750-166 CB780 - CB784 PDF

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Cleaver-Brooks
CB780/CB784
Operation and Maintenance Manual
750-166
DIVISION OF AQUA-CHEM, INC.

TO: Owners, Operators and/or Maintenance Personnel
This manual presents information that will help to properly operate and care for 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 to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all
applicable instructions and warnings may result in severe personal injury or death.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who are servicing,
repairing, or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and mechanical
devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating techniques and
maintenance procedures must be followed at all times. Although these components afford a high degree of protection and safety,
operation of equipment is not to be considered free from all dangers and hazards inherent in handling and firing of fuel.
"Automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely free him of
certain repetitive chores and give him more time to devote to the proper upkeep of equipment.
It is solely the operator's responsibility to properly operate and maintain the equipment. No amount of written instructions can replace
intelligent thinking and reasoning, and this manual is not intended to relieve operating personnel of the responsibility for proper
operation.
Operating controls will normally 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 most cases,
these conditions can be traced directly to carelessness and deficiencies in testing and maintenance.
Operation of this equipment by the owner and his operating personnel must comply with all requirements or regulations of his
insurance company and/or other authority having jurisdiction. In the 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
© Aqua-Chem, Inc., 1995
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

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 Computer 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
safety, functional capability and features beyond the capacity
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 features: —Flame signal strength.
—Interlock check. —Expanded annunciator status.
—Closed loop logic test. —Total cycles of operation.
—Dynamic Auto-Check. —Total hours of operation.
—Dynamic input check. —Fault history of six most recent faults:
—Dynamic safety relay test. • Cycles of operation at time of fault.
—Dynamic self-check logic. • Expanded annunciator data at time of fault.
—Expanded safe-start check. • Fault message and code.
—High Fire Purge Switch test. • Hours of operation at time of fault.
—Internal hardware status monitoring. • Sequence status at time of fault.
—Low Fire Start Switch test. • Sequence time at time of fault.
—Tamper resistant timing and logic. —Diagnostic information:
■ Access for external electrical voltage checks. • Device type.
■ Application flexibility. • Flame amplifier type.
■ Communication interface capability. • Flame failure response time.
■ Dependable, long-term operation provided by microcom- • Manufacturing code.
puter technology. • On/Off status of all digital inputs and outputs.
■ First-out annunciation and system diagnostics provided by • Selected prepurge time.
a 2 row by 20 column Vacuum Fluorescent Display (VFD) • Software revision and version of CB780/CB784 and
located on the Keyboard Display Module. Keyboard Display Module.
■ First-out expanded annunciation with 26 Light Emitting • Status of configuration jumpers.
Diodes (LEDs) for limits and interlocks (optional). • Status of Run/Test Switch.
■ Five sequence information Light Emitting Diodes (LEDs).
■ Five function Run/Test Switch. CONTENTS
■ Interchangeable plug-in flame amplifiers.
■ Local or remote annunciation of operation and fault Specifications ............................................................... 2
information. Principle Technical Features ...................................... 6
■ Nonvolatile memory for retaining history files and sequenc- Safety Provisions ......................................................... 7
ing status after loss of power. Installation ................................................................... 9
■ Remote reset (optional). Wiring ........................................................................ 11
■ Report generation (optional). Assembly .................................................................... 15
■ Burner controller data: Operation ................................................................... 18
—Sequence status. Static Checkout .......................................................... 25
Checkout .................................................................... 27
—Sequence time. Troubleshooting ......................................................... 34
—Hold status.
—Lockout/alarm status.
750-166 1-1
CB780/CB784
SPECIFICATIONS
Specifications
ELECTRICAL RATINGS, see Table 1: Power Dissipation:
Voltage and Frequency: 120 Vac (+10/-15%), 50 or CB780/CB784: 10W maximum.
60 Hz (+/- 10%)5. Display Module: 3W maximum.
Keyboard Display Module: 13 Vdc peak full wave Maximum Total Connected Load: 2000 VA.
rectified (+20/-15%). Fusing: Total Connected Load: 20A maximum, type
FRN or equivalent.
TABLE 1—TERMINAL RATINGS.

Terminal No. Description Ratings
G Flame Sensor Ground 1
Earth G Earth Ground 1
L2(N) Line Voltage Common
3 Alarm 120 Vac, 1A pilot duty.
4 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50 or 60 Hz (±10%). 2,5
5 Burner Motor 120 Vac, 9.8AFL, 58.8ALR (inrush).
6 Burner Controller and Limits 120 Vac, 1 mA.
7 Lockout/Running Interlock 120 Vac, 9A.
8 Pilot Valve/Ignition 120 Vac, 4.5A ignition and 50VA pilot duty.3
9 Main Fuel Valve 120 Vac, 2A pilot duty.4
10 Ignition 120 Vac, 4.5A Ignition. 3
F(11) Flame Sensor 60 to 220 Vac, current limited.
12 Firing Rate High Fire 120 Vac, 75 VA pilot duty.
13 Firing Rate Common 120 Vac, 75 VA pilot duty.
14 Firing Rate Low Fire 120 Vac, 75 VA pilot duty.
15 Firing Rate Modulate 120 Vac, 75 VA pilot duty.
16 Unused
17 Unused
18 Low Fire Switch Input 120 Vac, 1 mA.
19 High Fire Switch Input 120 Vac, 1 mA.
20 Preignition Interlock Input 120 Vac, 1 mA.
21 Interrupted/Pilot Valve/First Stage Oil Valve 120 Vac, 2A pilot duty.
22 Shutter 120 Vac, 0.5A.
1
The CB780/CB784 must have an earth ground providing a connection between the subbase and the control panel or the equipment.
The earth ground wire must be capable of conducting the current to blow the 20A fuse (or breaker) in event of an internal short circuit.
The CB780/CB784 needs a low impedance ground connection to the equipment frame which, in turn, needs a low impedance
connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be made by minimum
length conductors having maximum surface areas. Wide straps or brackets are preferred rather than leadwires. Be careful to ensure
that mechanically tightened joints along the ground path, such as pipe or conduit threads or surfaces held together with fasteners, are
free of nonconductive coatings and are protected against mating surface corrosion.
2
2000 VA maximum connected load to CB780/CB784 Assembly.
3
Can also be 120 Vac, 1A pilot duty.
4
Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.
5
Operating frequency chosen by CB780/CB784 selection.
1-2 750-166
CB780/CB784
SPECIFICATIONS
ENVIRONMENTAL RATINGS: WEIGHT:

Ambient Temperature: CB780/CB784: 1 pound 10 ounces, unpacked.
Operating: -40°F to 140°F. Keyboard Display Module: 4 ounces, unpacked.
Storage: -40°F to 150°F.
Humidity: 85% RH continuous, noncondensing. IMPORTANT: Flame Detection System available for use
Vibration: 0.5G environment. with CB780/CB784. To select your Plug-in Flame
DIMENSIONS: Refer to Figs. 1 and -2. 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
Flame
Failure
Part Response Part
Type Color Self-Checking Number Time Fuel Type Number
Infrared Red No 833-2722 3 sec. Gas, oil, Infrared 817-1742
coal (Lead Sulfide)
Dynamic AMPLI- 833-2723c Gas, oil, Infrared 817-1742
Dynamic
CHECK™ Auto-Check coal (Lead Sulfide)
Ultraviolet Purple No 833-2724 Gas, oil Ultraviolet 817-1743 a
Ultraviolet Green Dynamic Self- 833-2741b Gas, oil, Ultraviolet 817-1121
Self-Check Check coal (Purple
Peeper)
a
The 817-1743 Flame Detector should be used only on burners that cycle on-off at least once every twenty-four hours. Appliances with
burners that remain on for twenty-four hours continuously or longer should use the 817-1121 Flame Detector with the 833-2741 Amplifier
as the ultraviolet flame detection system.
b
Circuitry tests all electronic components in the flame detection system (amplifier and detector) 12 times a minute during burner operation
and shuts down the burner if the detection system fails.
c
Circuitry tests the flame signal amplifier 12 times a minute during burner operation and shuts down the burner if the amplifier fails.
TABLE 3—SEQUENCE TIMING FOR NORMAL OPERATION.2

Flame
Establishing Post Firing Energy Approval
Period Purge Interlock Rate Saving Code
Device Initiate Standby Purge Pilot Main Run Timing Circuits Circuit Prepurge Bodies
CB 780/ 10 sec * ** 4 or 10 or * 15 sec Preignition, 4-wire No FM/IRI
CB 784 10 sec 15 sec 1 Lockout, modulating Modulating
High and
Low Fire
* STANDBY and RUN can be an infinite time period.
** PURGE will be determined by which purge card is selected.
1
The MFEP will be determined by which terminal is used, see Figs. 7 and 18.
2
The operating sequence of the CB780 and CB784 Relay Modules are identical. The only difference between the Relay
Modules is that the Keyboard Display Module is standard with the CB780 and optional with the CB784.
APPROVAL BODIES: Factory Mutual approved, Report No. JI1V9A0.AF.

