge drive to Low Fire state. Line supply

voltage should be present. If not, the switch adjustment is

incorrect and/or the switch is defective and needs replacing.

Reset and sequence the relay module. If line supply voltage

was present between the Low Fire Switch and terminal 18,

and the fault still persists, replace the relay module.

Check wiring; correct any errors.

Inspect the fan; make sure there is no blockage of the air

intake and that it is supplying air.

Make sure the Interlock Switches are working properly and

Fault 21 *Running ILK*

Running Interlock fault during PREPURGE.

that all switch contacts are free of contaminants.

Reset and sequence the relay module to PREPURGE (place

the

Run/Test Switch in the Test position, if available). Measure

the voltage between terminals 7 and G (ground). Line voltage

should be present.

If steps 1 through 4 are correct and the fault persists, replace

the relay module. Fault 22 *Lockout ILK*

Fault 23 *Airﬂow Switch*

Fault 24 *Internal fault*

Fault 25 *Internal fault*

Lockout Interlock fault during PREPURGE.

Combustion airﬂow interlock fault during PREPURGE. The ﬂame interlock (relay module) was on when it should be off. The ﬂame interlock (relay module) was off when it should be on.

Check for F leadwire routing. Make sure routing is in its con-

duit and isolated from noise-producing circuits.

Check wiring and correct any errors.

Make sure that the Manual Open Valve Switch is fully open.

Make sure that the Manual Open Valve Switch is functioning

Fault 26 *Man-Open Sw. Off*

The Manual Open Valve Switch was off when it should be on (RM7838B only).

properly and that the switch contacts are free from contam-

inants.

Reset and sequence the relay module.

Make sure that the Manual Open Valve Switch provides an

electrical path when closed. Verify that the relay module is

receiving power at terminal 17.

If steps 1 through 5 are correct and the fault persists, replace

the relay module.

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