(isa) eaves Veanag” TERULEDS LtDG Cleaver-Brooks _ hk CB780/CB784__ one “‘sQperation and Maintenance Manual ~ ‘Do not operate, service, or repair this equipment unless you fully understand all applicable sections of this| ‘manual. Do not allow others to operate, service, or repair this equipment unless they fully understand all applicable| sections of this manual. Failure to follow all applicable warnings and instructions may result in severe personal injury or death "TO: Owners, Operators and/or Maintenance Personnel ‘This manual presents information that wil help to properly operate and care fr the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should ‘be made o operate the unit unt the principles of operation and all ofthe components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death tis the responsibility of the owner to train and advise not only hit ar her personnel, but the conractos' personnel who are servicing, repairing, or operating the equipment, in all safety aspects. CCleaver-Brooks equipment is designed and enginoered 1o give long life and excelent service on the job. Te electrical and mechanical ‘ovices supplied as part of the unit were chosen because oftheir known ability to perform; however, proper operating techniques and ‘maintenance procedires must be followed a all imes. Although these components afford a high degree of protection and safety, ‘operation of equipment isnot to be considered free from all dangers and hazards inberent in handling ané firing of fue “Automatic” features included inthe design do not relieve the alendant of any responsibilty. Such features merely free him of ‘certain repetitive chores and give him more time to devote to the proper upkeep of equipment Itis solely tis operator's responsibility to properly operate and maintain the equipment. No amount of writen instructions can replace {neligent thinking and reasoning, and this manual is not intended to relieve operating personnel of the responsibility for proper ‘operation, Operating controls will normaly function for long periods of time. Do not become lax in daily or monthly testing, assuming that ‘normal operation will continue indefinitely. Malfunctions of controls lead to uneconomical operation and damage and, in mos cass, these conditions can be traced directly to carelessness and deficiencies in testing and maintenance. (Operation ofthis equipment by the owner and his operating personnel must comply with all requirements or regulations of his {insurance company and/or other authority havin jurisdiction. Inthe event of any conflict or inconsistency between such requirements and the warnings or instructions contain herein, please contact Cleaver-Brooks before proceeding.Cleaver-Brooks CB780/CB784 Operation and Maintenance Manual Cleaver?i{Brooks’ Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part Number 750-166 6/95 Rev 10/95 Printed in U.S.A.CONTENTS Section 1 — Installation and Operating Instructions Section 2 ~ System Annunciation Diagnostics and TroubleshootingCleave rooks’ Section 1 - CB780/CB784 Installation and Operating Instructions The Cleaver Brooks CB780/CB784 is a microprocessor based integrated burner control for automatically fired ‘gas, oil, or combination fuel single burner applications. The (CB780 consists of a Relay Module and Keyboard Display ‘Module. The CB784 consists of the Relay Module only. The Keyboard Display Module is optional with the CB784. Sub- base, Amplifier, and Purge Card are required to complete the system. Options include Personal Compute Interface, Control ‘Bus, Remote Display Mounting, First Out Expanded Annun- ciator and Combustion System Managment software The CB780/CB784 is programmed to provide a level of se, ston apy ad ete byond hcp of conventional controls Functions provided by the CB780/CB784 include auto ‘matic burner sequencing, flame supervision, system status indication, system or self diagnostics and troubleshooting ——_ Safety feaures: Interlock check Closed loop logic test. Dynamic Auto-Check. Dynamic input check Dynamic safety relay vst. Dynamic sel-check ogi —Expanded sefe-sart check. —High Fie Purge Switch test Internal hardware status monitoring. Low Fite Sta Switch text. —Tamper resistant ming and logic. ‘Access fr extemal electrical volage checks ‘Application flexibly Corimunidtion interface capably MH Dependabie, longterm operation provided by microcom- pater technology. 'W Fist out annunciation and system diagnostics provided by 42 r0W by 20.column Vacutim Fluorescent Display (VED) located on the Keyboard Display Module. First-out expanded annuneistion with 26 Light Emitting Diodes (LEDs) for limits and interlocks (optional). Five sequence information LightEmiting Diodes (LEDs) Five funtion Run/Test Swit, Interchangeable plug-in fame ampli. Local or remote annunciation of operation and fault information 1 Nonvolatie memory forretining histor files and sequenc- ing sta alter los of power. Remote reset (optional 1M Report generation (optional) 1B Burner controler data: -Sequence sats Sequence time. ~Hold stats —Leckoutllarm status. Flame signal strength Expanded annuncetor status “Total cytes of operation. Total hours of operation. — Fault history of sx most recent faults: + Cycles of operation atime of Ea ‘Expanded annunciator data at ime of fault + Faultmessage and code + Hours of operation atime of faut + Sequence stats atime of fault. + Sequence time atime of fault, —Diaggoste information + Device ype. + Flame amplifier ype Flame fale response time + Manufacturing coe. + On/Off status ofall digital inputs and outputs + Selected prepurge time. + Software revision and version of CB780/CB784 and ‘Keyboard Display Module. + Status of configuration jumpers. + Status of Run/fest Swich CONTENTS SpecifCation’ .rosnennnn Principle Technical Features ‘Safety Provisions. Installation. Wiring. Assembiy Operation rs Statie Checkout Checkout Troubleshooting 750-166CB780/CB784 SPECIFICATIONS Specifications FLECTRICAL RATINGS, see Table Power Dissipation: Voltage an Peeps 120 Vac (610-158), 0 or CBTROCDTEA10W maximum, GO He cv. 108) Disply Modul: 3 msi, Keyboard Display Module: 13 Vde pak fll wave Maxima Toal Connected Lon: 3000 VA Teted (201139), Fusing: Total Comected Load: 208 muximum, type RN orequivalet ‘TABLE 1_TERMINAL RATINGS. ‘Terminal No. Description Ratings G Flame Sensor Ground! Earth G Earth Ground! T20) [Line Vatage Common 3 [Alam 0 Vae, TA pt day 4 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz (110%). 5 Bumer Motor 120 Vac, 9.8AFL, 58.8ALR (inrush). 6 | Barer Conrlier and ins 120 Vae, Lm 7 [eackourRunningTterock 720 Vee, 9A. 8 Pilot Valve/Ignition 120 Vac, 4.5A ignition and SOVA pilot duty.> 9 “Main Fuel Valve 120 Vac, 2A pilot duty.* 10 Ignition 120 Vac, 4.5A Ignition. FL) Flame Sensor 60 to 220 Vac, current limited. 12 [Pirng Rate High Fie 120 Vae, 75 VA pilot dy. 13 [ing Rate Common 120 Vac, 75 VA pilot dy 14 [ing Rate Low Fire 120 Vue, 75VA pilot dy. 15 [Fring Rate Moat 120 Vac, 75-VA pilot dy Tense 17 [Unused 18 ] Low Fire Such Tap 20 Vas, mA 19 [High Fire Switch inp 120 Vac, IA, 20 [ reign nrook lapat 120 Vae, mA, 21 [nterapied Plt ValvelFirs Stage OI Valve [120 Vac, 2A plot dy 22 | Shute 120 Vac, 05, "The CB780/CB784 must have an earth ground providing a connection between the subbase and the control panel or the equipment. ‘Theearth ground wiremustbe capable cr eondueting the cumentto blow the 204 fuse (or breaker inevent of an intemal shor ere ‘The CB7S0ICB784 neods 2 low impedance ground connection to the equipment frame which n tm, needs a low impedance connection to eth ground. Fora ground pt tobe low impedance at RF frequencies, the connection mist be nude by minimum length conductors having maximum surface areas. Wide tps or brackets are preferred rather tan leadwites, Be cart to ensure ‘hat mechanically dghtened joins along the ground path, such as pipe or condi threads or surfaces held together wih fasteners, are Jive of noncondictive coatings and are protected against mating surface comosion. 22000 VA maximum eoancted load to CB TSQ/CHT84 Asser. 3Gan also be 120 Vee, 1A plo duty ‘Canals be 65 VA pilot duty with motorized valve, 1150 VA inush, 460 VA open, 250 VA old Operating frequency chosen by CB7SOICB7S4 selection, 12 750-166CBT80/CB784 SPECIFICATIONS ENVIRONMENTAL RATINGS: ‘Ambient Temperature: Operating: 40°F to 140°F. ‘Storage: -40°F to 150°F. Humidity: 85% RH continuous, noncondensing. Vibration: 0.5G environment. DIMENSIONS: Refer to Figs. 1 and 2. WEIGHT: (CB780/CB784: 1 pound 10 ounces, unpacked. Keyboard Display Module: 4 ounces, unpacked, IMPORTANT: Flame Detection System available for use with CB780/CB784. To select your Plug-in Flame Signal Amplifier and matching Flame Detector, see Table 2. ‘TABLE 2—FLAME DETECTION SYSTEMS (FIGS. 3,4, 5) Plug-In Flame Amplifiers ‘Applicable Flame Detectors Part Part Type | Color | Setf-checking | Number Type ‘Number Infrared | Red No 833-2722 Tnfrared 817-1742 (Lead Sulfide) 833-2723" Infrared 817-1742, Hynamic Auto-Check (Lead Sulfide) Untraviolet [Purple | No 833-2724 Ulwaviolet [817-1743 Untraviotet [Green [Dynamic Self | 833-2741 Unwaviolet 817-1121 Self-Check Check (Purple Peeper) “The 817-1743 Flame Detector should be used only on burers that cycle on-off at leaktonoe every twenty-four hours, Appliances with ‘bumers that remain oa for twenty-four hours continuously or longer should use the 817-1121 Flame Detector withthe 833-2741 Amplifier asthe ultravoles lame detection system. * Circuitry tests all electronic components in the ame detection systom (amplifier and detector) 12 times a minute during burer operation and shuts down the burner i Une detection system fails. Circuitry tests the flame signal amplifier 12 times a minute during bummer operation and shuts down the bumer if the amplifier fails, ‘TABLE 3 SEQUENCE TIMING FOR NORMAL OPERATION? Flame Establishing Approval Period ‘Code Initiate | Standby | Purge | Plot | Main | Run Gireuits | Circult Bodies cB 7a0/ [IOs |* Pe \aor fide |» Preignitio, [wire [No rir [ca 784 10sec | 15sec! Lockout, | modulating Modulating High and Low Fire = STANDBY and RUN can be an infinite tine period. "4 PURGE will be determined by which purge cad is selected. 2 The MFEP will be determined by which terminal i used, ee Figs. 7 and 18 * The operating sequence of the CB780 and CB784 Relay Modules are identical. The only difference between the Relay ‘Modules is thatthe Keyboard Display Module is standard with the CB780 and optional with the CB784. APPROVAL BODIES: Factory Mutual approved, Report No. JUV9A0.AR, ‘Underwriters Laboratories Inc, listed, File No. MP268,, IRL acceptable, Guide No. MCCZ, Federal Communications Commission, Part 15, lass B- Canadian Standards Association certified, LR9S329-3. Emissions. 750-166 13CCB780/CB784_ SPECIFICATION MOUNTING: 833-2725 for panel mount, ACCESSORIES: REQUIRED COMPONEN Optional: ‘CB780: 120 Vacl60 Hz, 833-2718, Control Bus—part no. 833-2729. Provides ‘CB780: 120 Vac/50 Hr, 833-2719. ‘communication and remote reset capabilities on (CB784: 120 Vac/60 Hz, 833-2720, (CB784; remote display capabilites on CB780 (CB784: 120 Vac! 50 Hz, 833-2721 and CB784. Plug-in Flame Signal Amplifier, see Table 2 (€B783 Expanded Annuncistor—part no, 833-2726, Plug-in Purge Timer Cards: selectable: Keyboard Display Module—part no. 833-2727, 833-2730 30 sec. (Standard on CB780; optional on CB784.) 833-2731 60sec. Remote Mounting Kit for the Keyboard Display, 833-2732 90sec. NEMA 4—part no, 833-2740, 833.2733 2-1/2 min, “Tester—part no, 626-5050. NOTE: The CB780 and CB784 are identical except for the ‘Keyboard Display Module which is standard with the (CB780 and optional with the CB784. Fig. 1—Mounting dimensions of CB780/CB784 Relay Module and 833-2725 Subbase, in inches (mm) Q — | = camvei#porets | BURNER CONTROL 5 5 ( B ! 