Underwriters Laboratories Inc. listed, File No. MP268, IRI acceptable.
Guide No. MCCZ. Federal Communications Commission, Part 15, Class B—
Canadian Standards Association certified, LR9S329-3. Emissions.
750-166 1-3
CCB780/CB784
SPECIFICATIONS
MOUNTING: 833-2725 for panel mount. ACCESSORIES:

REQUIRED COMPONENTS: Optional:
CB780: 120 Vac/60 Hz, 833-2718. Control Bus—part no. 833-2729. Provides
CB780: 120 Vac/50 Hz, 833-2719. communication and remote reset capabilities on
CB784: 120 Vac/60 Hz, 833-2720. CB784; remote display capabilities on CB780
CB784: 120 Vac/ 50 Hz, 833-2721 and CB784.
Plug-in Flame Signal Amplifier, see Table 2. CB783 Expanded Annunciator—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 60 sec. Remote Mounting Kit for the Keyboard Display,
833-2732 90 sec. 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)
BURNER CONTROL
5
SCROLL MODE (127)
SAVE
POWER
PILOT
FLAME
MAIN
ALARM 1
RESET
5-1/4 (133)
5 (127)
1 REMOVE ONLY FOR TERMINAL TEST ACCESS. M7399
1-4 750-166
CB780/CB784
SPECIFICATIONS
Fig. 2—Mounting dimensions of Keyboard Fig. 4—Ultraviolet detector.

Display Module, in inches (mm).
,
4 (102) 6 FOOT (1.83 METER)
LEADWIRES (2)
3-1/2 (89)
BURNER CONTROL
1-1/16
(27)
,

2-3/4
(69)

SCROLL MODE COLLAR WITH 1/2-14 NPSM M7419
SAVE
INTERNAL THREADS
817-1743

4-27/32 (123)
5/32 29/32
(4) (23)
4-3/32 (104) Fig. 5—Infrared detector.
5/16
19/32 1-1/4 1-1/32 (8)
(15) (32) (26) CELL MOUNT HEAT BLOCK
1-5/8 (41)
2-3/4
1-1/16 (27)
(70)
1-15/16 7/16 (11) 1/2
(49) (13)
2-5/16 (58) 1-1/4
2-1/32 1-1/4
(32)
(52) (32)
29/32 2 LEADS IN A
(23) 48 INCH [1.2 METER]
APERTURE
FLEXIBLE CONDUIT
3/4-14 3/4-14 NPSM
BUSHING WITH NPSM INTERNAL
MAGNIFYING LENS COLLAR, 3/4-14 NPSM THREADS
5/32 (4) 5/15
15/ 13/ INTERNAL THREADS M1982A
32 3-7/8 (99) (8)
32
(12) M7405
(11) 817-1742
833-2727
(Standard with CB780, optional with CB784)
Fig. 3—Ultraviolet Self-Check detector.

MOUNTING FLANGE 3/4–14 NPT
7-7/32
(183)
5-1/8 (130)
3-3/4
(95)
3-7/16
(87)
1/2–14 NPSM
5-1/4 (133)
LEADWIRES
FACEPLATE M1962A
817-1121
750-166 1-5
CB780/CB784
PRINCIPAL TECHNICAL FEATURES
Principal Technical Features

The CB780/CB784 provides all customary flame safe- i. Internal system fault.
guard functions while providing significant advancements in j. Purge card is removed.
the areas of safety, annunciation and system diagnostics. k. Purge card is bad.
4. PILOT FLAME ESTABLISHING Period (PFEP)
SAFETY SHUTDOWN (LOCKOUT) OCCURS IF: a. Low Fire Switch opens.
1. INITIATE Period b. Lockout Interlock opens.
a. Purge card is not installed or removed. c. Ignition/pilot valve/intermittent pilot valve terminal
b. Purge card is bad. is not energized.
c. Configuration jumpers were changed (after d. Early Spark Termination terminal is energized af-
200 hours). ter five seconds.
d. AC line power errors, see Operation. e. No flame is present at end of PFEP.
e. Four minute INITIATE period is exceeded. f. Internal system fault.
2. STANDBY Period g. Purge card is removed.
a. Flame signal is present after 40 seconds. h. Purge card is bad.
b. Preignition Interlock is open an accumulative time 5. MAIN FLAME ESTABLISHING Period (MFEP)
of 30 seconds. a. Low Fire Switch opens.
c. Interlock check feature is enabled and the Inter- b. Lockout Interlock opens.
lock String (including the airflow switch) is closed c. Ignition/pilot valve/intermittent pilot valve termi-
for 120 seconds with controller closed. nal is not energized.
d. Ignition/pilot valve/intermittent pilot valve termi- d. Main valve terminal is not energized.
nal is energized. e. No flame is present at end of MFEP.
e. Main valve terminal is energized. f. Internal system fault.
f. Internal system fault. g. Purge card is not installed or removed.
g. Purge card is not installed or removed. h. Purge card is bad.
h. Purge card is bad. 6. RUN Period
3. PREPURGE Period a. No flame is present.
a. Preignition Interlock opens anytime during b. Lockout Interlock opens.
PREPURGE. c. Main valve terminal is not energized.
b. Flame signal detected after first ten seconds during d. Internal system fault.
PREPURGE. e. Purge card is not installed or removed.
c. High Fire Switch fails to close within four minutes, f. Purge card is bad.
fifteen seconds after firing rate motor is commanded 7. POSTPURGE Period
to drive to high fire position at start of PREPURGE. a. Preignition Interlock does not close within five sec-
d. Low Fire Switch fails to close within four minutes, onds or opens after five-second time period.
fifteen seconds after firing rate motor is commanded b. Ignition/pilot valve/intermittent pilot valve termi-
to drive to low fire position at end of PREPURGE. nal is energized.
e. Lockout Interlock does not close within 10 seconds. c. Main valve terminal is energized.
f. Lockout Interlock opens during PREPURGE. d. Internal system fault.
g. Ignition/pilot valve/intermittent pilot valve termi- e. Purge card is removed.
nal is energized. f. Purge card is bad.
h. Main valve terminal is energized.
1-6 750-166
CB780/CB784
SAFETY PROVISIONS
Safety Provisions
INTERNAL HARDWARE STATUS MONITORING DYNAMIC SELF-CHECK SAFETY CIRCUIT
The CB780/CB784 checks the purge card for correct The microcomputer tests itself and related hardware
parity to prevent purge timing shifts and circuitry failures. It while at the same time the safety relay system tests the micro-
also analyzes the integrity of the configuration jumpers and computer operation. If a microcomputer or safety relay
internal hardware. The POWER LED blinks every four failure occurs and does not allow proper execution of the
seconds, signifying an internal hardware check. self-check routine, safety shutdown will occur and all safety
critical loads will be de-energized.
CLOSED LOOP LOGIC TEST
The test verifies the integrity of all safety critical loads, EXPANDED SAFE-START CHECK
terminals 8, 9, 10 and 21. If the loads are not energized The conventional safe-start check, which prevents burner
properly; i.e., the main valve terminal is powered during start-up if flame is indicated at start-up, is expanded to
PREPURGE, the CB780/CB784 will lockout on safety shut- include a flame signal check during STANDBY, a preigni-
down. The CB780/CB784 must react to input changes but tion interlock check, an interlock check, and a safety critical
avoid the occurrence of nuisance shutdown events. Signal load check.
conditioning is applied to line voltage inputs to verify proper
operation in the presence of normal electrical line noise such HIGH FIRE PURGE AND LOW FIRE START
as transient high voltage spikes or short periods of line SWITCH TESTS
dropout. Signal conditioning is tolerant of synchronous noise High Fire Purge Switch Test examines the Purge Posi-
(line noise events that occur at the same time during each line tion Interlock Switch at the moment the firing rate motor is
cycle). commanded to the high fire position. If the switch is by-
passed, welded or otherwise closed prematurely, the system
DYNAMIC AUTO-CHECK will automatically add 30 seconds to allow additional drive
Dynamic Auto-Check circuitry tests the flame signal time for the firing rate motor to reach or near the open
amplifier during burner operation and shuts down the CB780/ position before starting the purge timing; otherwise, purge
CB784 if the flame amplifier fails. timing starts when the High Fire Switch is closed. This
switch will also cause a hold (four minutes, fifteen seconds)
DYNAMIC FLAME AMPLIFIER AND SHUTTER condition when the switch is open before purge or opens
CHECK during purge. The CB780/CB784 will lockout and annunci-
Self-checking circuitry tests all electronic components in ate an alarm if the switch fails to close within the hold time
the flame detection system and amplifier 10 to 12 times per period.
minute and shuts down the CB780/CB784 if the detection Low Fire Start Switch Test examines the Low Fire Start
system fails. Switch at the moment PREPURGE is completed. If the
switch is bypassed, welded or otherwise prematurely closed,
DYNAMIC INPUT CHECK the system automatically adds 30 seconds to allow the firing
All system input circuits are examined to verify that the rate motor additional time to reach or near the low fire start
CB780/CB784 is capable of recognizing the true status of position before ignition trials; otherwise, ignition trials start
external controls, limits and interlocks. If any input fails this after the Low Fire Switch closes. The test also is used to prove
test, a safety shutdown occurs and the fault is annunciated. that the firing rate motor is at low fire position throughout
the ignition trial period. This switch will also cause a hold
DYNAMIC SAFETY RELAY TEST (four minutes, fifteen seconds) condition if the switch opens
Checks the ability of the dynamic safety relay contacts to after purging is complete. The CB780/CB784 will lockout
open and close. It also verifies that the safety critical loads, and annunciate an alarm if the switch fails to close within the
terminals 8, 9, 10 and 21, can be de-energized, as required, by hold time period.
the Dynamic Self-Check logic.
750-166 1-7
CB780/CB784
SAFETY PROVISIONS
MANDATORY PURGE First-out Annunciation reports the cause of a safety shut-

