Lighting Pager User Manual

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CHECKOUT AND TEST

65-0229-1

7800 SERIES

Relay Modules

This publication provides general checkout and troubleshooting procedures for the 7800 SERIES Relay Modules.

SYSTEM CHECKOUT

IMPORTANT

Perform all Static Checkout Procedures in the

applicable relay module installation instructions

before starting these procedures.

WARNING

Explosion Hazard.

Can cause serious injury or death.

Do not allow fuel to accumulate in the combustion

chamber for longer than a few seconds without

igniting to prevent danger of forming explosive mixture

Close manual fuel shutoff valve(s) if flame is not

burning at end of specified time.

WARNING

Electric Shock Hazard.

Can cause serious injury or death.

1. Use extreme care while testing system. Line

voltage is present on most terminal connections

when power is on.

2. Open master switch before removing or installing

7800 SERIES Relay Module or Keyboard Display

Module connector.

Make sure all manual fuel shutoff valve(s) are closed before

starting initial lightoff check and Pilot Turndown tests.

Do not put the system in service until you have satisfactorily

completed all applicable tests in this section and any others

recommended by the original equipment manufacturer..

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.

CAUTION

Equipment Malfunction or Damage Hazard.

Each relay module type is unique. Using existing

wiring on a relay module change can cause

equipment damage.

Make wiring changes when a relay module is replaced

with a different 7800 SERIES Relay Module to

sequence burner.

IMPORTANT

1. If the system fails to perform properly, note the

fault code, fault message, equipment status, and

sequence time on the display. Then refer to the

Troubleshooting section.

2. Repeat all required Checkout tests after all

adjustments are made. All tests must be satisfied

with the flame detector(s) in their final position.

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.

Summary of content (20 pages)