5 se Hl dn 5 100+ Oma 5 ‘Ovome wll p Sam 5 lA 5 A, bs B Aa sum |_ smc A, newove cy fon Tenens E87 A00088 a 14 730-166CB780/CB784 SPECH CATIONS Fig. 2—Mounting dimensions of Keyboard Display Module, in inches (mm). Ciamerfysroces [BURNER CONTROL Fig. 4—Ultraviolet detector, [eel = =e +BG+ Gud __) |F | [=e cen ———] Fo gee wre eb F 1 IZA is Wa yt t wl ee de of same) fit tg oy 833-2727 (Standard with CB780, optional with CB784) Fig. 3—Ultraviolet Self-Check detector. fe-secisa er7-1121 750-166 ea <=) ———>| = 1 I o wy X ' 817-1743 Fig. 5—Infrared detector. CELL MOUNT HEAT BLOCK vm ae} pat [ciel wea aueoonn RSE fram | 817-1742 seg, Esto 1sCBIB0/CB784 PRINCIPAL TECHNICAL FEATURES Principal Technical Features ‘The CB780/CB784 provides all customary flame safe- ‘guard functions while providing significant advancementsin the areas of safety, annunciation and system diagnostics. SAFETY SHUTDOWN (LOCKOUT) OCCURS IF: 1, INITIATE Period a. Purge card isnot installed or removed. b. Purge card is bad. ©. Configuration jumpers were changed (after 200 hours) 4. AC line power errors, see Operation, ce. Four minute INITIATE period is exceeded. 2. STANDBY Period ‘a. Flame signal is present after 40 seconds. b. Preignition Interlock is open an accumulative time (of 30 seconds. c. Interlock check feature is enabled and the Inter- Jock String including the airflow switch) is closed for 120 seconds with controller closed. 4. Ignition/pitot valve/intermittent pilot valve termi- nal is energized, fe. Main valve terminal is energized, £. Internal system fault, &. Purge card isnot installed or removed. 1h. Purge card is bad, 3, PREPURGE Period a. Preignition Interlock opens anytime during PREPURGE. ». Flame signal detected after firstten seconds during. PREPURGE. ©. High Fite Switch fails to close within four minutes, fifteen seconds after firing rate motoris commanded to drive tohigh fire postion at start of PREPURGE. 4. Low Fire Switch fails to close within four minutes, fifteen sooonds afte firing rate motor is commanded to drive to low fire position at end of PREPURGE. Lockout Interlock does not close within 10 seconds. Lockout Interlock opens during PREPURGE. . Ignition/pilot valvefintermittent pilot valve termi- nal is energized. ‘Main valve terminal is energized, 16 4, Internal system fault, 4 Purge card is removed, Purge card is bad. PILOT FLAME ESTABLISHING Period (PFEP) a. Low Fire Switch opens. ’. Lockout Interlock opens. Ignition/pilot valvefintermittent pilot valve terminal is not energized, 4. Barly Spark Termination terminal is energized af- ter five seconds. ¢. No flame is present at end of PFEP. £. Internal system fault ag. Purge card is removed. hi, Purge card is bad. MAIN FLAME ESTABLISHING Period (MFEP) a. Low Fire Switch opens. ’. Lockout Interlock opens. . Ignition/pilot valve/intermittent pilot valve termi- nal is not energized. ‘Main valve terminal is not energized. [No flame is present at end of MFEP. Tntemal system fault Purge card is not installed or removed. Purge card is bad. Prime o RUN Period 'No flame is present. Lockout Interlock opens. ‘Main valve terminalis not energized. Intemal system fault, Purge card is not installed or removed. urge card is bad. . POSTPURGE Period 2. Preignition Interlock does not close within five sec- ‘onds or opens after five-second time period. >. Ignition/pilot valvefintermittent pilot valve termi- nal is energized. ‘Main valve terminalis energized. |. Internal system faut, Purge card is removed. f. Purge card is bad. pap 750-166_CB780/CB784 SAFETY PROVISIONS Safety Provisions INTERNAL HARDWARE STATUS MONITORING ‘The CB780/CB784 checks the purge card for correct, pvity to prevent purge timing shifts and circuitry failures. It also analyzes the integrity of the configuration jumpers and internal hardware. The POWER LED blinks every four seconds, signifying an intemal hardware check. CLOSED LOOP LOGIC TEST ‘The test verifies the integrity of al safety eritical loads, terminals 8, 9, 10 and 21. If the loads are not energized properly; ie. the main valve terminal is powered during PREPURGE, the CB780/CB784 will lockout on safety shut- down. The CB780/CB784 must react to input changes but avoid the occurrence of nuisance shutdown events. Signal ‘conditioning s applied to line voltage inputsto verify proper ‘operation in the presence of normal electrical line noise such as transient high voltage spikes or short periods of line ‘dropout, Signal conditioning istolerantof synchronous noise (ine noise events that occur at the same time duringeach line cycle). DYNAMIC AUTO-CHECK Dynamic Auto-Check circuitry tests the flame signal ‘amplifier during burner operation and shuts down the CB780) (CB784 ifthe flame amplifier fils. DYNAMIC FLAME AMPLIFIER AND SHUTTER CHECK ‘Self-checking circuitry tests all electronic cémponents in the flame detection system and amplifier 10 to 12 times per ‘minute and shuts down the CB780/CB784 if the detection system fails. DYNAMIC INPUT CHECK Al system input circuits are examined to verify thatthe (CB780/CB784 is capable of recognizing the true status of extemal controls, limits and interlocks. If any input fils this ‘est, a safety shutdown occurs and the faut s annunciated. DYNAMIC SAFETY RELAY TEST ‘Checks the ability of the dynamic safety relay contacts to ‘open and close. It also verifies that the safety critical loads, terminals8,9, 10and21, can be de-energized, asrequired, by the Dynamic Self-Check logic. 750-166 DYNAMIC SELF-CHECK SAFETY CIRCUIT ‘The microcomputer tests itself and related hardware while at the same time the safety relay system ests the micro- computer operation. If a microcomputer or safety relay failure occurs and does not allow proper execution of the self-check routine, safety shutdown will occur and al safety ritical Toads wil be de-energized EXPANDED SAFE-START CHECK ‘The conventional safe-start check, which prevents bumer start-up if lame is indicated at startup, is expanded to include a flame signal check during STANDBY, a preigni- tion interlock check, an interlock check, and a safety critical load check. HIGH FIRE PURGE AND LOW FIRE START SWITCH TESTS High Fire Purge Switch Test examines the Purge Pos tion Interlock Switch atthe moment the fring rate motor is ‘commanded tothe high fre position. Ifthe switch is by- passed, welded or otherwise closed prematurely, the system Will automatically ad 30 seconds to allow additonal drive time for the firing rate motor to reach or near the open position before starting the purge timing; otherwise, purge timing starts when the High Fire Switch is closed. This switch wil also cause a hold (four minutes, fifteen seconds) condition when the switch is open before purge or opens during purge. The CB780/CB784 will lockout and annune- ate an alarm ifthe switch fils to close within the hold time petiod. Low Pire Start Switch Test examines the Low Fire Start Switch at the moment PREPURGE is completed. If the switch is bypassed, welded or otherwise prematurely closed, the system automatically adds 30 seconds to allow the fring rate motor additional time to reach or near the low fire start position before ignition trials; otherwis, ignition tials start afterthe Low Fire Switch closes, The tes also is usedo prove that the firing rate motor is at low fire position throughout the ignition tal period. This switch will also cause a hold (Courminutes, teen seconds) condition ifthe switch opens afer purging is complete. The CB780/CB784 will lockout and annunciatean alarm the switch fils to lose with the hold time period.CB780/CB784 SAFETY PROVISIONS MANDATORY PURGE, If lockout occurs after the initiation of ignition trials, (or at anytime during a sequence when the fuel valves may have been energized), a mandatory POSTPURGE period is ‘imposed, OFF CYCLE (STANDBY OR PREPURGE) FLAME SIGNAL CHECK ‘The flame detection subsystem (flame detector and am- plifier) is monitored during STANDBY. Ifa flame simulat- ing condition oran actual flame exists, a system hold occurs and star-up is prevented. Ifthe flame signal exists at any time after the frst 40 seconds of STANDBY, a safety shut- 1. With the firing rate motor at the low fire position: a. The pilot valve and the ignition transformer, terminals 8, 10 and 21, are energized. The (CBT80/CB784 has a fifteen second interrupted pilot valve, terminal 21 and a ten second inter- rupted pilot valve/ignition, terminal 8. », During PFER the Low Fire Switch must remain closed. IF it opens, a safety shutdown occurs. ¢. The Preignition Interlock input is ignored throughout the Ignition Trial state. 2. Flame must be proven by the end of the four or ten second PFEP to allow the sequence to continue. If flame is not proven by the end of PFEP, a safety shutdown occurs 3. With flame proven, the ignition, terminal 10, is de- energized for early spark termination, . MainFlameEstablish- ing Period (MFEP 1. The CB780CB784 has a selectable ten second or fifteen second MEP. After the Ignition Trials, and with the pres- ence of flame, the main fuel valve, terminal 9, is powered, Ifa flameout occurs, the CB780/CB784 will lockout within 3 seconds. MAINIGN 00:15 ‘Flame Signal 2.7V RUN 1. Aten second stabilization period occurs at the begin- ning of the RUN period. 2. The firing rate motor releases to modulation, 3, The CB780/CB784 is now in RUN and will remain in RUN until the controller input, terminal 6, opens, indicating thatthe demand is satisfied or a limit has opened, POSTPURGE The CB780/CB784pro- (9, vides a fifteen second | SUN ssdea annun.> POST-PURGE following the completion of the RUN period. The blower motor output is powered to drive all ‘products of combustion and any unbumed fuel from the 750-166CBT80/CB784 OPERATION combustion chamber. Italsosupplis combustonsirtobum 2, The Prcignition = fuel being purged fom the fuel line downstream ofthc fuel _Intelockeloses withinthe | ROST.PURGE on:12 shutoff valve. frst ive seconds of 1. Themain fuel valve andintermitent pilot valve,termi- _POSTPURGE. nals 9 and 21 are de-enerpized and the fring rte motoris 3. Afterthe fiften second POSTPURGE peeod is com- commandedtothelow irepostiontobeginthe POSTPURGE pleted, the CB7S0/CB784 renters STANDBY. period Fig. 18—C8780/08784 sequence. [a roves Je von [@ ronen |@ row fe sccm Jw ronan Je rowen [@ rowan Baw lo Jo" fomor Jomor femor fertcr fomor fo” |o iS |o—Jonam Jonnie forme fern fonwe fo fo fo Jomo Jorn [O unm wm fo [6 iS _ [6 [Gam [ons [orm [Ono onan [o_o rn = ao 5 pape Sa | amen G) aA po TAA amano FBO thtimoces Farmer | | eaeurmraranecaas OC) 72 aca OAT =e Tm nO parma Rewrcan ra a Seco TET = ron ovis swum] Qro@ | O~® \Qu@ KEYBOARD DISPLAY MODULE (VFD) Fig. 19—Keyboard Display Module and “The fist in of the Vacuum Fluorescent Display (VFD) __ sequence status LEDs (Table 4) provides current status of the burner sequence (STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN and POS: ESuwuicarons: rewore PURGE) timinginformation (PURGE, PILOTIGN, MAIN KETOMDOSRATAND REMOTE egEY; 1A Bera IGN and POSTPURGE) in minutes and seconds, hold infor- NCTE TE asoeaTon ‘mation (PURGE HOLD: T19) and lockout information seovence (Lockout, Fault Code, Message and Sequence); see Fig. 19. fine ‘The extreme right side of the fist line will either be blank or itil’ sow a all ow poiwing (ote soon te SEN {alowed by atweictercnk DEDasws emadin, GEE" nua stay Taforaton ond EA apd Aan iieo Whentieemwaniwoltercoicwedpiei ace indicates the second line is showing a selectable message re submenu. The second line will display selectable or preemp. tive messages, selectable message supplies information for flame suength, system status indication, sytem or sel-diag- nostes and toubleshooting,A preemptive message will have parentheses arouid the message and supply a detailed mes- Sage to support the sequence status information. A preemp- tive message can also be a lockout message. A preemptive AOTE REMOTE RESET MCE MOUNTED WT TT 750-166 