If lockout occurs after the initiation of ignition trials, down or identifies the cause of a failure to start or continue
(or at anytime during a sequence when the fuel valves may the burner control sequence with an English text and num-
have been energized), a mandatory POSTPURGE period is bered code via the Keyboard Display Module. It monitors all
imposed. field input circuits, including the Flame Signal Amplifier
and Firing Rate Position Switches. The system distinguishes
OFF CYCLE (STANDBY OR PREPURGE) FLAME 118 modes of failure and detects and annunciates difficult-
SIGNAL CHECK to-find intermittent failures.
The flame detection subsystem (flame detector and am- Self-Diagnostics adds to the First-out Annunciation by
plifier) is monitored during STANDBY. If a flame simulat- allowing the CB780/CB784 to distinguish between field
ing condition or an actual flame exists, a system hold occurs (external device) and internal (system related) problems.
and start-up is prevented. If the flame signal exists at any Faults associated within the flame detection subsystem,
time after the first 40 seconds of STANDBY, a safety shut- CB780/CB784 or plug-in Purge Card, are isolated and re-
down will occur and be annunciated. A shutter-check ampli- ported by the Keyboard Display Module. See the Diagnos-
fier and self-checking detector are energized for the first tics and Troubleshooting section of the CB780/CB784 Op-
40 seconds during STANDBY and the last two seconds eration and Maintenance Manual, Manual Number 750-166.
before exiting STANDBY. If a flame exists, a safety shut-
down occurs. An Auto-Check Amplifier is energized con- INTERLOCK REQUIREMENTS
tinually through STANDBY and PREPURGE to detect any The following interlock inputs are provided:
possibility of a runaway detector or a flame. If either situa-
tion happens, a safety shutdown occurs. A standard amplifier Low Fire Interlock
is energized continually through STANDBY and This interlock verifies the firing rate motor is in the low
PREPURGE. If either situation happens, a safety shutdown fire position before and during ignition trials.
occurs.
High Fire Interlock
PREIGNITION OUTPUT CIRCUIT CHECK This interlock verifies the firing rate motor is in the high
At the end of PREPURGE, the Dynamic Safety Relay fire position prior to and during PREPURGE.
operation is checked. Also, all safety critical loads, terminals
8, 9, 10 and 21 are checked to verify the terminals are not Lockout Interlock
powered. If the Dynamic Safety Relay operation is faulty, or This interlock (ILK) input signifies a Lockout Interlock.
if any of the safety critical loads are powered, safety shut- If the Lockout Interlock is open for more than ten seconds
down occurs and is annunciated. into PREPURGE, the CB780/CB784 will lockout. After
entering PREPURGE, if the Lockout Interlock opens during
TAMPER RESISTANT TIMING AND LOGIC the first ten seconds, the purge timer will be reset. This
Safety and logic timings are inaccessible and cannot be provides a continuous PURGE to occur without interruption
altered or defeated. before the Pilot Flame Establishing Period. If a Lockout
Interlock opens anytime after ten seconds into PURGE,
VERIFIED SPARK TERMINATION during the Ignition Trials or Run, it causes a lockout.
The ignition terminal is monitored to verify early spark A typical Lockout Interlock string contains an airflow
termination (five seconds ignition and pilot and five seconds switch (see Fig. 7). The Interlock Check is a site configur-
pilot only). able option (see Table 7). If this feature is enabled, the
CB780/CB784 will lockout after 120 seconds whenever
FIRST-OUT ANNUNCIATION AND control terminal 6 is energized, and the Lockout Interlock
SELF-DIAGNOSTICS string (including airflow switch) is closed during STANDBY.
Sequence Status Lights (LEDs) provide positive visual
indication of the program sequence: POWER, PILOT, Preignition Interlock
FLAME, MAIN and ALARM. The green POWER LED The Preignition Interlock input is typically connected to
blinks every four seconds to signify the CB780/CB784 proof-of-closure switches for fuel valve(s). The Preignition
hardware is running correctly. Interlock must be energized throughout PREPURGE. If the
Multi-function Keyboard Display Module (standard with Preignition Interlock opens during STANDBY, it causes a
CB780, optional with CB784) shows elapsed time during hold (30 seconds). The CB780/CB784 will lockout if the
PREPURGE, PILOT IGN, MAIN IGN, and POSTPURGE. interlock does not close within 30 seconds during STANDBY.
As an additional troubleshooting aid, it provides sequence If the Preignition Interlock opens during PREPURGE, it
timing, diagnostic information, historical information and will lockout. If the Preignition Interlock is open after five sec-
expanded annunciator information when a safety shutdown onds into POSTPURGE, the CB780/CB784 will lockout.
or hold or normal operation occurs. The Preignition Interlock is ignored during the ignition trials
state and during RUN.
1-8 750-166
CB780/CB784
INSTALLATION
Installation
3. This equipment generates, uses and can radiate radio
WARNING frequency energy and, if not installed and used in
accordance with the instructions, may cause interfer-
FIRE OR EXPLOSION HAZARD ence to radio communications. It has been tested and
CAN CAUSE PROPERTY DAMAGE, found to comply with the limits for a Class B comput-
SEVERE INJURY, OR DEATH. ing device of Part 15 of FCC rules which are designed
To prevent possible hazardous burner operation, to provide reasonable protection against such inter-
verification of safety requirememts must be per- ference when operated in a commercial environment.
formed each time a control is installed on a burner. Operation of this equipment in a residential area may
cause interference; in which case, the users at their
own expense may be required to take whatever mea-
WHEN INSTALLING THIS PRODUCT…
sures are required to correct this interference.
1. Read these instructions carefully. Failure to follow
4. This digital apparatus does not exceed the Class B
them could damage the product or cause a hazardous
limits for radio noise for digital apparatus set out in
condition.
the Radio Interference Regulations of the Canadian
2. Check the ratings given in the instructions and Department of Communications.
marked on the product to make sure the product is suitable
for the application.
HUMIDITY
3. Installer must be a trained, experienced, flame safe-
Install the CB780/CB784 where the relative humidity
guard service technician.
never reaches the saturation point. The CB780/CB784 is
4. After installation is complete, check out the product
designed to operate in a maximum 85% RH continuous,
operation as provided in these instructions. noncondensing, moisture environment. Condensing mois-
ture may cause a safety shutdown.
CAUTION
VIBRATION
1. Disconnect the power supply before beginning
Do not install the CB780/CB784 where it could be sub-
installation to prevent electrical shock, equip-
ment and control damage. More than one power jected to vibration in excess of 0.5G continuous maximum
vibration.
supply disconnect may be involved.
2. Wiring connections for the CB780/CB784 are
WEATHER
unique; therefore, refer to Figs. 6, 7, 8 or 9 or
The CB780/CB784 is not designed to be weather tight. If
the correct Specifications for proper subbase
wiring. installed outdoors, the CB780/CB784 must be protected by
an approved weather-tight enclosure.
3. Wiring must comply with all applicable codes,
ordinances and regulations.
MOUNTING WIRING SUBBASE
4. Wiring, where required, must comply with NEC
Class 1 (Line Voltage) wiring.
NOTE: For installation dimensions, see Fig. 1.
5. Loads connected to the CB780/CB784 must not
exceed those listed on the CB780/CB784 label
1. Mount the subbase in any position except horizontally
or the Specifications, see Table 1.
with the bifurcated contacts pointing down. The standard
6. Limits and interlocks must be rated to simulta-
vertical position is recommended. Any other position de-
neously carry and break current to the ignition
creases the maximum ambient temperature rating.
transformer, pilot valve, and main fuel valve(s).
2. The 833-2725 Wiring Subbase can be mounted di-
7. All external timers must be listed or component
recognized by authorities who have jurisdiction rectly in the control cabinet. Be sure to allow adequate clear-
ance for servicing, installation, access or removal of the
for the specific purpose for which they are used.
CB780/CB784, Expanded Annunciator, Keyboard Dis-
play Module, flame amplifier, flame amplifier signal voltage
IMPORTANT: probes, Run/Test Switch, electrical signal voltage probes
1. For on-off gas-fired systems, some authorities who and electrical field connections.
have jurisdiction prohibit the wiring of any limit or 3. For surface mounting, use the back of the subbase as a
operating contacts in series between the flame safe- template to mark the four screw locations. Drill the pilot
guard control and the main fuel valve(s). holes.
2. Two Flame Detectors can be connected in parallel with 4. Securely mount the subbase using four no. 6 screws.
the exception of Infrared Flame Detector (817-1742).
750-166 1-9
CB780/CB784
INSTALLATION
Fig. 6—Internal block diagram of the CB780/CB784 (see Figs.7,8,9, or 10 for detailed wiring instructions).
L1
(HOT) L2
1
4 L2
120 Vac
PLUG-IN PURGE
CONFIGURATION
TIMER CARD
JUMPERS
TEST
FLAME SIGNAL JACK
RUN/TEST F
SWITCH
PLUG-IN
MICROCOMPUTER FLAME G
TEST AMPLIFIER
RESET 22
PUSHBUTTON
2K
3K
4K
RELAY
DRIVE 5K
RELAY
CIRCUIT 6K
STATUS
7K FEEDBACK
8K AND LINE
VOLTAGE
9K INPUTS
SAFETY RELAY 1K
CIRCUIT
STATUS LEDs
CONTROL
POWER SUPPLY
POWER
20
PRE-IGNITION
INTERLOCK
LOCKOUT
LIMITS CONTROLLER INTERLOCK
1K1 2K1 5K1
6 7 10 IGNITION
4K1
LOW FIRE SWITCH
8 PILOT
18 7K1
21 PILOT/V2
HIGH FIRE SWITCH
2K2
19 9 MAIN VALVE
6K1
5 BLOWER
3K1
3 ALARM
HIGH FIRE
12
KEYBOARD
DDL DISPLAY MODULE 8K1 COMMON
13 INDICATES FEEDBACK SENSING
RS485 TO RELAY STATUS FEEDBACK
8K2 MODULATE AND LINE VOLT INPUTS
1 15
9K1
DDL 2 9K2
3 REMOTE LOW FIRE FIELD WIRING
COMMUNICATIONS 14
RESET 2 INTERNAL WIRING
1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M7420
2 REMOTE RESET MUST BE MOUNTED WITHIN SIGHT OF THE BOILER CONTROL PANEL.
1-10 750-166
CB780/CB784
WIRING
Wiring
1. a. For proper subbase wiring, refer to Fig. 7. important. Be aware that modules on the closest
b. For proper remote wiring of the Keyboard Dis- and farthest end of the daisy chain configuration
play Module, refer to Fig. 8, 9 or 10 or to the string require a 120 ohm (1/4 watt minimum) resis-
Specifications for the Keyboard Display Module, tor termination across terminals 1 and 2 of electri-
Communication Interface Base Unit or Control cal connectors, for connections over 100 feet, see
Bus. Fig. 8, 9 and 10.
2. Disconnect the power supply from the main discon- d. Remote Reset*—Use no. 22 AWG or greater
nect before beginning installation to prevent electrical twisted pair wire, insulated for low voltage; see
shock and equipment damage. More than one disconnect Fig. 8, 9 and 10.
may be involved. e. Communication Interface ControlBus Module—
3. All wiring must comply with all applicable electrical For communications purposes, use an unshielded
codes, ordinances and regulations. Wiring, where required, 22 AWG 2-wire twisted cable if the leadwire run
must comply with NEC, Class 1 (Line Voltage) wiring. and noise conditions permit or use a Belden 8771
4. Recommended wire size and type: shielded cable or equivalent. The Keyboard
a. All Line Voltage terminals use no. 14 or 16 cop- Display Module, Control Bus (for remote mount-
per conductor (90°C or higher) 600 volt insula- ing or communications) or Communication Inter-
tion wire (wire size must be coordinated with fuse face ControlBus Module must be wired in a daisy
protection). For high temperature installations, chain configuration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)).
use wire selected for a temperature rating above The order of interconnection of all the devices
the maximum operating temperature. All leadwires listed above is not important. Be aware that
should be moisture resistant. modules on the closest and farthest end of the
b. Keyboard Display Module—For communica- daisy chain configuration string require a 120
tions purposes, use an unshielded 22 AWG 2-wire ohm (1/4 watt minimum) resistor termination
twisted cable and one wire for ground if the across terminals 1 and 2 of the electrical connec-
leadwire run and noise conditions permit; how- tors, for connections over 100 feet, see Fig. 8, 9
ever, some installations may need up to five wires, and 10.
three for communications and two for remote reset f. Use the recommended wire size for the 13 Vdc
(in either a single cable or separate cables for com- full wave rectified transformer power input of
munications or remote reset) or use Belden 8771 no. 18 AWG wire insulated for voltages and tem-
shielded cable or equivalent. The Keyboard Dis- peratures encountered in the application. Sug-
play Module, Control Bus (for remote mounting or gested wire types include TTW(60C), THW(75C)
communications) or Communication Interface and THHN(90C).
ControlBus Module must be wired in a daisy chain 5. Recommended grounding practices:
configuration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The a. The earth ground provides for a connection be-
order of interconnection of all the devices listed tween the subbase and the control panel of the equip-
above is not important. Be aware that modules on ment. The earth ground wire must be capable of
the closest and farthest end of the daisy chain conducting the current to blow the 20A fuse (or
configuration string require a 120 ohm (1/4 watt breaker) in event of an internal short circuit. The
minimum) resistor termination across terminals CB780/CB784 needs a low impedance ground
1 and 2 of the electrical connectors, for connec- connection to the equipment frame which, in
tions over 100 feet, see Fig. 8, 9 and 10. turn, needs a low impedance connection to earth
c. Control Bus—For communications purposes, ground. For a ground path to be low impedance
use an unshielded 22 AWG 2-wire twisted cable at RF frequencies, the connection must be made
if the leadwire run and noise conditions permit; with minimum length conductors that have a
however, some installations may need up to five maximum surface area. Wide straps or brackets
wires, three for communications and two for re- are preferred rather than leadwires. Be careful to
mote reset (in either a single cable or separate ensure that mechanically tightened joints along
cables) or use a Belden 8771 shielded cable or the ground path, such as pipe or conduit threads
equivalent. The Keyboard Display Module, Con- or surfaces held together with fasteners, are free
trol Bus (for remote mounting or communications) of nonconductive coatings and are protected
or Communication Interface ControlBus Module against corrosion on mating surfaces.
must be wired in a daisy chain configuration, b. Keyboard Display Module, Control Bus, or
(1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order of inter- Communication Interface ControlBus Module—
connection of all the devices listed above is not
*Note: Remote Reset must be mounted within sight