PAGE 1
7800 SERIES Relay Modules CHECKOUT AND TEST This publication provides general checkout and troubleshooting procedures for the 7800 SERIES Relay Modules. SYSTEM CHECKOUT CAUTION IMPORTANT Perform all Static Checkout Procedures in the applicable relay module installation instructions before starting these procedures. Equipment Malfunction or Damage Hazard. Each relay module type is unique. Using existing wiring on a relay module change can cause equipment damage.
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7800 SERIES RELAY MODULES Table 1. Checkout Steps and Applicable 7800 Series Systems.
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7800 SERIES RELAY MODULES 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.
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7800 SERIES RELAY MODULES 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. 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.
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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.
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7800 SERIES RELAY MODULES 9. If the detector is relocated or resighted, or the amplifier is replaced, repeat all required Checkout tests. 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.
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800 SERIES RELAY MODULES The KDM displays a sequence status message indicating: STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN and POSTPURGE. 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. 6.
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7800 SERIES RELAY MODULES Table 2. Keyboard Display Module Sequence and Status Hold Messages. Sequence INITIATE mm:ss 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 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.
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7800 SERIES RELAY MODULES Table 2. Keyboard Display Module Sequence and Status Hold Messages (continued). Sequence Status If the relay module is in a PURGE HOLD status, the following conditions could exist (continued): PURGE HOLD: T18 (Low Fire Switch Jumpered) 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.
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary. Fault Code System Failure Fault 1 *No Purge Card* No card is plugged into the purge card slot. Recommended Troubleshooting 1. 2. 3. 4. 5. 6. Fault 2 *AC Frequen/Noise* Excess noise or device running on slow ac. Make sure the purge card is seated properly. Inspect the purge card and connector on the relay module for damage or contaminants. Reset and sequence the relay module. If the fault code reappears, replace the purge card.
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Fault 11 *Running ILK On* Running Interlock powered at improper sequence point. Recommended Troubleshooting 1. 2. 3. Fault 12 *Lockout ILK On* Lockout Interlock powered at improper point in sequence. 4. Fault 13 *Airflow Sw. On* Combustion airflow interlock fault during STANDBY. 5. High Fire Interlock Switch failure to close during PREPURGE. 1. 2. 3. Fault 14 *High Fire Sw.* 4. 5.
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code Fault 18 *Flame Detected* System Failure Flame sensed when shutter is open and no flame is expected during PREPURGE. Recommended Troubleshooting 1. 2. 3. 4. 5. 6. 7. Fault 19 *Main Flame Ign.* Flame was lost during MFEP or the first 10 seconds of the RUN state. 1. 2. 3. Fault 20 *Low Fire Sw. Off* Low Fire Interlock switch failure to close during PREPURGE. 1. 2. 3. 4. 5.
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code Fault 27 *Start Switch On* System Failure Start Switch was on during PREPURGE (RM7838A, RM7838B only). Recommended Troubleshooting 1. 2. 3. 4. 5. Fault 28 *Pilot Flame Fail* Pilot flame failure. 1. 2. 3. 4. 5. Fault 29 *Lockout ILK* Lockout Interlock fault. 1. 2. 3. 4. 5. Fault 30 *Running ILK* Running Interlock fault. 1. 2. 3. 4. Fault 31 *Low Fire Sw.
PAGE 14
7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code Fault 32 *Airflow Switch* System Failure Combustion Airflow Interlock fault. Recommended Troubleshooting 1. 2. 3. 4. 5. Fault 33 *Preignition ILK* Preignition interlock fault. 1. 2. Check wiring; correct any errors. Inspect the fan; make sure there is no blockage of the air intake and it is supplying air.
PAGE 15
7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code Fault 45 *Low Fire Sw. Off* System Failure Low Fire Interlock switch failure to close or stay closed. Recommended Troubleshooting 1. 2. 3. 4. 5. Fault 46 *Flame Amp Type* Fault 47 *Jumpers Changed* This fault indicates: a. The Flame Failure Response Time (FFRT) or TYPE input from the amplifier changed while the device was powered; or b. A standard amplifier was used in a pilot valve application; or c.
PAGE 16
7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code System Failure Fault 51 *Flame Too Strong* Flame signal value is too high to be valid. Recommended Troubleshooting 1. 2. 3. 4. 5. 6. 7. 8. Fault 52 *Call Service* Fault 53 *Lockout Switch* Pilot Valve 2 (terminal 21) was 1. off when it should be on. 2. 3. Inspect terminal 21 and connections. Make sure that the valve is operating properly. Reset and sequence the relay module.
PAGE 17
7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code Fault 68 *Preignition ILK* System Failure Preignition Interlock fault. Recommended Troubleshooting 1. 2. 3. 4. 5. 6. Fault 69 - 70 *Call Service* Fault 71 *Dynamic LFS* Fault 71 *Limits Complete* Unused faults.  Low Fire Switch closed, High Fire Switch must be open (EC/RM7850 only). 1. Limit input (terminal 7) is off when it should be on (RM7888 only). 1. 2. 2. 3. 4. 3. 4.
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7800 SERIES RELAY MODULES Table 3. Hold and Fault Message Summary (continued). Fault Code Fault 109 *Call Service* System Failure Negative cycle test failed, earth ground absent or line voltage phasing improper. Recommended Troubleshooting 1. 2. 3. 4. Fault 110 *Call Service* The configuration jumpers differ from stored values. 1. 2. 3. 4. Fault 111 *Call Service* Fault 112 - 126 *Call Service* Fault 127 *Call Service* 65-0229—1 Relay Module configuration jumper test failure.
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7800 SERIES RELAY MODULES 19 65-0229—1
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7800 SERIES RELAY MODULES Home and Building Control Honeywell Inc. Honeywell Plaza P.O. Box 524 Minneapolis MN 55408-0524 65-0229—1 G.R. Rev. 4-98 Home and Building Control Honeywell Limited-Honeywell Limitée 155 Gordon Baker Road North York, Ontario M2H 3N7 Printed in U.S.A. on recycled paper containing at least 10% post-consumer 20 paper fibers. www.honeywell.