19‘CB780/CB784 OPERATION _ message will replace a selectable message to support the sequence status information. It will also replace a selectable message after 60 seconds if it or a lockout message is available. The CB780ICB784 LEDs provide positive visual indication of the program sequence: POWER, PILOT, FLAME, MAIN and ALARM, ‘TABLE 4—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 19). NOTE: Normal encesare in BOLD TYPE, while abnormal sequences are not in bold type. ‘Burner Sequence LEDs Energized INITIATE minutes:seconds selectablo—message INITIATE HOLD: AC (AC FreqnNoise) INITIATE HOLD: AC (AC Line Dropout) INITIATE HOLD: AC (AC Frequency) INITIATE HOLD: AC (Low Line Voltage) POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM ‘STANDBY fselectable —message STANDBY HOLD: REM ‘(Remote Control) STANDBY HOLD: F/G (lame Detected) STANDBY HOLD: 120 (@Preignition ILK) STANDBY HOLD: T7 (Running LK) STANDBY HOLD: T7 (Lockout ILK) PURGE HOLD: T19 (High Fire Switch) PURGE DELAY: T19 (High Fire Jumprd) PURGE HOLD: TEST (Run/Test Switch) PURGE DELAY: T18 (Low Fire Jumprd) PURGE HOLD: F/G (lame Detected) POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM. POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM. POWER, PILOT, FLAME, MAIN AND ALARM, POWER, PILOT, FLAME, MAIN AND ALARM PURGE HOLD: TIS (Low Fire Switch) POWER, PILOT, FLAME, MAIN AND ALARM PURGE minutes:seconds fselectable—message PURGE HOLD: T7 Running ILK) POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM. PILOT IGN minutes:seconds dsclectable—message PILOT HOLD: TEST (Run/Test Switch) ‘POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM ‘MAIN IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM sclectable—message RUN POWER, PILOT, FLAME, MAIN AND ALARM ‘selectablo—messaze RUN POWER, PILOT, FLAME, MAIN AND ALARM fselectable—message RUN LOWFIRE: TEST (Run/Test Switch) POWER, PILOT, FLAME, MAIN AND ALARM 1-20 (continued) 750-166CBT80/CB784 ‘OPERATION ‘TABLE 4—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 19) (Continued), NOTE: Normal sequences are in BOLD TYPE, while abnormal sequences are notin bold type. ‘Burner Sequence LEDs Energized POSTPURGE minutes:seconds 4selectable—message Waiting for connection. RESET/ALARM TEST selectable —message ‘POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM. ‘Additioan! sequence status information when an Expanded Annunclator is connected to the relay module, Also see (CB780/CB784 Operating and Maintenance Manual, Manual Number 750-166. BURNER OFF: T6 (Burner Switch) STANDBY HOLD: 16 (Expanded Annuneiator hold message) STANDBY HOLD: T6 (Circuit Fault) POWER,PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM POWER, PILOT, FLAME, MAIN AND ALARM KEYBOARD FUNCTIONS The Keyboard contains four pushbutions and each has seperate functions (SCROLL-Down, SCROLL-Up, MODE and Change-Level). The MODE and Chenge-Level push- ‘buttons, when pressed together, provide a SAVE function, 1. SCROLL Down-Up pushbuttons (1), see Fig. 20. ‘The SCROLL Down-Up pushbuttons (f) are used to scroll through the selectable messages. The double-headed arrow (1), which is located in the lower left position of the second line of the display, represents the SCROLL Down- Up pushbuttons. The SCROLL Down-Up pushbuttons (1) canbe pressed to display selectable messages one at atime or hheld down to scroll through the selectable messages at arate of two per second. When the last item of the selectable message is viewed, the display wraps around and displays the first selectable message again. Fig. 20—(1) SCROLL pushbutton function. chotiporeets[sunnen conrron. | | site en conc. | AUN 4 Total Cycles 333 me = 8 + Ore Me) RUN Total Hours 1332 wae woe a 2. Change-Level pushbutton (4), see Fig, 21 ‘The Change-Level pushbutton is used to change between the first hierarchy of selectable messages to a subset of selectable messages. The Change-Level pushbutton can also bbe used to change from a subset message to a first level selectable message. The symbol (>) located on the second line in the lower tight comer of the VED represents a first level hierarchy of selectable messages. The symbol (<) located on the second line in the lower right comer of the VED represents a subsct of selectable messages. 750-166 3, MODE pushbutton, see Fig. 22. ‘The MODE pushbutton instantaneously switches the display from a second-line-selectable message to second- line-preempted message. The sixty second timeout function also can be used for this task. The MODE pushbutton will, work only if there is a second-line-preempted message or lockout message. 1atCB780/CB784 OPERATION Fig. 21 (€4)—Change-Level pushbutton function Ceaverfiorocks burner conrnos com ovrnen conrnos | PILOTIGN 00:05 Fault History. > PILOTIGN 00:10 vH1 Fault cycle 174 « Fig. 22—MODE pushbutton function. [Cleeverthiroots BURNER CONTROL Cloaverfiaroots [BURNER CONTROL LOCKOUT #17 MFEP Main Valve TO Off ¢ LOCKOUT #17 MFEP ‘Main Flame Fall” wz of | *OOr no 4, SAVE function; see Fig. 23. ‘The SAVE function enables users to identify the select- able message they wantto view upon power restoration. The second line selectable message will be restored to the most recently saved selection when power returns. The SAVE. function is performed by pressing and holding the MODE key and then pressing the Change-Level pushbutton (¢->). The second line of the display will briefly note “...SAV- ING...” to confirm the key press, SELECTABLE MESSAGES ‘VED Second Line Display, Two-Level Hierarchy, soe ‘Table 5. ‘The display values areas follows: x represents a numbered value. ‘T represents the terminal number. x represents the suffix leter of the Relay Module, 122 Fig. 23—SAVE function. Cumin [BURNER contnos | PURGE 00:30 SAVING 750-166CB780/CB784 OPERATION BLE S— SELECTABLE SSAGI (Second Line) = Message nav ‘Hota Hours sant Paul Histrye> {Fault Cele anna < JL Fault Hous saanan < Lit Patt Code mn < iat {fault —messaget< bn Isequence—message< ta ‘Nseconé-ine-msg)< tH TElt Cycle rinonn < U2 Fault Hours nanan < U2 TFauit Code mm < dia {Ptault —messaget in Jsequenco—messagec in {iGeoond ine mse) ay Fault Cyele rannn < JH3 {Feult Hours san < JB Fault Code man < as 4 efault—messager< us Tsequence—messagec is {Geeond lne-ms)< ts Fault Cycle fannnn < UKs Fault Hours roam < Ua $FauitCode mm < aia fait —messaget ta $sequenco—mestagec aa {iGecond.ine msg tus ‘Sault Cycle rnnnn < LHS {Fault Hours fanaa < 15 ‘eule Code nm < sas fault —message*< us Jseqvence—messege< tas (Gecond. tine mp) is $PaukeCycle anna < JH Fault Hours ‘nonnn < LH6 $Fault Code san < ts {fault —messager< ts {sequence —message< Hs Teecond lne-msg)< tis Diagnostic Info Device RMTBnmx < Jor Device Sux sma < tor Runes Sw. RUN oc TEST < tor Operating Control (OpexConto) 16 ONor OFF < tor Hnterioek TT ONor OFF < tor Pitot Valve 1% ONerOFF < tor {Main Valve 19 ONcrOFF < tor Hgnition TIO ONGrOFF < {Dr tLowFire Sw TIS ONor OFF < {DL IHighFireSw 119 ONorOFF < tor {Preignition lteclock (PrelgnILK) 120 ONr OFF < tor {Pilot Valve/Frst Stage OlValve(Valv/Stat.V25) | T21 ON or OFF < ti Jumper INTACT or CLIPPED < or amper2 INTACT or CLIPPED < Li Bumper INTACT or CLIPPED < br Amplifier Type (Amp Type) NORMAL or AMP.CHECK or SHUTTER tor {Flame Response O88 or3s < tor {Purge Time mms < tor ‘Manufacturing Code (Mtg, Code) rma < or Software Revision (SW Rev.) nvann < tor {tBxpanded Annun.e> (se Table 5) Remote Command NONBHOLDATEILE 750-166 1.23CB780/CB784 OPERATION EXPANDED ANNUNCIATOR MESSAGES, SEE TABLE 6 ‘The Expanded Annunciator (EA) may or may not be connected because itis an optional device. If the EA is not connected, a display message of “(EA not connected)” will shown, see Table 6 and the Diagnostic and Troubleshooting, section of the CB780/CB78¢ Operation and Maintenance Manual, Manual No, 750-166, Tables 6 and 7 for fault codes. ‘When accessing Expanded Annunciator Messages, follow the same operations as used with the Selectable Messages. be shown, Ifthe EA is connected, display messages will be "TABLE 6—EXPANDED ANNUNCIATOR MESSAGES. Selectable Message Display Value First Line (Second Line) (Second Line) Message ‘Expanded Amun {Fsxpanded Annunciator (EA not connected)< {Current Status (CS:)* EA Message< BA Valve Closure (Valve Close) m4 ON or OFF< 4EA ‘TBumer Switch (Burner Sw.) TS ON or OFF< 4EA ‘Operating Control (OperControl) 16 ON or OFF< 4EA {Auxiliary Limit (Aux Limit 1) 7 ON or OFF< EA ‘Auxiliary Limit (Aux Limit 2) 8 ON or OFF< EA JLow Water Cutoff (LWCO) 19 ON or OFF< 4EA [High Limit igh Limi TIO ONorOFFe EA {Auxiliary Limit (AuxLimit 3) Ti ON or OFF< EA {Oi Selection Switch (Oil Select) TI2 ON or OFF< dBA {High Oil Pressure Switch (Hi OilPres) 713, ON or OFF< EA iLow Oil Pressure Switch (LowOilPres) Tid ON or OFF ea {High Oi Temperature Switch (Hi OiITemp) TIS ONor OFF Lea {Low Oil Temperature Switch (LowOilTemp) TI6 ON or OFF< LEA ‘{Atomizing Switch (Atomize Sw) TI9 ON or OF F<, LEA ‘Gas Selection Switch (Gas Select) TIT ON or OFF< 4EA ‘qHigh Gas Pressure Switch (Hi GasPres) T18 ON or OFF< 4EA {Low Gas Pressure Switch (LowGasPres) TI9 ON or OFF< {EA {Airflow Switch (Airflow Sw) 120 ON or OFF< {EA {Auxiliary Interlock (Aux ILK 4) T21 ON or OFF<_ EA YAniliayInertock (AUX ILK 5) T™ Nor OFF Jes ‘TEA Fault Code nmn< EA {Software Revision (SW Rev.) npnn< BA * Expanded Annunciator Diagnostic Current Status Messages can be reviewed in CB780/CB78+ Operating and Maintenance Manual, Manual Number 750-166, RUN/TEST SWITCH FUNCTIONS, ‘The Run/Test Switch is located on the top side of the (CBT80/CB784; se Fig. 19. The Run/Test Switch allows the ‘bumer sequence to be altered as follows: 1, InPrepurgeDrive To High Fire Position, the Run/Test ‘Switch, when placed in the TEST position, will hold in PREPURGE with the firing rate motor in the High Fire position. 2, Inthe measured PREPURGE sequence, the Run/Test ‘Switch, when placed in the TEST position, will cause the PREPURGE timing to stop. ‘The firing rte motor will be in the High Fire position, 3, InPrepurge Drive to Low Fire position, the Run/Test, ‘Switch, when placed in the TEST position, will hold the bbumer sequence in PREPURGE with the firing rate motorin the Low Fire position. 4. In PFEP, the Run/Test Switch, when placed in the ‘TEST position, will stop the timer during the first eight seconds when @ ten second PFEP is selected or during the first three seconds when a four second PFEP is selected, allowing pilot-turn-down test and other burner adjustments 124 to be made, This activates a fifieen second flameout timer ‘that permits pilot flame adjustment without nuisance safety shutdowns, The RunTest Switch will be ignored during PFEP for the CB780/CB784 if terminals 8 and 9 or 9 and 21 are jumpered. 5, During RUN, the Run/Test Switch, when placed inthe ‘TEST position, will drive the firing rate motor to the Low Fire position. NOTE: When CB780/CB784isswitched othe TEST mode, it will stop and hold at the next Run/Test Switch point in the operating sequence. Make sure that the Run/Test ‘Switch isin the RUN position before leaving the installa- tion, SELECTABLE SITE-CONFIGURABLE JUMPERS ‘The CB780/CB784 has two site-configurable jumper options; see Fig. 24 and Table 7. The site-configurable |jumpers should be clipped with side cutters and the resistors ‘removed from the Relay Module. 750-166TABLE 7—SITE CONFIGURABLE JUMPER OPTIONS. Jumper Number | Description | Intact | Clipped JRL [Pilot Flame | 10 Seconds | 4 Seconds Establishing Period (PFEP) TRS | Startup Disabled | Enabled Interlock Check NOTE: For all standard installations, these jumpers should be left intact, unless otherwise indicated on wiring diagram. Fig. 24—Selectable site-configurable jumpers. teres on “sre jmeuay nono Static Checkout CAUTION 1. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on. 2.Open the master switch before installing or remov- ing a jumper on the subbase. 