of the boiler control panel.
750-166 1-11
CB780/CB784
WIRING
The shield, if used, should be connected to the 2. Do not route Remote Reset wires in conduit
signal ground terminal 3(c) provided as part of the with line voltage circuits.
CB780/CB784 device ControlBus connection.
Connect the shield at both ends to earth ground. NOTE: A 13 Vdc power supply must be used any time more
c. CB780/CB784—Each CB780/CB784 will have than one Keyboard Display Module is used.
an earth ground terminal that must be grounded to
the metal control panel with wire as short as prac- 7. Maximum wire lengths:
tical. Each ground wire must be capable of carrying a. CB780/CB784 leadwires—The maximum length
a fault current equal to the rating of the protec- of leadwire is 300 feet to terminal inputs (Control,
tive fuse (20A). A number 14 copper conductor Preignition Interlock, Running/Lockout Interlock,
is adequate, but wide straps or brackets are pre- High Fire Switch and Low Fire Switch).
ferred rather than leadwires. b. Flame Detector leadwires—The maximum flame
6. Recommended wire routing: sensor leadwire length is limited by the flame
a. Flame detector leadwires: signal strength.
1. Do not run high voltage ignition transformer c. Remote Reset leadwires—The maximum length
wires in the same conduit with the flame detec- of wire is 1000 feet to a Remote Reset pushbutton.
tion wiring. d. Control Bus—The maximum Control Bus cable
2. Do not route scanner wires in conduit with line length depends on the number of system modules
voltage circuits. connected, the noise conditions and the cable used.
3. Enclose scanner wires without armor cable in The maximum length of all interconnecting wire
metal cable or conduit. is 1000 feet.
4. Follow directions in flame detector Instructions. 8. Make sure loads do not exceed the terminal ratings.
b. Control Bus: Refer to the label on the CB780/CB784 or to the ratings in
1. Do not run high voltage ignition transformer Specifications; see Table 1.
wires in the same conduit or close proximity 9. Check the power supply circuit. The voltage and fre-
with the Control Bus wiring. quency tolerance must match those of the CB780/CB784. A
2. Do not route Control Bus wires in conduit with line separate power supply circuit may be required for the
voltage circuits. CB780/CB784. Add the required disconnect means and
c. Keyboard Display Module (VFD): Because the overload protection.
VFD is powered from a low voltage, energy lim- 10. Check all wiring circuits and complete the Static
ited source, it can be mounted outside of a control Checkout, see Table 8, before installing the CB780/CB784
panel if it is protected from mechanical damage. on the subbase.
d. Remote Reset: 11. Install all electrical connectors.
1. Do not run high voltage ignition transformer 12. Restore power to the panel.
wires in the same conduit with the Remote Reset
wiring.
1-12 750-166
CB780/CB784
WIRING
FIG. 7—WIRING CB780/CB784
SERIES 90
FIRING RATE SERIES 90
833-2725 MOTOR CONTROLLER
HIGH FIRE
G 12 B B
COMMON
L2 13 R R
LOW FIRE
120V ALARM 3 14 W W
MODULATE
4 (L1) 15
BURNER MOTOR 2
(BLOWER) 5 16
BURNER 17
CONTROLLER/LIMITS 6
LOCKOUT INTERLOCKS LOW FIRE