3. Before continuing to the next test, be sure to re- ‘move test jumpers) used in the previous test. 4, Replace all limits and interlocks that are not oper- ating properly. 5. Close all manual fuel shutott valve(s) before start- ing these tests. After checking all wiring, perform this checkout before installing the CB780/CB784 on the subbase. These tests verify the Wiring Subbase is wired correctly, and the exter- nal controllers, limits, interlocks, actuators, valves, trans- formers, motors and other devices are operating properly NOTE: Do not perfoom a dielectric test with theCB780(CB784 installed. Intemal surge protectors will break down and ‘conduct current, This could cause the CB780/CB784 to fail the dielectric test or possibly destroy the intemal lightning and high current protection. 750-166 EQUIPMENT RECOMMENDED 1. Voltmeter (20 kohm/volt minimum sensitivity) set on the 0.300 Vac seale 2. Two jumper wires; no. 14 wire, insulated, 12 inches [304.8 mm] long with insulated alligator clips at both ends GENERAL INSTRUCTIONS 1. Perform all applicable tests listed in Static Checkout, Table 8, in the order listed, 2. Make sure all manual uel shutoff alve(s)are closed. 3. Raise the setpoint of the operating controler to simu- late call for heat 4. For each test, open the master switch and install the jumper wie(s) between the subbase wiring terminals listed inthe Test Jumpers column. 5. Close the master switch before observing operation, 6, Read the voltage between the subbase wiring termi- ral listed in the Voltmeter column. 7. If there is no voltage or the operation is abnormal, ‘check the circuits and external devices as described in the last column 8. Check all wiring for comect connections, ight termi- nal screws, comect wire, and proper wiring techniques, Re- place all damaged or incorrectly sized wires. 9. Replace faulty controllers, limits, interocks, cuators, valves, transformers, motors and other devices as required, 10. Ensure normal operation is obtained for each required test before continuing the checkout 11, After completing each test, be sure to remove the test jumpers). 1.25 CBT80/CB784 OPERATION + STATIC CHECKOUTCB780/CB784 STATIC CHECKOUT STATIC CHECKOUT, Test | Test | Volt- If Operation is Abnormal, Check the No. [Jumpers] meter Normal Operation Tiems Listed Below AWARNING| Be sure all manual fuel shutoff valves are closed. lMPORTANT: Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if required). Nove [412] Line voltage at terminal 4 1. Master switch. 2 Power connected to the master switch. 3. Overload protection (fuse, circuit breaker, et.) has not opened the powerline. 2 [None Tine voltage at terminal 6 1 Limits 2. Burner controler 3 [None [20-L2 [Line voltage at tomminal 20. 1, Preignition interlocks, 4 [#5 [712 [1 Bumer motor (fan or blower) stars. T. Bumer motor circuit. 2. Line voltage at terminal 7 within a Manual switch of burner motor. 10 seconds, 'b, Burner motor power supply, ‘overload protection, and starter, © Bumer motor 2, Running or Lockout Interlocks Gacluding Airflow Switch). 3 [+10 | — |fanition spark Gf ignition transformer is 1. Waich for spark or listen for buzz connected to terminal 10). a Ignition electrodes are clean b._Tgnition transformer is okay, 6 |e — |i Tegnition spark Gfignition wansformer is 1. Watch for spark or listen for buzz connected to terminal 8) 2 Tenition electrodes are clean, 2. Automatic pilot valve opens (if con- b._Tenition transformer is okay. nected to terminal 8). 2. Listen for cick or feel head of valve ving for activation. NOTE: Refer to wiring diagram of system rnc ane Gingram oF syste Actuator if use. b._ Pilot valve 7 [ear | — | Same as text no, 6 for connections to terminal 8.| Same as test no. 6. f using direct spark fusing direct spark ignition, check the first ignition, check the first stage fuel valve(s) stage fuel valve(s) instead of pilot valve. isntead ofthe pilot valve 8 [as — [Automatic main fuel valve(@) open. Ifusing |. Listen for and observe operation of direct spark ignition with intermittent pilot on | "the main fuel valve(s) and actuato(s). terminal 21, check the optional second stage |2._Valve(s) and actuator(s). fuel valve, if used. 9 [a3 —_ [Alarm Gif used) tums on 1 Alarm, 10, [4-Sand [1812 [Firing rate motor drives open; zero volts at |. Low Fire Start Switch, 1213 terminal 18 after motor starts driving open. __|2._ Firing rate motor and transformer. 11 |4Sand [18-12 [Firing rate motor drives closed; line voltage at 1. Low Fire Start switch 1413 terminal 18 after motor is in Low Fire position. |2_ Firing rate motor and transformer, 12 |4Sand [19-12 [Firing rate motor drives open; line voltage at | 1. High Fire Purge Switch a3 terminal 19 after motor isin High Fire position, [2 Firing rate motor and transformer. 13 [Sand [19-12 [Firing rate motor drives closed; zero volts at__[1. Low Fire Start Switch. 14.13 terminal 19 after m otor starts driving closed. _|2._ Firing rate motor and transformer, (Coninued) 1.26 750-166TABLE 8 CBTR0/CB784 STATIC CHECKOUT + CHECKOUT ATIC CHECKOUT (Continued). Test | Test | Volt- No. |Jumpers| meter Normal Operation Tf Operation is Abnormal, Check the Items Listed Below WARNING Be sure all manual fuel shutoff valves are closed. IMPORTANT: Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if required). Ta [i513 — [i Raise set point of Series 90 controler [1, Series 90 Controle. firing rate motor should drive toward open. |2. Firing rate moor and transformer, 2 Lower setpoint of Serie 90 controler fring rate motor should dive toward closed. Final A CAUTION ‘On completing these tests, open the master switch and remove all test jumpers from the subbase terminals. ‘Also remove bypass jumpers trom the low fuel pressure limits (if used). Checkout Do not allow fuel to accumulate in the ‘combustion chamber. if fue! Is allowed to enter the chamber for longer than a few seconds without igniting, an explosive mixture could result, It is recommended that you limit the trial {or pilot to 10 seconds, and limit the attempt to light the main burner to 2 seconds from the time the fuel has reached the burner nozzle. In any case, do not exceed the nominal lightoft time ‘specified by the equipment manufacturer; close the manual fuel shutoff valve(s) ifthe flame is not burning at the end of the specified time. CAUTION 1. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on, 2. Open the master switch before removing or install ing the CB780/CB784 or Keyboard Display Module connector. 3, Be sure all manual fuel shutoff valve(s) aro closed before starting the inital ightoff check and the pilot turndown tests. 4, Do not place the system in service until you have satisfactorily completed all applicable tests in this section and any others required by the equipment ‘manufacturer, —_____} 750-166 IMPORTANT: 1. Ifthe system fails to perform properly, note the fault code, fault message, equipment status, and sequence time on the display. Refer to the Troubleshooting sec- Fon ofthe CB780/CB784 Operation and Maintenance ‘Manual, Manual Number 750-166. 2, Repeat ALL required Checkout tests after all adjust- ‘ments are made. ALL tests must be satisfied with the flame detector(s) in its FINAL position. EQUIPMENT RECOMMENDED ‘Volt-ohmmeter (20kohnv/volt minimum sensitivity) with: + 0-300 Vac capability. + 0-6000 ohm capability + 0-10 Ve capability. (CHECKOUT SUMMARY + Preliminary inspection—all installations. ‘+ Flame signal measurement —al installations. + Initial lightoff check for proved pilot—allinstallations, using a pilot. + Initial lightoff check for direct spark ignition of oil— all burners using DSI. ‘+ Pilot tumdown test—all installations using a pilot ‘+ Hot refractory saturation test—all installations using Infrared (lead sulfide) Flame Detectors. + Hot refractory hold-in test—all installations. + Ignition interference test—all installations using lame. rods, + Ignition spark pickup—all installations using Ulta- violet Flame Detectors. + Response to other ultraviolet sources—all installa- tions using Ultraviolet Flame Detectors. 127CB780/CB784 CHECKOUT + Flame signal with hot combustion chamber—all installations. + Safety shutdown tests—all installations. See Figs. | and 2 for location of component parts and Fig. 7or wiring subbase specifications fortermins) locations. PRELIMINARY INSPECTION Perform the following inspections to avoid common problems. Make certain that: 1. Wiring connectionsare correct and allterminal serews are tight. 2. Flame detectors) is clean, and installed and positioned. properly, Consult the applicable instructions. 3. Corect combination of amplifier and flame det tor(s) is used, See Table 2 in the Specifications soction. 4. Plug-in amplifier and purge card are securely in place. ‘5. Bumer is completely installed and ready to fie; con. sult equipment manufacturer instructions. Fuel lines are purged of air. 6. Combustion chamber and flues ate clear of fuel and fuel vapor. 7. Power is connected to the system disconnect switch, (master switch), 8. Lockout is reset (pushin reset button) only ifthe Relay Module is powered; see Figs. 1 and 2. 9. RunvTest Switch is in RUN position. 10, System is in the STANDBY condition. STANDBY message is viewable in the VED. 11, Al imits and interlocks are reset. FLAME SIGNAL MEASUREMENT (TABLE 9 AND FIG. 26) Measure the flame signal at the appropriate times as Gefined in the following Checkout tests. Read the flame signal in volts de at the flame amplifier test jacks + and (Com) or at the Keyboard Display Module 1. Use IM ohm/volt meter with a0 to 10 Vac capability. 2. Set the IM ohn/volt meter to the 0 to 10 Vide range. 3, Insert the positive (red) probe into the + jack of the flame amplifier. Insert the negative (black) probe into the (Com) jack of the lame amplifier; see Fig, 26. 4, Allow a few seconds for the meter reading to stabilize. TABLE 9—FLAME SIGNAL, Flame ‘Flame Signal “Minimum Acceptable “Maximum Expected Detector Amplifier Steady de Voltage* de Voltage 817-1121 33.2741 1.25 Vde 5.0 Ve at Keyboard B17-1742 33-2722 oF Display Module 833.2723 or wre B33.2704 5.0 Ve at IM ohm/volt meter, This minimum or stronger signal should casily be obtainedif the detectors correctly installed and positioned to properly sense the flame, This voltaged must be obtained before completing checkout. © The flame signal amplifier circuitry istested one-half second every bbumer if the amplifier fel insallations). © This lame amplifier is Auto-Checktype. Fig. 26—Flame signal measurement. eats nesarve yy EEL 1-28 /e seconds during burner operation and shuts down the. 5, Ifusing Auto-Check or shutter check amplifiers, read the average stable voltage, disregarding the peaks and val- leys caused by the self-checking operation. 6. Themeter reading mustbe as specified in Table 8 after all tests are completed and all adjustments made. ‘Asanoption, the flame signal canbe checked by using the Keyboard Display Module. ‘If the signal is unstable or les than the minimum accept- able voltage, check flame detector installation and circuitry. 1, Cheek the supply voltages at terminals 4 (L1) and L2 (N). Make sure the master switch is closed, connections are ‘correct, and the power supply is of the correct voltage, fre- ‘quency and is sinusoidal. 2. Check the detector wiring for defects including: + Incorrect connections, Wrong type of wire. Deteriorated wire, Open circuits. Shor circuits Leakage paths caused by moisture, soot or accu: ‘mulated din. 750-1663. For all optical detectors, clean the detector viewing ‘window and inside ofthe sight pipe as applicable. 4. With the bumer sunning, check temperature atthe de- tector. IFitexceeds the detector maximum rated temperature: + Add a heat block to stop conducted heat traveling up the sight pipe. + Adda shield or screen to reflect radiated heat + Ad cooling (refer to sight pipe ventilation in the ‘detector Instructions). 5. Make sure the flame adjustment is not too lean, 6. Make sure the detectors properly sighting the flame. 7. Ifnecessary,resight or reposition the detector. INITIAL LIGHTOFF CHECK FOR PROVED. PILOT 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. Ifthe pi takeoff is downstream from the manual main fuel shutoff valve(s), very slightly open the manual main valveto supply pilot gas flow. Make sure the main fuel is shut off just up- steam from the burner inlet, or disconnect power from the automatic main fuel valve(3) 3. Close the master switch and start the system with a call for heat by raising the set point ofthe operating control- ler, see Fig. 19 or CB780/CB784 sequence. The program should start the ten second INITIATE sequence. 4, Letthe sequence advance through PREPURGE. When the PILOT IGN status is displayed oa the Keyboard Display Module, ignition spark should occur and the pilot should light. Ifthe pilot ignites, the FLAME LED will be energized, Proceed to step 7. 5. Ifthe pilot flame is not established inten seconds, safety shutdown occurs. Let the sequence complete its cycle. Consult the equipment operating manual for further information, 6. Push the reset pushbutton, and let the system recycle once. Ifthe pilot still does not ignite, make the following ignition/piot adjustments: ‘4 Open master switch and remove the CB780/CB784 from the subbase. . On the subbase, temporarily jumper terminal 4 to ignition terminals 8, 10 or 21; refer tothe appropri- ate wiring diagram to determine the proper termi- nal. Disconnect the leadwire to the pilot valve if it is connected to the same terminal ©. Close the master switch to energize only the igni- tion transformer. 4. If the ignition spark isnot strong and continuous, fopen the master switch and adjust the ignition electrode spark gap setting to the manufacturer recommendations. . Make sure the ignition electrodes are clean. £. Close the master switch and observe the spark. 750-166 _CB780/CB784 CHECKOUT 8. Afteracontinuoussparkis obtained, openthe master switch and add a jumper on the subbase from terminal 4 (L1) tothe pilot terminal 8 or 21. Recon- rect the leadwire from the pilot valve if it was disconnected in step b. 1, Close the master switch to energize both the igni- tion transformer and the pilot valve. i. Ifthe pilot does not ignite and ifthe ignition spazk is still continuous, adjust the pressure regulator until a pilot is established. |i. When the pilot ignites properly and stays ignited, open the master switch and remove the jumper(s) from terminals 4-8, 4-10 and 4-21 of the subbase. kk. Check for adequate bleeding ofthe fuel line 1. Reinstall the CB780/CB784 on the subbase, close the master switeh, and then return fo step 4. 7. When pilot ignites, measure the flame signal. If the pilot flame signal is unsteady or approaching the 1.25 Vde ‘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 MAINIGN periods displayed on the VED, ‘make sure the automatic main fuel valve is open; then smoothly open the manual main fuel shutoff valve(S) and watch for main bumer flame ignition. When the main bumer flame is established, proceed to step 15. 10. If the main burner flame is not established within ten seconds, 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 reattempt may have been re- quired to purge the lines and bring sufficient fuel to the bummer.) 13, If the main burner flame is not established within five seconds or the normal ightoff time specified by the ‘equipment manufacturer, close the manual main fuel shutof? valves(s). Check all bumer adjustments. 14, Ifthe main bumer flame is not established after two attempts: a. Check for improper pilot size. 'b. Check for excess combustion air at low fire. ‘Check for adequate low fire fuel flow. Check for proper gas supply pressure. ‘Check for proper valve operation. Cheek for proper plot flame positioning 15, Repeat steps 10 through 14 to establish the main ‘bumer flame; then proceed to step 16. 16, With the sequence in RUN, make bumer adjustments for flame stability and Btu input rating, 17. Shutdown the system by opening the bumer switch or by lowering the set point of the operating controller. Make surethe main flame goes out. There may beadelay dueto gas trapped between the valve(s) and bumer. Make sure all, automatic fuel valve(s) close, 1-29CB780/CB784 CHECKOUT 18, Restartthe system by closing the bumer switch and/or raising the set point 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 lightof time. 19. Measure the flame signal. Continue to check for the proper signal, see Table 9, through the RUN period. Check the signal at both High and Low Firing Rate positions and while modulating. 20. Run the bumer through another sequence, observing the flame signal for: ‘a. Pilot flame alone (DSI. », Pilot and main flame together. cc Main flame alone (unless monitoring an intermit- tent pilot). Also observe the time it takes to light the ‘main lame. Ignitionof main flame shouldbesmooth. 21. Make sure all readings are in the required ranges before proceeding. 22, Retum the system to normal operation. NOTE: After completing these tests, open the master switch and remove all test jumpers from the subbase terminals, limitsfeontrols or switches. INITIAL LIGHTOFF CHECK FOR DIRECT SPARK IGNITION This check applies to gas andoil bumers notusing apilot It should immediately follow the preliminary inspection Refer to the appropriate sample block diagram of field ‘wiring forthe ignition transformer and fuel valve(s) hookup. NOTE: Low fuel pressure limits, if used, could be open. Ifso, bypass them with jumpers diving 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 equip- ‘ment manufacturer. 3. Close all manual main fuel shutoff valve(s). Check that the automatic fuel valve(s) are closed. Make sure fuel is ‘not entering the combustion chamber, 4, Close the master switch and start the system with call for heat by raising the setpoint of the operating controller, ‘ee Fig.18 for CB780/CB784 sequencing. The program sequence should start the ten second INITLATE sequence. 'S. Letthe sequence advance through PREPURGE. Igni- tion spark should occur after PREPURGE period. Listen for the click of the frst stage fuel solenoid valve(s). 6. Let the program sequence complet its cycle. 7. Open the manual fuel shutoff valve(s). 8. Push the reset button and recycle the program so- ‘quence through PREPURGE. 9, When PILOT IGN status is displayed , watch thatthe first stage bumer flame is established. If it is established, proceed to step 15, 10, Ifthe first stage bumer flame is not established within ten seconds, close the manual fuel shutoff valve(s),and open ‘the master switch after POSTPURGE is completed, LL. Check all burner adjustments 12, Wait about three minutes. Close the master switch, open the manual fuel shutoff valve(s), and try to lightoff the ‘bumer again, Tho first attempt may have been required to ‘purge the lines and bring sufficient fuel to the burner. 13, Ifthe fist stage bumer flame is not established within ten seconds, close the manual fuel shutoff valve(S),and open the master switeh, 14, Tnecessary, repeatsteps LI through 13 toestablish the first stage burner flame, Then proceed to step 15. 15, When the first stage burner flame is established, the sequence will advance to RUN. Make burner adjustments for flame stability and input rating. Ifa second stage is used, ‘proceed to step 18, 16, Shutdown the system by opening the burner switch or by lowering the set point of the operating controller. Make sure the bumer flame gocs out andall automatic fuel valve(s) close 17. If used, remove the bypass jumpers from the low fuel pressure limit and subbase. 18, Ifasecond stage is used, make sue the automatic sec- ‘ond stage fuel valve(s) has opened. Check the lightoff as follows (otherwise proceed to step 19): a, Open the manual second stage fuel valve(s) ’, Restatt the system by raising the set point of the ‘operating controler. ‘c. When the first stage bummer flame is established, watch for the automatic second stage fuel valve(s) ‘to open, Observe that the second stage lights off properly. 4. Make bumer adjustments for flame stability and input rating. €. Shut down the system by lowering the set point of the operating controller. Make sure the bumer flame goes out and all automatic fuel valve(s) close. £. Proceed to step 19, 19, Restartthe system by closing the bummer switch and/or raising the setpoint of the operating controller. Observe that the burner flame is established during PILOT IGN, within the ‘normal ightof time specificdby the equipment manufacturer. 20, Measure the flame signal. Continue to check for the proper signal, sce Table 9, through the RUN period. Check the signal at both high and low firing rate positions and while ‘modulating. Any pulsating or unsteady readings will require futher attention. 21, Make sure all readings are in the required ranges before proceeding, NOTE: Upon completing these tests, open the master switch and remove all test jumpers from the subbase terminals, limits/controls or switches. 22, Retum the system to normal operation, PILOT TURNDOWN TEST (ALL INSTALLATIONS, USING A PILOT) ?Perform this check on all installations that use a plot. The purpose of this testis to verify thatthe main bumer can be lit bby the smallest pilot flame that will hold in the flame 750-166‘amplifier and energize the FLAME LED. Clean the flame detector(s) to make sure that it will detect the smallest acceptable pilot flame, Ifusing Auto-Check or Self-Check- ing Amplifier and 1M ohnvvolt meter, the flame signal will, fluctuate 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 tumidowa test 4. Open the manual plot shutoff valve(). 5. Close the master switch and stat the system with a call for heat. Raise the set point of the operating control Jer. The program sequence should start, and PREPURGE should begin. 6. Whenthe PILOTIGN begins, set the Run/Test Switch, to TEST postion to stop the sequence. The FLAME LED ‘will come on when the pilot ignites. NOTE: Ifthe 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 eight seconds or three seconds, depending on PFEP selected, to postion the Rur/Test ‘Switch othe TEST position to stop the sequence afer the start ofthe PILOT IGN period. 7. Tam the pilot pressure down very slowly, reading the ‘manometer (or pressure gauge) as it drops. Stop instantly when the FLAME LED goes out. Note the pressure at the (CB780/CB784 flame relay dropout point. The pilots atthe ‘minimum tumdown positon. Immediately tum up the pilot pressure until the FLAME LED comes on again or the flame signal increases to 1.25 Vek NOTE: If there is no flame for fifteen seconds with the sequence stopped at this point, the CB780/CB784 will lockout and flash a lockout message; see Fig. 27 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 tum it down slowly to obtain apressure reading just above the dropout point or until the flame signal increases to 1.25 Vée. 750-166 CB780/CB784 CHECKOUT Fig. 27—Flame-out timer lockout. LOCKOUT #16 PFEP * Flame-out Timer Condition at the time of lockout . PILOT HOLD: (Run/Test Sw) 10, Set the Run/Test Switch in the RUN position and let the sequence proceed, At ten seconds into the Ignition Trial period, make sure the automatic main fuel valve(s) open; 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 bumer ignition. Ifthe main burner flame is established, proceed to step 18. NOTE: This step requires two people, one to open the ‘manual valve(s) and one to watch for ignition. 11, Ifthe main bumer flame is not established within ten seconds, close the manual main fuel shutoff valve(s) and. ‘open the master switch If the lightoff was rough, the pilot flame size is too small 12. Recycle the burner and stop the sequence in the Pl- LOT IGN period by using the RunTest Switch. 13, Increase the plot flame size by increasing its fuel flow unt a smooth main flame is accomplished. 