(INC. AIR FLOW SWITCH) 7 18
START SWITCH
10 SEC. INTERRUPTED 8 19 HIGH FIRE

PILOT/IGNITION PURGE SWITCH
MAIN FUEL
VALVE(S) 9 20 PREIGNITION
INTERLOCK
5 SECOND IGNITION
(EARLY SPARK)t 10 21 15 SEC.
(EARLY SPARK INTERRUPTED
(TERMINATION)
TERMINATION) PILOT VALVE
F 22
817-1742 L1
INFRARED (HOT)
(LEAD SULFIDE) 1
FLAME DETECTOR L2
MASTER
SWITCH
OR
WHITE 817-1743 BLUE FOR DIRECT SPARK IGNITION (OIL

ULTRAVIOLET OR GAS)
FLAME DETECTOR
IGNITION
10 TRANSFORMER
OR
YELLOW 817-1121 BLUE 8 L2

ULTRAVIOLET
FLAME DETECTOR
WHITE 2ND STAGE
9
FUEL VALVE
WHITE (OPTIONAL)
L2
BLACK
L1
BLACK
L2
1 120V, 60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
M7408
2 DO NOT WIRE TO ANY UNUSED TERMINALS.
750-166 1-13
CB780/CB784
WIRING
Fig. 8—Wiring the Keyboard Display Module with Fig. 9—Wiring multiple Keyboard Display Modules.
Communication Interface ControlBus Module.
833-2727 KEYBOARD DISPLAY MODULE
(MOUNTED ON CB 780/CB 784)
833-2727 KEYBOARD DISPLAY MODULE
(MOUNTED ON CB 780/CB 784)
+13 VDC
C (GND)
MOMENTARY
RESET
PUSH BUTTON
+13 VDC
C (GND)
MOMENTARY
RESET
SWITCH
B
PUSH BUTTON 2
SWITCH
A
2 1 2 3 4 5
1 2 3 4 5
120 OHM
RESISTOR
120 OHM
RESISTOR
1
1 120 OHM 13 VDC
RESISTOR POWER SUPPLY
120 OHM
RESISTOR L2
1 L1
1 (HOT)
1 2 3 4 5
1 2 3 833-2734
+13 VDC
C (GND)
RESET
A
B
COMMUNICATIONS
INTERFACE
C
A
CONTROLBUS
MODULE
833-2727 REMOTE KEYBOARD DISPLAY MODULE
1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120 OHM TERMINATING RESISTORS ARE REQUIRED FOR
OHM TERMINATING RESISTORS ARE REQUIRED FOR CONNECTIONS OVER 100 FEET. CABLE SHIELD MUST BE
CONNECTIONS OVER 100 FEET (30 METERS). CABLE SHIELD TERMINATED TO EARTH GROUND AT BOTH ENDS. IF SHIELDED
MUST BE TERMINATED TO EARTH GROUND AT BOTH ENDS. CABLE IS NOT USED, TWISTED PAIR WIRE MUST BE USED.
IF SHIELDED CABLE IS NOT USED, TWISTED PAIR M7409
M7406
WIRE MUST BE USED. 2 REMOTE RESET MUST BE MOUNTED WITHIN SIGHT OF
2 REMOTE RESET MUST BE MOUNTED WITHIN SIGHT OF THE BOILER CONTROL PANEL.
THE BOILER CONTROL PANEL.
Fig. 10—Wiring the Control Bus with remote Keyboard Display Module.
833-2729 DATA CONTROLBUS MODULE™
(MOUNTED
833-2729 ON CBBOX
CONTROL 780/CB 784)
(MOUNTED ON CB780/CB784)
+13 VDC
C (GND)
MOMENTARY
RESET
PUSH BUTTON
SWITCH 3
A
1 2 3 4 5
120 OHM
RESISTOR 2
1
120 OHM
RESISTOR
1 2 3 4 5
+13 VDC
C (GND)
RESET
A
833-2727 REMOTE KEYBOARD DISPLAY MODULE
1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

OHM TERMINATING RESISTORS ARE REQUIRED FOR
CONNECTIONS OVER 100 FEET. CABLE SHIELD MUST BE
TERMINATED TO EARTH GROUND AT BOTH ENDS. IF SHIELDED
CABLE IS NOT USED, TWISTED PAIR WIRE MUST BE USED.
2 WHEN CONNECTING THE KEYBOARD DISPLAY MODULE DATA

CONTROL BUS,MODULE™,
CONTROLBUS OR REMOTEOR
RESET MODULE
REMOTE RESET MODULE
EXTERNAL FROM THE CONTROL CABINET, APPROPRIATE
MEASURES MUST BE TAKEN TO MEET EN60730 SAFETY
LOW VOLTAGE REQURIEMENTS (SEE APPROVALS). M7407
3 REMOTE RESET MUST BE MOUNTED WITHIN SIGHT OF

THE BOILER CONTROL PANEL.
1-14 750-166
CB780/CB784
ASSEMBLY
Assembly
MOUNTING CB780/CB784
Fig. 11—Electrical panel installation.
NOTE: For installation dimensions, see Fig. 1.
RELAY MODULE MOUNTING

1. Mount the CB780/CB784 vertically, see Fig. 11, or
mount horizontally with the knife blade terminals pointing
downward. The CB780/CB784 must be in an electrical
enclosure.
2. Select the location in the electrical enclosure. Be sure
to allow adequate clearance for servicing, installation and
removal of the CB780/CB784, Keyboard Display Module,
flame amplifier, flame amplifier signal voltage probes, elec-
trical signal voltage probes, and electrical connections.
a. Allow an additional two inches below the CB780/CB784
for the flame amplifier mounting.
d. Allow an optional three-inch minimum to both sides
of the CB780/CB784 for electrical signal voltage
probes.
3. Make sure no subbase wiring is projecting beyond the
terminal blocks. Tuck wiring in against the back of the sub-
base so it does not interfere with the knife blade terminals or
bifurcated contacts.
IMPORTANT: The CB780/CB784 must be installed with a

plug-in motion rather than a hinge action. IMPORTANT: The CB780 will not function properly with-
out one of the following mounted correctly: Keyboard
4. Mount the CB780/CB784 by aligning the four L shaped Display Module, or Control Bus .
corner guides and knife blade terminals with the bifurcated
contacts on the wiring subbase and tightening the two screws MOUNTING KEYBOARD DISPLAY MODULE
securely without deforming the plastic. (VFD)
1. Align the two interlocking ears of the Keyboard Dis-
INSTALLING THE PURGE CARD play Module with the two mating slots on the CB780/CB784;
1. Remove the Keyboard Display Module or Control see Fig. 13.
Bus, see Fig. 13 or 14. 2. Insert the two interlocking ears into the two mating slots
2. Remove the current Purge Card from the CB780/CB784 and with a hinge action push on the lower corners of the
by pulling the plastic support cover upward . Keyboard Display Module to secure it to the CB780/CB784.
3. Make sure that the Purge Card selected has the desired 3. Verify the Keyboard Display Module is firmly in place.
timing.
4. Insert Purge Card into the opening of the CB780/CB784 MOUNTING CONTROL BUS
compartment, see Fig. 12. 1. Align the two interlocking ears with the two mating
5. Reinstall the Keyboard Display Module or Control slots on the CB780/CB784; see Fig. 14.
Bus onto the CB780/CB784 and restore power to the 2. Insert the two interlocking ears into the two mating
device. slots and push on the lower corners of the Control Bus to
6. Run the burner system through at least one complete secure it to the CB780/CB784.
cycle to verify the system is operating as desired. 3. Be sure the Control Bus is firmly in place.
750-166 1-15
CB780/CB784
ASSEMBLY
MODULE (VFD)
Fig. 12—Purge Card installation. 1. The Keyboard Display Module (VFD) can be mounted
either on the face of a panel door or on other remote locations;
see Fig. 15.
2. When mounting the Keyboard Display Module on the
face of a door panel, closely follow these instructions:
a. Select the location on the door panel for flush mount-
ing. Pay attention to the insertion dimension of the two
Keyboard Display Module screws, two interlocking
ears and the two plug-in connectors to allow for
sufficient clearance, 1/4 inch minimum inward from
the surface of the door panel.
b. Use the Keyboard Display Module as a template; see
Fig. 28. Mark the two screw locations, two interlock-
ing ear locations and two plug-in connector locations.
Drill the pilot holes for the mounting screws. Provide
for two holes on the door panel for the interlocking
ears and plug-in connector holes.
c. Mount the Keyboard Display Module securing the
two no. 4 screws.
Fig. 13—Keyboard Display Module mounting. INSTALLING PLUG-IN FLAME SIGNAL

AMPLIFIER
1. Disconnect power supply before beginning installation
to prevent electrical shock and equipment damage. More than
one disconnect may be involved.
2. Align the amplifier circuit board edge connector with
the keyed receptacle on the CB780/CB784. Verify the am-
plifier nameplate faces away from the Relay Module, see
Fig. 16.
3. Push in the amplifier until the circuit board is fully
inserted into the receptacle and then push the amplifier
toward the CB780/CB784 retaining clasp.
4. Verify the amplifier is firmly in place.
5. Perform all required checkout tests.
INSTALLING THE FLAME DETECTOR
NOTE: Table 2 lists the flame detection systems available

for use with the CB780/CB784. Make sure the correct
Fig. 14—Control Bus mounting. combination of amplifier and flame detector(s) is used.
REMOTE MOUNTING OF KEYBOARD DISPLAY Proper flame detector installation is the basis of a safe and
reliable flame safeguard installation. Refer to the instruc-
tions packed with the flame detector and the equipment
manufacturer instructions; see Fig. 17.
Keep the flame signal leadwires as short as possible from
the flame detector to the wiring subbase. Capacitance in-
creases with leadwire length, reducing the signal strength.
The maximum permissible leadwire length depends on the
type of flame detector, leadwire and conduit. The ultimate
limiting factor in the flame detector leadwire is the flame
signal; see Table 9.
1-16 750-166
CB780/CB784
ASSEMBLY
Fig. 15—Remote mounting of Keyboard Fig.17—Flame detector wiring.

Display Module.
INFRARED (817-1742)
F
3
G
ULTRAVIOLET (817-1743)
BLUE
F
1
WHITE
G
SOLID STATE SELF-CHECKING

ULTRAVIOLET (817-1121)
Fig. 16—Flame signal amplifier mounting.
BLUE
F
2 YELLOW
G
WHITE
22
WHITE
L2
BLACK
L1
BLACK
L2
1 FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD

MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING
TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
2 FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD

MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING
TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
3 1 BROWN WIRE AND 1 WHITE WIRE FROM THE 817-1742,

CONNECT TO THE CB 780/CB 784 WIRING SUBBASE, COLOR
NOT IMPORTANT. KEEP WIRES AS SHORT AS POSSIBLE
AND TWIST THEM. M7410
750-166 1-17
CB780/CB784
OPERATION
Operation
SEQUENCE OF OPERATION d. The Lockout Interlock or Running Interlock inputs
The CB780/CB784 has the following operating sequence, (interlock circuit including Airflow Switch) must close
see Fig. 18 and Table 4. by ten seconds into PREPURGE; otherwise, a safety
shutdown occurs.
INITIATE e. After the firing rate motor reaches the PREPURGE
The CB780/CB784 enters the INITIATE sequence when rate position and PREPURGE timing is completed, the
the Relay Module is powered. The CB780/CB784 can also firing rate motor will drive to the low fire position.
enter the INITIATE sequence if the Relay Module verifies f. When the firing rate motor reaches low fire position,
voltage fluctuations of +10/-15% or frequency fluctuations the Low Fire Switch, terminal 18, input must be
of +/-10% during any part of the operating sequence. The energized before entering the Ignition Trial state.
INITIATE sequence lasts for ten seconds unless the voltage
or frequency tolerances are not met. When the tolerances are IGNITION TRIALS
not met, a hold condition will be initiated and will be a. Pilot Flame Establish- PILOT IGN 00:10
displayed on the VFD for at least five seconds. When the ing Period (PFEP): Fault History
tolerances are met, the INITIATE sequence will restart. If 1. With the firing
the condition is not corrected and the hold condition exists rate motor at the low fire position:
for four minutes, the CB780/CB784 will lockout. Causes for a. The pilot valve and the ignition transformer,
hold conditions in the INITIATE sequence: terminals 8, 10 and 21, are energized. The
a. AC line dropout is detected. CB780/CB784 has a fifteen second interrupted
b. AC line frequency error caused by using a 60 Hz device pilot valve, terminal 21 and a ten second inter-
on a 50 Hz line, or vice versa. rupted pilot valve/ignition, terminal 8.
c. AC line noise that can prevent a sufficient reading of b. During PFEP, the Low Fire Switch must remain
the line voltage inputs. closed. If it opens, a safety shutdown occurs.
d. Brownouts caused by a low line voltage. c. The Preignition Interlock input is ignored
The INITIATE sequence throughout the Ignition Trial state.
also delays the burner motor INITIATE 00:10 2. Flame must be proven by the end of the four or ten
Diagnostic Info
starter from being energized second PFEP to allow the sequence to continue. If
and de-energized from an flame is not proven by the end of PFEP, a safety
intermittent AC line input or control input. shutdown occurs.
3. With flame proven, the ignition, terminal 10, is de-
STANDBY energized for early spark termination.
STANDBY
The CB780/CB784 is b. Main Flame Establish-
Total Cycles 132 MAIN IGN 00:15
ready to start an operating ing Period (MFEP): Flame Signal 2.7V
sequence when the operat- 1. The CB780/CB784
ing control determines a call for heat is present. The burner has a selectable ten second or fifteen second
switch, limits, operating control and all microcomputer moni- MFEP. After the Ignition Trials, and with the pres-
tored circuits must be in the correct state for the CB780/ ence of flame, the main fuel valve, terminal 9, is
CB784 to continue into the PREPURGE sequence. powered. If a flameout occurs, the CB780/CB784
will lockout within 3 seconds.
NORMAL START-UP
PURGE 00:30
PREPURGE Total Hours 396
RUN
The CB780/CB784 pro- 1. A ten second stabilization period occurs at the begin-
vides a PREPURGE timing ning of the RUN period.
selectable from 30 seconds to 2-1/2 minutes with power 2. The firing rate motor releases to modulation.
applied and the CB780/CB784 operating control indicating 3. The CB780/CB784 is now in RUN and will remain in
a call for heat: RUN until the controller input, terminal 6, opens, indicating
a. Running Interlocks, Preignition Interlocks, Burner that the demand is satisfied or a limit has opened.
Switch, Run/Test Switch, Lockout Interlocks and all
microcomputer monitored circuits must be in the cor- POSTPURGE
rect operating state. The CB780/CB784 pro-
b. The blower motor output, terminal 5, is powered to vides a fifteen second RUN
Expanded Annun.
start the PREPURGE sequence. The firing rate motor POST-PURGE following
is driven to the high fire position. The PREPURGE the completion of the RUN
timing does not begin until the Lockout Interlock period. The blower motor output is powered to drive all
String and High Fire Switch are both closed. products of combustion and any unburned fuel from the
c. The Preignition Interlock input must remain closed
throughout PREPURGE; otherwise, safety shutdown
occurs.
1-18 750-166
CB780/CB784
OPERATION
combustion chamber. It also supplies combustion air to burn 2. The Preignition

fuel being purged from the fuel line downstream of the fuel Interlock closes within the POST PURGE 00:12
FlameRM7800L
Device Signal 0.0V
shutoff valve. first five seconds of
1. The main fuel valve and intermittent pilot valve, termi- POSTPURGE.
nals 9 and 21, are de-energized and the firing rate motor is 3. After the fifteen second POSTPURGE period is com-
commanded to the low fire position to begin the POSTPURGE pleted, the CB780/CB784 reenters STANDBY.
period.
Fig. 18—CB780/CB784 sequence.