14, Reposition the flame scanner sight ube or use orifices ‘until the pilot flame signal voltage isin the range of 1.25 to 1.50 Vac. 15. When the main bumer lights reliably with the pilot at tumdown, disconnect the manometer (or pressure gauge) ‘and tum the pilot gas flow up to that recommended by the ‘equipment manufacturer, 16. Ifused, remove the bypass jumpers from the sub- base terminals, imits/controls, or switches. 17. Run the system through another cycle to check for ‘normal operation, 18, Retum the system to normal operation 131CB780/CB784 CHECKOUT HOT REFRACTORY SATURATION TEST (ALL INFRARED DETECTORS) Test to make certain that radiation from hot refractory does not mask the flickering radiation of the flame itself Start the bumer and monitor the flame signal during the ‘warmup period. A decrease in signal strength as the efrac- tory heats up indicates hot rfractory saturation. I saturation, is extreme, the flame signal will drop below 1.25 Vde and the system will shut 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 cll 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 (ALL INFRARED DETECTORS) Test 10 make certain hot refractory will not delay the flame detection system response to flameoat. This condi- tion can delay esponse to flame failure and also can prevent a system restart as long as hot refractory is detected Infrared (lead sulfide) detectors can respond to infrared rays emittedby ahot refractory, even when the refractory has visibly ceased to glow. Infrared radiation from a hot refrae- tory 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 hotrefractory."The refractory steady signal canbemade to fluctuate itisreflected, bent or blocked by smoke or fuel mist within the combustion chamber. Be careful when ap- plyingan infrared system to verify its response to flame only. “To check infrared (lead sulfide) detectors for hot refrac- tory hold-in, operate the bumer until the refractory reaches its maximum temperature Ifthe installation ha a mult-fuel bbumer, bum the heavier fuel that is most likely to reflect, bend or obscure the hot refractory steady infrared radiation. ‘When the maximum refractory temperature is reached, close all manual fuel shutoff valve(s),or openthe electrical circuits ‘of all automatic fuel valve(s). Visually observe when the bbumer flame or FLAME LED goes out. If this takes more than three seconds, the infrared detector is sensing hot refractory. Immediately terminate the firing cycle. (Lower the set point to the operating controler, or set the Bumer ‘Switch to OFF. Do not open the master switch.) NOTE: Some burners continue to purge il lines betweenthe valve(s) and nozzle(S) even though the fuel valve(s) are closed, Terminating the fring cycle (instead of opening. the master switch) will allow purging the combustion ‘chamber. This will reduce a buildup of fuel vapors in the combustion chamber caused by cil ine purging, Ifthe detectors sensing hot refractory, the condition must be corrected, Add an orifice plate in front ofthe cell 0 restrict ‘the viewing area of the detector. If this does not correct the problem, resight the detector at cooler, more distant part of the combustion chamber. While resighting the detector, be 132 aware that it mustalso properly sightthe flame. For an infrared _| selectable message. The second line will display Diagnostic Information, 2 | Press change level keyto | (>) | STANDBY Use the change Key to access the access Diagnostic Diagnostic Infor | Diagnostic Information. Information 3 | Continue display of @ _ [STANDBYDI Push the (4) serll Key to scroll tothe next Diagnostic Information. Device RM7800<__ | Diagnostic message, 4, Continue through remaining Diagnostic Info mation display following step 3 as required. ‘S| Press change level key to | (<) | STANDBY ‘Another display can be selected or return to the first level of Diagnostic Info> _ discontinue accessing Diagnostic Informnation review. Diagnostic Information data prompt or to other selectable messages, NOTE: Historical Files may be selected similarly. 2 750-166‘TABLE 3 SELECTABLE MESSAGES (see CB780/CB784 Relay Module, Manual Part Number 750-166). Selectable Possible States/Range Message/Display Description (Terminals) Comments Flame Signal Flame signal strength. [0-5.0 VdeFlame | Flame relay pullin and drop- Amp (+ and -(Com))_| out value 1.25 Wée. Total Cycles “Total number of equipment [0-99,999 cycles | Cycle counter will be updated operating cycles cach time the main valve is energized. Total Hours ‘Total number of equipment | 0- 99,999 hours Hour counter will be updated ‘operating hours. cach time the main valve output is energized for 60 minutes. Fault History> (six most | First level prompt for recent felts) history information. Has subset level Fault Cycle AHL | Cycle when the fault 0 - 99,999 cycles occurred. Fault Hours Aut | Run hour when the fault | 0- 99,999 hours HI occurred. Fault Code Aut | Number that identifies the | 0-999 reason forthe lockout. ‘*Fault Message* AHI | Indicates lockout cause. ‘Sequence Message AHI | Indicates where the lockout ‘occurred in the sequence. (Second Line Message) | Second Line Message Aut explains any further information available from the CB 780/CB 784 or may be blank if there is not a preemptive second line. H2.,.H6 etc. Diagnostic Information> | First level prompts for history information. Has subset level. Device Device type number. RM7800x or RM78405 Device Suffix Device suffix number. [ann Run/Test Sw Position of Run/Test RUN or TEST Indicates if CB 780/CB 784 is switch, in RUN or TEST mode. ‘OperControl 76 | Operating Control Input. [1 or Indicates if input is on or off, energized or de-energized. Interlock 7 | Running/Lockout Interlock. | 1 or 0 Tndicates if input is on or off, energized or de-energized. Pilot Vaive 8 | Pilot Valve. Tord Tndicates if output terminalis on or off, energized or de-energized, Main Valve TD | Main Fuel Vaive Tord Indicates if output terminalis on or off, energized or sde-energized. Tagnition THO [gnition Tord Indicates if output terminal is on or off, energized or de-energized. 750-166 (Continued) 25‘TABLE 3—SELECTABLE MESSAGES (Continued). Selectable Possible States/Range Message/Display Description (Terminals) Comments LowFire Sw TI8 | Low Fire Switch. Tord Indicates if input is on or off, energized or deenergized. HighFire Sw TI9 | High Fire Switch. Tord Indicates if input is on or off, ‘energized or deenergized. Prelgn LK, 720 | Preignition Interlock. Lord Indicates if input is on or off, energized or deenergized. Valv/Start, ‘Tai [Interrupted/Intermitent — [1 or0 Tndicates if output is on or off, Pilot Valve. First stage oil energized or deenergized. valve or start input. Jumper 1 Pilot Flame Establishing | INTACT/CLIPPED | Display shows state of PFEP Period (PFEP) jumper. If jumper is intact, the (CB 780/CB 784 will have a 10 second PFEP. If jumper is clipped, the CB 780/CB 784 will have a4 second PFEP. Jumper? NOT USED JUMPER 3 Tnterlock Check C) INTACT Disabled _| Display shows state of Star- CLIPPED Enabled | Up Interlock Check (IC) jumper. If jumper is clipped, ‘CB 780/CB 784 IC check is cenabled, If jumper is intact, ICis disabled. ‘Amp Type Defines type of amplifier |NORMAL/AMP- | Display shows type of flame installed. CHECK/SHUTTER _ | detection system installed (i.c., as NORMALStandard, AMP- (CHECK/AMPLI-CHECK™, and SHUTTER /Dynamic Self- Checking). Flame Response ‘Amplifier Flame Failure [3 seconds| Response Time (FFRT) in seconds. Purge Time ‘Timing value of purge card. | mm:ss 30 seconds to 2-1/2 minutes Mig Code “Manufacturing code is five [ nnnon digit code representing date code. ‘SW Rev Software revision and ‘annvnnnn First four digits represent the version code for Keyboard software revision of the Display Module and. Keyboard Display Module. CB 780/CB 786. Second four digits represent the software revision of the relay module. Expanded Annunciator | First evel prompt for ‘See Table 5. Expanded Annunciator information and has subset level (Table 5). Remote Command ‘Status of firing rate NONE/HOLD command from remote | HF/LF controller, 26 750-166LOCKOUT MESSAGES (TABLE 4) ‘When the CB780/CB78+4 is locked out, it displays a repeating cycle of messages (in English text); see Table 4. In addition to the lockout messages, Table 4 provides the system failure and recommended troubleshooting. There ate four states inthe cycle: 1, STATE 1, see Fig I: First state message display lasts six seconds. First line displays the word LOCKOUT fol- lowed by the fault code number, and possibly a lower case letter if an Expanded Annunciator is connected, The status of the Relay Module atthe time of lockout is shown on the sight side of the frst line as either INITIATE, STANDBY, PURGE, PFEP, MFEP, RUN or POSTPRG. The lockout reason corresponding to the fault code number is displayed ‘on the second line, highlighted by asterisks on each side. IF the lockout reason is being enhanced due to the presence of an Expanded Annunciator, a lower case letter follows the fault code number. This letter corresponds to the first-out code supplied by the Expanded Annunciator. 2. STATE 2, see Fig. 2: Display of the socond state ‘message lasts two seconds. Fig. 1—Lockout message state 1. Geavertitroots |auANER CONTROL LockoUT #23 PURGE “Airflow Sw* HG: Bath 750-166 3. STATE 3, see Fig. 3: Display of the third state mes- sage lasts three seconds. Iisa replica of the burner status as itexisted atthe time of lockout. The second line willbe blank if the burner status atthe time of lockout did not include a pre-emptive message (in parentheses) for the second line. 4, STATE4: Inthe fourth state, both lines are blanked for ‘one-half second, then sequence to the first state, Fig. 2—Lockout message state 2. Condition at the time of lockout .. wan 0 ew 7 + Oro Fig. 3Lockout message state 3. Cleavertifbreoks | BURNER CONTROL (_ mamear (Airflow Sw.) 27TABLE 4—FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING. Fault Code System Failure ‘Recommended Troubleshooting Fault O1 *No Purge Card* No card is plugged into the ‘purge card slot. I “Assure the purge card is seated properly. Inspect the purge card and the connector on the relay module for damage or contaminants. Reset and sequence the CB 780/CB 784. IF fault code reappears, replace the purge card. Reset and sequence the CB 780/CB 784, I fault persists, replace the relay module. Fault 02 AC Frequen/Noise* Excess noise or device running. on slow AC. Flaere ‘Check the relay module and display module connections. Reset and sequence the CB 780/CB 784. ‘Check the CB 780/CB 784 power supply to assure that both frequency and voltage meet, specifications. Check the backup power supply as appropriate. Fault 03 AC Line Dropout* ‘AC Line dropout detected. ‘Check the relay module and display module ‘connections Reset and sequence the CB 780/CB 784, Check the CB 780/CB 784 power supply to assure that both frequency and voltage meet specifications. Check the backup power supply as appropriate Fault 04 *AC Frequency* Device running on fast AC. PP ‘Cheek the relay module and display module connections. Reset and sequence the CB 780/CB 784. Check the CB 780/CB 784 power supply t0 assure that both frequency and voltage meet specifications. Check the backup power supply as appropriate. Fault 05 Low Line Voltage* Low AC line detected. ‘Cheek the relay module and display module connections. Reset and sequence the CB 780/CB 784. Check the CB 780/CB 784 power supply to assure that both frequency and voltage meet specifications. Check the backup power supply as appropriate, Fault 06 Purge Card Error* ‘The purge card timing has changed from the original configuration, “Assure that the purge card is seated properly. Inspect the purge card and the connector on the relay module for any damage or contaminants Reset and sequence the CB 780/CB 784. If fault code reappears, replace the purge card. Reset and sequence the CB 780/CB 784. If code persists, replace relay module, Fault 07 Flame Amplifier* Flame not sensed when checked for a nonself-check version. ‘Check wiring; correct any errors ‘Assure thatthe flame detector and flame ‘amplifier are compatible. Remove the flame amplifier and inspect its ‘connections. Reseat the amplifier. Reset and sequence the CB 780/CB 784. Ifthe code reappears, replace the flame amplifier and/or the flame detector. If fault persists, eplace the relay module. 