CB 780/CB 784
VFD 00 PREPURGE 00 00 PREPURGE 00 10 20 25 00 15
DRIVE TO TIMED DRIVE TO PFEP
DISPLAY INITIATE STANDBY HIGH FIRE PURGE LOW FIRE 4 OR 10 SEC MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER
LED PILOT PILOT PILOT PILOT PILOT
DISPLAY
FLAME FLAME FLAME FLAME FLAME
MAIN MAIN MAIN MAIN MAIN
ALARM ALARM ALARM ALARM ALARM
BURNER BURNER/BLOWER MOTOR 5
10 IGN. 5 SEC.
10 SEC. IGN./PILOT 8
15 SEC. PILOT 21
MAIN VALVE 9
OPERATING L1 TO 6
CONTROLS LIMITS AND BURNER CONTROLLER CLOSED
AND
INTERLOCKS INTERLOCK CHECK LOCKOUT INTERLOCKS CLOSED 6 TO 7 IC
PREIGNITION INTERLOCK CLOSED 4 TO 20 PII
5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18
FLAME
SIGNAL SAFE START CHECK FLAME PROVING SSC
MOTOR OUTPUT SWITCHING 13 TO 15

13 TO 14 13 TO 14
13 TO 12
FIRING
RATE MOTOR ACTION
MOTOR
M7411
KEYBOARD DISPLAY MODULE (VFD) Fig. 19—Keyboard Display Module and

The first line of the Vacuum Fluorescent Display (VFD) sequence status LEDs (Table 4).
provides current status of the burner sequence (STANDBY, FIVE WIRE CONNECTOR FOR
PURGE, PILOT IGN, MAIN IGN, RUN and POST- COMMUNICATIONS, REMOTE DI = DIAGNOSTICS
KEYBOARD DISPLAY AND REMOTE RESET * H1 = HISTORY
PURGE), timing information (PURGE, PILOT IGN, MAIN EA = EXPANDED
RUN/TEST SWITCH ANNUNCIATOR
IGN and POSTPURGE) in minutes and seconds, hold infor-
mation (PURGE HOLD: T19) and lockout information CAPTIVE
SEQUENCE MOUNTING
(Lockout, Fault Code, Message and Sequence); see Fig. 19. STATUS SCREW
The extreme right side of the first line will either be blank or SELECTABLE PLUG-IN
it will show a small arrow pointing to the second line MESSAGE OR PURGE
PREEMPTIVE CARD
followed by a two-letter code (DI-Diagnostic Information, MESSAGE
Hn-Fault History Information, and EA-Expanded Annun- KEYBOARD
DISPLAY
ciator). When the arrow and two-letter code are displayed, it SEQUENCE MODULE
STATUS
indicates the second line is showing a selectable message LEDs
RELAY
submenu. The second line will display selectable or preemp- MODULE
RESET
tive messages. A selectable message supplies information for PUSH
FLAME
flame strength, system status indication, system or self-diag- BUTTON
AMPLIFIER
nostics and troubleshooting. A preemptive message will have FLAME
FLAME CURRENT
SIMULATOR INPUT
parentheses around the message and supply a detailed mes- TEST JACKS M7395
sage to support the sequence status information. A preemp-

* NOTE: REMOTE RESET MUST BE MOUNTED WITHIN SIGHT
tive message can also be a lockout message. A preemptive OF THE BOILER CONTROL PANEL.
750-166 1-19
CB780/CB784
OPERATION
message will replace a selectable message to support the available. The CB780/CB784 LEDs provide positive visual
sequence status information. It will also replace a selectable indication of the program sequence: POWER, PILOT,
message after 60 seconds if it or a lockout message is FLAME, MAIN and ALARM.
TABLE 4—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 19).

NOTE: Normal sequences are in BOLD TYPE, while abnormal sequences are not in bold type.
Burner Sequence LEDs Energized
INITIATE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
↕selectable—message
INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(AC Freq/Noise)
(AC Line Dropout)
(AC Frequency)
(Low Line Voltage)
STANDBY POWER, PILOT, FLAME, MAIN AND ALARM
↕selectable —message
STANDBY HOLD: REM POWER, PILOT, FLAME, MAIN AND ALARM
(Remote Control)
STANDBY HOLD: F/G POWER, PILOT, FLAME, MAIN AND ALARM
(Flame Detected)
STANDBY HOLD: T20 POWER, PILOT, FLAME, MAIN AND ALARM
(Preignition ILK)
(Running ILK)
(Lockout ILK)
PURGE HOLD: T19 POWER, PILOT, FLAME, MAIN AND ALARM
(High Fire Switch)
PURGE DELAY: T19 POWER, PILOT, FLAME, MAIN AND ALARM
(High Fire Jumprd)
PURGE HOLD: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
PURGE DELAY: T18 POWER, PILOT, FLAME, MAIN AND ALARM
(Low Fire Jumprd)
PURGE HOLD: F/G POWER, PILOT, FLAME, MAIN AND ALARM
(Flame Detected)
(Low Fire Switch)
PURGE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
(Running ILK)
PILOT IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
PILOT HOLD: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
MAIN IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
RUN POWER, PILOT, FLAME, MAIN AND ALARM
RUN POWER, PILOT, FLAME, MAIN AND ALARM
RUN LOWFIRE: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
(continued)
1-20 750-166
CB780/CB784
OPERATION
TABLE 4—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 19) (Continued).

NOTE: Normal sequences are in BOLD TYPE, while abnormal sequences are not in bold type.
Burner Sequence LEDs Energized
POSTPURGE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
Waiting for connection… POWER, PILOT, FLAME, MAIN AND ALARM
RESET/ALARM TEST POWER, PILOT, FLAME, MAIN AND ALARM
Additional
Additioanlsequence
sequencestatus
statusinformation
information when an Expanded
Expanded Annunciator
Annunciatorisisconnected
connectedtotothe
therelay
relaymodule.
module, alsosee
Also see
CB 780/CB
CB780/CB784 784 System
Operating AnnunciationManual,
and Maintenance Diagnostics andNumber
Manual Troubleshooting,
750-166. Bulletin Number CB-7803.
BURNER OFF: T6 POWER,PILOT, FLAME, MAIN AND ALARM
(Burner Switch)
(Expanded Annunciator hold message)
(Circuit Fault)
KEYBOARD FUNCTIONS arrow (↕), which is located in the lower left position of the
The keyboard contains four pushbuttons and each has second line of the display, represents the SCROLL Down-
separate functions (SCROLL-Down, SCROLL-Up, MODE Up pushbuttons. The SCROLL Down-Up pushbuttons (↕)
and Change-Level). The MODE and Change-Level push- can be pressed to display selectable messages one at a time or
buttons, when pressed together, provide a SAVE function. held down to scroll through the selectable messages at a rate
1. SCROLL Down-Up pushbuttons (↕), see Fig. 20. of two per second. When the last item of the selectable
The SCROLL Down-Up pushbuttons (↕) are used to message is viewed, the display wraps around and displays
scroll through the selectable messages. The double-headed the first selectable message again.
Fig. 20—(↕) SCROLL pushbutton function.
BURNER CONTROL BURNER CONTROL
RUN RUN
Total Cycles 333 Total Hours 1332
SCROLL SCROLL
MODE MODE
SAVE SAVE
M7401
2. Change-Level pushbutton (↔), see Fig. 21. 3. MODE pushbutton, see Fig. 22.
The Change-Level pushbutton is used to change between The MODE pushbutton instantaneously switches the
the first hierarchy of selectable messages to a subset of display from a second-line-selectable message to second-
selectable messages. The Change-Level pushbutton can also line-preempted message. The sixty second timeout function
be used to change from a subset message to a first level also can be used for this task. The MODE pushbutton will
selectable message. The symbol (>) located on the second work only if there is a second-line-preempted message or
line in the lower right corner of the VFD represents a first lockout message.
level hierarchy of selectable messages. The symbol (<)
located on the second line in the lower right corner of the
VFD represents a subset of selectable messages.
750-166 1-21
CB780/CB784
OPERATION
Fig. 21 (↔)—Change-Level pushbutton function.
PILOT IGN 00:05 PILOT IGN 00:10 H1

Fault History Fault Cycle 174
SCROLL SCROLL
MODE MODE
SAVE SAVE
M7402
Fig. 22—MODE pushbutton function.
LOCKOUT #17 MFEP LOCKOUT #17 MFEP

Main Valve T9 Off *Main Flame Fail*
SCROLL SCROLL
MODE MODE
SAVE SAVE
M7403
4. SAVE function; see Fig. 23. Fig. 23—SAVE function.

The SAVE function enables users to identify the select-
able message they want to 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 BURNER CONTROL
key and then pressing the Change-Level pushbutton (↔).
The second line of the display will briefly note “…SAV-
ING…” to confirm the key press. PURGE 00:30
... SAVING ...
SELECTABLE MESSAGES
VFD Second Line Display, Two-Level Hierarchy, see SCROLL
MODE
Table 5. SAVE
The display values are as follows:
n represents a numbered value.
T represents the terminal number. M7404
x represents the suffix letter of the Relay Module.
1-22 750-166
CB780/CB784
OPERATION
TABLE 5—SELECTABLE MESSAGES.