28 (Continued) 750-166‘TABLE 4~FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). Fault Code System Failure ‘Recommended Troubleshooting Fault 08 **Flame Amp/Shute* Flame sensed when checked for shutter-check or ampli-check ae ‘Check wiring; correct any errors. ‘Assure that the flame detector and flame amplifier are compatible. Remove the flame amplifier and inspect its connections. Reseat the amplifier. Reset and sequence the CB 780/CB 784. If the code reappears, replace the flame amplifier and/or the flame detector. If fault persists, replace the relay module. Fault 09) *Flame Detected* Flame sensed when shut open and no flame is expected during Standby. ve PR Te (Check that flame is not present in the combustion, chamber, correct any errors. Check wiring; correct any errors. Remove the flame amplifier and inspect its connections. Reseat the amplifier. Reset and sequence the CB 780/CB 784, If the code reappears, replace the flame amplifier and/or the flame detector. If fault persists, replace the relay module. Fault 10 *Preignition ILK* Preignition interlock fault during Standby. PP Re ‘Cheek wiring; correct any errors. (Check Preignition Interlock switches to assure proper functioning. Check fuel valve operation. Reset and sequence the CB 780/CB 784; monitor the Preignition interlock status, Ifcode persists, replace the relay module. Fault 12 Lockout ILK On* ‘Lockout Interlock powered at ‘improper point in sequence. |. Check wiring to assure that the Lockout Interlocks are connected properly between terminals 6 and 7. Correct any errors Reset and sequence the CB 780/CB 784. If the fault persists, measure the voltage between terminals 6 and G (ground), then terminal 7 and G (ground). If there is 120 Vac 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 120 Vac at terminal 7 while the controller is closed and the fault persists, check for a welded or jumpered Running Interlock, Lockout Inierlock or Airflow switch. Correct any errors. Ifsteps 1 through 4 are correct and the fault persists, replace the relay module. 750-166 (Continued) 29‘TABLE 4 FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). Fault Code System Failure Recommended Troubleshooting Fault 14 *High Fire Sw.* High fire interlock switch failure to close during prepurge. Check wiring; correct any errors. Reset and sequence the CB 780/CB 784. 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 ‘witch while in this state to assure that itis closing properly. Measure the voltage between terminal 18 and G (ground) while in the Prepurge Drive to High Fire state, 120 Vac should be present. If not, the switch adjustment is incorrect and/or the switch is defective and should be replaced. Reset and sequence the CB 780/CB 784. If 120 Vac was prosent between the High Fire switch and terminal 18, and the fault still persists, replace the relay module. Fault 15 *Flame Detected* Flame sensed when shutter open] ‘and no flame is expected. ‘Check that flame is not prevent in the combustion ‘chamber; correct any errors. ‘Assure that the flame amplifier and flame detector are compatible. Check wiring and correct any errors. Remove the flame amplifier and inspect its connectors, Reseat the flame amplifier. Reset and sequence the CB 780/CB 784. Ifthe code reappears, replace the flame amplifier and/or the flame detector. If fault persists, replace the relay module, Fault 16 *Flame-Out Timer* Tntegrated no-flame time exceeded the limit during Pilot Flame Establishing Period. Measure the flame signal, If one exists, does it meet specifications? Make appropriate burner adjustments. “Assure that the flame amplifier and the flame detector are compatible. Replace the flame amplifier and/or the flame detector, if necessary. IE the fault persists, replace the relay module. rekyy *Main Flame Fail* ‘Main flame failure during Run after flame was established and on for atleast 10 seconds. Tnspect the main fuel valve(s) and its ‘connection(s). Verify that the fuel pressure is sufficient enough to supply fuel to the combustion chamber. Inspect the connections to the fuel pressure switches, Assure tproper functioning, Inspect the Airflow Switch and assure that it is functioning properly. Check the flame detector sighting position; reset ‘and eycle. Measute flame signal strength, Does it meet specifications? If not, refer to the flame detector and/or flame amplifier checkout procedures in the installation instructions, 210 (Continued) 750-166‘TABLE 4 FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). Fault Code System Failure ‘Recommended Troubleshooting Fault 18 ‘Flame Detected* ‘Flame sensed when shutter open | and no flame is expected during Propurge ‘Check that flame is not present in the combustion ‘chamber. Correct any errors. ‘Assure thatthe flame amplifier and flame detector are compatible. Check wiring; correct any errors. ‘Remove the flame amplifier and inspect the ‘connectors. Reseat the flame amplifier. Reset and sequence the CB 780/CB 784. If the code reappears, replace the flame amplifier and/or the flame detector. If the fault persists, replace the relay module. Fault 19 Main Flame Ign.* } Flame was lost during MFEP or the first 10 seconds of the Run state, Tnspect the main fuel valve(@) and connections. Verify that the Fuel pressure is sufficient 10 supply fuel to the combustion chamber. Inspect the connections to the fuel pressure switshes 10 assure proper functioning. Inspect the Airflow Switch to assure proper functioning. Check the flame detector sighting position; reset and cycle. Measure flame signal strength. Does it meet specifications? If not, refer to the flame detector and/or flame amplifier checkout procedures in the installation instructions. Fault 20 Low Fire Sw. Off Low fire interlock switch failure to close during Prepurge. ‘Check wiring; correct any errors. Reset and sequence the CB 780/CB 786. Use either the manual motor potentiometer to drive the motor to the Low Fire position, or use the Rua/Test switch option (if available) sequence to Prepurge Drive to Low Fire and place in the TEST position, Adjust the Low Fire switch while inthis state to assure that i is closing properly. ‘While in the Prepurge Drive to Low Fire state, measure the voltage between terminal 19 and G (ground). 120 Vac should be present. If not, the switch adjustment is incorrect and/or the switch is defective and should be replaced. 5. Reset and sequence the CB 780/CB 784. If 120 Vac was present between the Low Fire switch and terminal 19 and the fault still persists, replace the relay module. ‘Fault 22, *Lockout ILK* Lockout Interlock fault during Prepurge. ‘i. 2 3. ‘Check wiring; correct any errors. Inspect the fan; assure that there is no blockage Of the air intake and that it is supplying air. ‘Assure that the Lockout Interlock switches are functioning properly and thatthe contacts are free from contaminants. Reset and sequence the CB 780/CB 784 to Prepurge (place the Run/Test switch into the ‘TEST position, if available). Measure the voltage between terminal 7 and G (ground). 120 Vac should be present. 5. If steps I through 4 are correct and the fault persists, replace the relay module. 750-166 (Continued) x‘TABLE 4—PAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). Fault Code ‘Recommended Troubleshooting Fal 34 “The Flame Interlock (relay g | 1. Reset and sequence the CB 780/CB 784 *Call Serviee* module) was on when isha. | 2. 1f felt persists, replace the relay module have been off Fault 25 “The Flame Interlock (ay | 1. Reset and sequence the CB 780/CB 784, +Call Service ‘odule) was off wien it should | 2 If fault persists replace the relay module, beon Fault 28 *Pilot Flame Fail* Pilot flame failure, ‘Check pilot valve wiring and operation. Correct any error. Check fuel supply, Check pilot pressure and repeat pilot tumdown test ‘Check ignition transformer electrode, flame detector, flame detector sighting, and flame amplifier. Ifsteps | through 4 are correct and the fault persists, replace the relay module. Fault 29 Lockout ILK* ‘Lockout Interlock fault. Assure that the Lockout Interlock switches are ‘Check wiring; correct any errors Inspect the fan; assure that there is no blockage Of the air intake and that it is supplying air. functioning properly and thatthe contacts are free from contaminants. Reset and sequence the CB 780/CB 784 to ‘Prepurge (place the Run/Test Switch into the TEST position, if available). Measure the voltage between terminal 7 and G (ground). 120 Vac should be present. Ifsteps | through 4 are correct and the fault persists, replace the relay module. Fault 31 Low Fire Sw. Off* Low Fire Interlock switch failure to close during Run. re 3. Use either the manual motor position to drive the (Check wiring; correct any errors. Reset and sequence the CB 780/CB 784, motor to the LOW FIRE position, or use the Run/ Test switch option (if available) sequence gun Drive to Low Fire and place in the TEST position, Adjust the Low Fire switch while in this, State to assure that it is closing properly. ‘While in Run Drive to Low Fire state, measure the voltage between terminal 19 and (ground). 120 Vac should be present. Ifnot, the switch adjustment is incorrect and/or the switch is defective and needs replacement. Reset and sequence the CB 780/CB 784. If 120 Vae was present between the Low Fire switch and terminal 19 and the fault still persists, replave the relay aiodule. 7 (Continued) 750-166‘TABLE 4FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued), Fault Code Fault 33 *Preignition ILK* System Failure Preigaition Interlock fault. . Recommended Troubleshooting ‘Check wiring; correct any errors. Inspect the Preignition Interlock switches and assure proper funcitoning, Check fuel valve operation, Valve must close within five seconds. Reset and sequence the CB 780/CB 784. During Standby or Prepurge, measure the voltage between terminal 20 and G (ground). 120 Vac should be present. If not, the Preignition Interlock switches may be defective and need replacement. If the fault persists, replace the relay module. Fault 35, Call Service? Safety relay was off when it should be on or fuse has blown, ‘Reset and sequence the CB 780/CB 784, If fault persists, replace the relay module, Fault 36 *Call Service* Main valve terminal was off when it should be on. Reset and sequence the CB 780/CB 784 [Ef fault persists, replace the relay module. Fault 37 *Call Service* Pilot (ignition) valve terminal ‘was off when it should be on, Reset and sequence the CB 780/CB 784. If fault persists, replace the relay module. Fault 38 *Call Servicet Ignition terminal was off when it should be on. Reset and sequence the CB 780/CB 784, If fault persists, replace the relay module. Fault 39 *Call Service* 'V2S valve terminal was off shen it should be on, ‘Reset and sequence the CB 780/CB 784, If fault persists, replace the relay module, Fault 40 Call Service* Safety relay was on when it should be off, Reset and sequence the CB 780/CB 784, If fault persists, replace the relay module. Fault 41 *Main Valve On* “Main valve terminal was on when it should be off. TIPE|P=|Pe|pe[pe|pel= ‘Warning! Remove system power, turn off fuel supply. Check wiring to terminal 9; correct any erors. Inspect the Main Fuel Valve(s) and connections. ‘Assure that switches are functioning correctly ‘and are not jumpered or welded. Reset and sequence the CB 780/CB 784. ._If the fault persists, replace the relay module, Fault 42 *Pilot Valve On* PPilot (ignition) valve terminal ‘was on when it should be off. ‘Warning! Remove system power; tum off fuel, supply. Check witing to terminal 8; corect any errors. Inspect the Pilot Fuel Valve(s) and connections. ‘Assure that switch is functioning correctly and is not jumpered or welded. Reset and sequence the CB 780/CB 786. If the fault persists, replace the relay module. Fault 43 “ignition On* Tgnition terminal was on when it should be off, ‘Warming! Remove system power, turn off fuel supply. ‘Check wising to terminal 10; correct any errors. Inspect the Ignition terminal and connections. ‘Assure that switch i functioning correctly and is not jumpered or welded, Reset and sequence the CB 780/CB 784. If the fault persists, replace the relay module. 750-166 (Continued) 243‘TABLE 4 FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). off, Fault Code ‘System Failure Recommended Troubleshooting Fault 44 ‘V2S valve terminal, used asa | 1, Warning! Remove system power; turn off fuel Pilot Valve 2 On* pilot, was on when it should be | supply. on Check wiring to terminal 21; correct any errors, Inspect the Pilot Fuel Valve 2 and connections. ‘Assure that switch is functioning correctly and is, not jumpered or welded. Reset and sequence the CB 780/CB 784, Ifthe fault persists, replace the relay module. Fault 45 Low Fire Sw. Off* Low fire interlock switch failure to close or stay closed >pelae Check wiring; corect any eos Reset and sequence the CB 78O/CB 784, Use ther te manual motor postion to dive the ‘motor t te LOW FIRE poston, or use the RunvTest switch opin, iravailable Sequence to the LOW FIRE position and place the switch in the TEST postion, Adjust the Low Fire switch wil ints tat to astue that ts elosing propery While i the Drive to Low Pie state, measure the Yoltage between lerminals 19 and G (ground). 120 Vec shouldbe present. Hn, the switch adjustments incorect and/or the switch is detective and should be replaces. Tf steps I trough 4 are corect an the fault til pests replace the relay module Fault 47 ‘Jumpers Changed* ‘The configuration jumpers differ from the sample taken at startup. Inspect the jumper connections. Assure that clipped jumpers were completely removed. 2, Reset and sequence the CB 780/CB 784. 3._If fault persists, replace the relay module. Fault 50 “The sequence logic detected a | 1. Inspect jumpers and consult the instruction and ‘Jumpers Wrong* combination of jumpers that is installaion guide for compatible jumper illegal for the sequence (e.g.,ifit] configurations. Assure clipped jumpers are was correct to clip jumper 1 or completely removed. jumper 2, but not both, this fault | 2. Reset and sequence the CB 780/CB 784. ‘would be used if both were 43. If fault persists, replace the relay module. clipped). Fault 51 Flame signal value is too high to | 1, Assure that flame detector and flame amplifier ‘Flame Too Strong* be valid. ‘are compatible. 2. Remove the flame amplifier and inspect its ‘connectors, Reset the flame amplifier. 3, Reset and sequence the CB 780/CB 784. 4, Cheek the flame detector sighting position, reset and eycle. Measure flame strength, Does it meet specifications? If not, refer to flame detector and/or flame amplifier checkout procedures in installation instructions. If the code reappears, replace the flame amplifier and/or the flame detector. If fault persists, replace the relay module Faulk 52 "internal Fault* Pilot Valve 2 terminal was off when it should be on. Tnspect Pilot terminal 21 and connections. Assure that Pilot is functioning properly. Reset and sequence the CB 780/CB 784. IE fault persists, replace the relay module, 214 (Continued) 750-166‘TABLE 4 FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). Fault Code ‘System Failure ‘Recommended Troubleshooting Fault 67 Ti and 12 miswired/exchanged. | 1. Check L1 and L2 for proper line phasing, *AC Phase* Fault 105 Relay Module self-test failure. | 1. Reset and sequence the CB 780/CB 784. *Call Service* 2. If fault reappears, remove power from the device, reapply power, reset and sequence the CB 780/CB 784. 3._If fault persists, replace the relay module. Fault 106 Relay Module self-test failure. | 1. Reset and sequence the CB 780/CB 784. Call Service* 2. If fault reappears, remove power from the device, reapply power, reset and sequence the CB 780/CB 784. 3,_If fault persists, replace the relay module. Fault 107 Relay Module flame signal 1. Reset and sequence the CB 780/CB 784. *Call Service* cross-check failure. 2. If fault reappears, remove power from the device, reapply power, reset and sequence the CB 780/CB 784, 3,_If fault persists, replace the relay module. Fault 109 Negative cycle test failed; earth | 1. Assure that a good earth ground connection *Call Service* ground absent or line voltage exists at the installation site and that all earth phasing improper. ground connections are complete and correct. 2. Assure that the CB 780/CB 784 and all loads ‘operate at the same Tine voltage phase. 3, Reset and sequence the CB 780/CB 784. 4._If fault persists, replace the relay module. Fault 110 ‘Configuration jumpers differ | 1. Tnspect the jumper connections. Assure they *Call Service from stored values. ‘match the original selection and clipped jumpers ‘were completely removed. 2. Reset and sequence the CB 780/CB 784. 3. If fault persists replace the relay module. 4, Configuration jumpers must be selected prior to 200 hours of operation. If configuration jumpers are changed after 200 hours of operation, lockout 110 occurs, Fault 111 Relay Module configuration | 1. Inspect the jumper connections. Assure they *Call Service* jumper test failure. ‘match the original selection and clipped jumpers have been completely removed. 2. Reset and sequence the CB 780/CB 784. 3._If fault persists, replace the relay module. Fault 112, Relay Module self-test failure, | 1. Reset and sequence the CB 780/CB 784. *Call Service* 2. If fault persists, replace the relay module. Fault 113 Relay Module selftest failure, | 1. Reset and sequence the CB 780/CB 784. *Call Service* 2. If fault persists, replace the relay module. Fault 114 Relay Module selftest failure. | 1. Reset and sequence the CB T80/CB 784, *Call Service* 2._If fault persists, replace the relay module. Fault 117 Relay Module selftest failure. | 1. Reset and sequence the CB T80/CB 784, *Call Service* 2._If fault persists, replace the relay module. Fault 118 Relay Module self-test failure. | J. Reset and sequence the CB 780/CB 784. Call Service* 2._If fault persists, replace the relay module, 750-166 (Continued) 21S‘TABLE 4—FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued). Fault Code ‘System Failure Recommended Troubleshooting Fault 119 *Call Service* Relay Module self-test failure. ‘Reset and sequence the CB 780/CB 784. If fault persists, replace the relay module. Fault 120 *Call Service* Relay Module self-test failure. ‘Resot and sequence the CB 780/CB 784. If fault persists, replace the relay module, Fault 121 *Call Service* Relay Module self-test failure. ‘Reset and sequence the CB 780/CB 784. If fault persists, replace the relay module. Fault 122 *Call Service* Relay Module self-test failure. ‘Resot and sequence the CB 780/CB 784. If fault persists, replace the relay module. Fault 123 *Call Service” Relay Module self-test failure. Reset and sequence the CB 780/CB 784. If fault persists, replace the relay module. Fault 125 *Call Service® Relay Module self-test failure. Reset and sequence the CB 780/CB 784. If fault persists, replace the relay module. Fault 126 Call Service* Relay Module self-rest failure. Reset and sequence the CB 780/CB 784, If fault persists, replace the relay module. Fault 127 *Call Service Safety relay feedback circuit ‘was in an improper state, Del PE]P=|PH]P=PP=|PeIR> Reset and sequence the CB 780/CB 784. If fault persists, replace the relay module. 216 750-166‘TABLE 5—CB783 EXPANDED ANNUNCIATOR HOLD CODES. ‘Annunciation Message [ Symbol | _ System Holds BURNER OFF: T6 TA Bumer switch is open (Bumer Switch) STANDBY HOLD: T6 A “Aunilary limit #1 is open (Aux. Limit #1) ‘STANDBY HOLD: T6 TA “Auxiliary limit #2 is open (Aux, Limit #2) STANDBY HOLD: 76 TA Open low water cutoff. «Lwco) STANDBY HOLD: T6 A “igh limit (pressure or temperature) exceeded. igh List) ‘STANDBY HOLD: T6 x “Auxiliary Timit #3 5 open. (Aux, Limit #3) ‘STANDBY HOLD: T6 TA No fuel selected. PuelSelect OF) STANDBY HOLD: 16 A Both fuels selected. BothFuelSelect) ‘STANDBY HOLD: T6 EA Oil pressure is above high ol pressure limit, High Oil Pres) STANDBY HOLD: 76 EN Oil pressure is below low oll pressure limit. ow Oil Pres) STANDBY HOLD: 76 HA Oil temperature is above high ol temperature lit igh Oi1 Temp.) ‘STANDBY HOLD: T6 EA (il temperature is below low oil temperatare Limit (Low Oil Temp.) STANDBY HOLD: T6 EN “Atomizing switch is open. (Atomizing Sw.) STANDBY HOLD: 16 TA Gas pressure is above high ges pressure limit. igh Gas Pres.) STANDBY HOLD: 6 EA Gas pressure is below low gas pressure Limit. (Low Gas Pres) STANDBY HOLD: T6 CN Control input isnot energized. (Circuit Fanlt 750-166 217TABLE 6—CBT783 EXPANDED ANNUNCIATOR FAULT CODES. ‘Annunciation Message | Symbol | System Faults LOCKOUT nna EA “Auxiliary limit #1 is open. Aux. Limit #1* LOCKOUT nab EA “Auxiliary limit #2 is open. Aux, Limit #2* LOCKOUT nne FA ‘Open low water cutoff. sLWOO* LOCKOUT nnd FA “High limit (pressure or temperature) is exceeded, “High Limie® LOCKOUT nne EA ‘Auxiliary Timit #3 is open. Aux, LimitW3* LOCKOUT nat FA ‘No fuel is selected, *PuelSelect Of" LOCKOUT mg. FA Both fuels are selected. *BothFuelSelect* LOCKOUT mh FA il pressure is above high oil pressure limit “High Oil Pres.* LOCKOUT ani FA Oil pressure is below low oil pressure limit Low Oil Pres.* LOCKOUT nnj FA (il temperature is above high oil temperature limit. *High Oil Temp.* LOCKOUT nik EA Oil temperature is below low oil temperature limit. Low Oil Temp.* LOCKOUT anm FA ‘Atomizing switch failed to close. *Atomiring Sw.* LOCKOUT nna FA ‘Gas pressure is above high gas pressure limit. “High Gas Pres.* LOCKOUT mmo FA ‘Gas pressure is below low gas pressure limit. "Low Gas Pres.* LOCKOUT nnp FA ‘The airflow switch is open when it should be closed or vice versa, *Airflow Switch* LOCKOUT nnq “Auxiliary interlock #3 is open. Aux. ILK #4¢ LOCKOUT anr EA “Auxiliary interlock #4 is open. Aux. ILK #5* ‘LOCKOUT ans EA ‘Other Auxiliary Interlocks are open. *Other ILKs* LOCKOUT nny EA Preignition Interlock or other valve closure switch is open, *Valve Closure* LOCKOUT nnz KA ‘Other Preignition Interlocks are open, Other PUls* 218 750-166(CB783 EXPANDED ANNUNCIATOR DIAGNOS- TIC CURRENT STATUS MESSAGES (TABLE 7) These messages are used to provide information from the (CBI83 Expanded Annunciator to the Keyboard Display ‘Module in the EA Diagnostic section under Current Status; see Table 7. This information explains the first limit or interlock inthe system that is de-energized. 750-166 ‘TABLE 7—CB783 EXPANDED ANNUNCIATOR DIAGNOSTIC CURRENT STATUS MESSAGES, Display Description Bumer Sw. Burner Switch Oper. Control ‘Operating Control ‘Aux, Limit #1 “Auxiliary Limit #1 ‘Aux. Limit #2 ‘Auxiliary Limit #2 LWCO. Low Water Cutoff High Limit High Temperature or High Pressure Limit ‘Aux. Limit #3 Auxiliary Limit #3 FuclSeleciOf Fuel Select Off BothfuelSelect Both Fuels Selected High Oil Pres. High Oit Pressure Low Oil Pres. Low Oil Pressure High Of Temp. High Oil Temperature Low Oil Temp, Low Oil Temperature ‘Atomizing Sw. ‘Atomizing Switeh High Gas Pres. High Gas Pressure Low Gas Pres. Low Gas Pressure Airflow Sw. ‘Airflow Switch ‘Aux. ILK #4 ‘Auxiliary Interlock #4 ‘Aux. ILK #5 “Auxiliary Interlock #5 ‘All switches on 219750-166Cleaver?!#Brooks’ Performance Proven Worldwide