Selectable Message Display Value First Line
(Second Line) (Second Line) Message
↕Flame Signal n.nV
↕Total Cycles nnnnn
↕Total Hours nnnnn
↕Fault History↔
↕Fault Cycle nnnnn < ↓H1
↕Fault Hours nnnnn < ↓H1
↕Fault Code nnn < ↓H1
↕*fault —message*< ↓H1
↕sequence—message< ↓H1
↕(second-line-msg)< ↓H1
↕Diagnostic Info↔
↕Device RM78nnx < ↓DI
↕Device Suffix nnnn < ↓DI
↕Run/Test Sw. RUN or TEST < ↓DI
↕Operating Control (OperControl) T6 ON or OFF < ↓DI
↕Interlock T7 ON or OFF < ↓DI
↕Pilot Valve T8 ON or OFF < ↓DI
↕Main Valve T9 ON or OFF < ↓DI
↕Ignition T10 ON or OFF < ↓DI
↕LowFire Sw T18 ON or OFF < ↓DI
↕HighFireSw T19 ON or OFF < ↓DI
↕Preignition Interlock (PreIgn ILK) T20 ON or OFF < ↓DI
↕Pilot Valve/First Stage OilValve (Valv/Start,V25) T21 ON or OFF < ↓DI
↕Jumper 1 INTACT or CLIPPED < ↓DI
↕Amplifier Type (Amp Type) NORMAL or AMP-CHECK or SHUTTER ↓DI
↕Flame Response 0.8s or 3s < ↓DI
↕Purge Time mm:ss < ↓DI
↕Manufacturing Code (Mfg Code) nnnn < ↓DI
↕Software Revision (SW Rev.) nnnn/nnnn < ↓DI
↕Expanded Annun.↔ (see Table 5)
↕Remote Command NONE/HOLD/HF/LF
750-166 1-23
CB780/CB784
OPERATION
EXPANDED ANNUNCIATOR MESSAGES, shown, see Table 6 and the Diagnostic and Troubleshooting
SEE TABLE 6 section of the CB780/CB784 Operation and Maintenance
The Expanded Annunciator (EA) may or may not be Manual, Manual No. 750-166, Tables 6 and 7 for fault codes.
connected because it is an optional device. If the EA is not When accessing Expanded Annunciator Messages, follow
connected, a display message of “(EA not connected)” will the same operations as used with the Selectable Messages.
be shown. If the EA is connected, display messages will be
TABLE 6—EXPANDED ANNUNCIATOR MESSAGES.
Selectable Message Display Value First Line
(Second Line) (Second Line) Message
↕Expanded Annun.↔
↕Expanded Annunciator (EA not connected)<
↕Current Status (CS:)a EA Message< ↓EA
↕Valve Closure (Valve Close) T4 ON or OFF< ↓EA
↕Burner Switch (Burner Sw.) T5 ON or OFF< ↓EA
↕Operating Control (OperControl) T6 ON or OFF< ↓EA
↕Auxiliary Limit (Aux Limit 1) T7 ON or OFF< ↓EA
↕Auxiliary Limit (Aux Limit 2) T8 ON or OFF< ↓EA
↕Low Water Cutoff (LWCO) T9 ON or OFF< ↓EA
↕High Limit (High Limit) T10 ON or OFF< ↓EA
↕Auxiliary Limit (AuxLimit 3) T11 ON or OFF< ↓EA
↕Oil Selection Switch (Oil Select) T12 ON or OFF< ↓EA
↕High Oil Pressure Switch (Hi OilPres) T13 ON or OFF< ↓EA
↕Low Oil Pressure Switch (LowOilPres) T14 ON or OFF< ↓EA
↕High Oil Temperature Switch (Hi OilTemp) T15 ON or OFF< ↓EA
↕Low Oil Temperature Switch (LowOilTemp) T16 ON or OFF< ↓EA
↕Atomizing Switch (Atomize Sw) T19 ON or OFF< ↓EA
↕Gas Selection Switch (Gas Select) T17 ON or OFF< ↓EA
↕High Gas Pressure Switch (Hi GasPres) T18 ON or OFF< ↓EA
↕Low Gas Pressure Switch (LowGasPres) T19 ON or OFF< ↓EA
↕Airflow Switch (Airflow Sw) T20 ON or OFF< ↓EA
↕Auxiliary Interlock (Aux ILK 4) T21 ON or OFF< ↓EA
↕Auxiliary Interlock (Aux ILK 5) T22 ON or OFF< ↓EA
↕EA Fault Code nnn< ↓EA
↕Software Revision (SW Rev.) nnnn< ↓EA
a
Expanded Annunciator Diagnostic Current Status Messages can be reviewed in CB780/CB784 Operating and Maintenance
Manual, Manual Number 750-166.
RUN/TEST SWITCH FUNCTIONS to be made. This activates a fifteen second flameout timer
The Run/Test Switch is located on the top side of the that permits pilot flame adjustment without nuisance safety
CB780/CB784; see Fig. 19. The Run/Test Switch allows the shutdowns. The Run/Test Switch will be ignored during
burner sequence to be altered as follows: PFEP for the CB780/CB784 if terminals 8 and 9 or 9 and 21
1. In Prepurge Drive To High Fire Position, the Run/Test are jumpered.
Switch, when placed in the TEST position, will hold in 5. During RUN, the Run/Test Switch, when placed in the
PREPURGE with the firing rate motor in the High Fire TEST position, will drive the firing rate motor to the Low
position. Fire position.
2. In the measured PREPURGE sequence, the Run/Test
Switch, when placed in the TEST position, will cause the NOTE: When CB780/CB784 is switched to the TEST mode,
PREPURGE timing to stop. The firing rate motor will be in it will stop and hold at the next Run/Test Switch point in
the High Fire position. the operating sequence. Make sure that the Run/Test
3. In Prepurge Drive to Low Fire position, the Run/Test Switch is in the RUN position before leaving the installa-
Switch, when placed in the TEST position, will hold the tion.
burner sequence in PREPURGE with the firing rate motor in
the Low Fire position. SELECTABLE SITE-CONFIGURABLE JUMPERS
4. In PFEP, the Run/Test Switch, when placed in the The CB780/CB784 has two site-configurable jumper
TEST position, will stop the timer during the first eight options; see Fig. 24 and Table 7. The site-configurable
seconds when a ten second PFEP is selected or during the jumpers should be clipped with side cutters and the resistors
first three seconds when a four second PFEP is selected, removed from the Relay Module.
allowing pilot-turn-down test and other burner adjustments
1-24 750-166
CB780/CB784
OPERATION • STATIC CHECKOUT
TABLE 7—SITE CONFIGURABLE

JUMPER OPTIONS. Fig. 24—Selectable site-configurable jumpers.
Jumper SELECTABLE CONFIGURATION JUMPERS
Number Description Intact Clipped
RUN/TEST SWITCH
JR1 Pilot Flame 10 Seconds 4 Seconds
Establishing
Period (PFEP)
JR3 Start-up Disabled Enabled
Interlock Check
NOTE: For all standard installations, these jumpers
should be left intact, unless otherwise indicated on
wiring diagram.
M7397
Static Checkout
EQUIPMENT RECOMMENDED
CAUTION 1. Voltmeter (20 kohm/volt minimum sensitivity) set on
1. Use extreme care while testing the system. Line the 0-300 Vac scale.
voltage is present on most terminal connections 2. Two jumper wires; no. 14 wire, insulated, 12 inches
when power is on. [304.8 mm] long with insulated alligator clips at both ends.
2. Open the master switch before installing or
removing a jumper on the subbase. GENERAL INSTRUCTIONS
3. Before continuing to the next test, be sure to 1. Perform all applicable tests listed in Static Checkout,
remove test jumper(s) used in the previous test. Table 8, in the order listed.
4. Replace all limits and interlocks that are not 2. Make sure all manual fuel shutoff valve(s) are closed.
operating properly. Do not bypass limits and 3. Raise the setpoint of the operating controller to simu-
interlocks. late a call for heat.
5. Close all manual fuel shutoff valve(s) before 4. For each test, open the master switch and install the
starting these tests. jumper wire(s) between the subbase wiring terminals listed
in the Test Jumpers column.
After checking all wiring, perform this checkout before 5. Close the master switch before observing operation.
installing the CB780/CB784 on the subbase. These tests 6. Read the voltage between the subbase wiring termi-
verify the Wiring Subbase is wired correctly, and the exter- nals listed in the Voltmeter column.
nal controllers, limits, interlocks, actuators, valves, trans- 7. If there is no voltage or the operation is abnormal,
formers, motors and other devices are operating properly. check the circuits and external devices as described in the
last column.
NOTE: Do not perform a dielectric test with theCB780/CB784 8. Check all wiring for correct connections, tight termi-
installed. Internal surge protectors will break down and nal screws, correct wire, and proper wiring techniques. Re-
conduct a current. This could cause the CB780/CB784 to place all damaged or incorrectly sized wires.
fail the dielectric test or possibly destroy the internal 9. Replace faulty controllers, limits, interlocks, actuators,
lightning and high current protection. 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 jumper(s).
750-166 1-25
CB780/CB784
STATIC CHECKOUT
TABLE 8—STATIC CHECKOUT.

Test Test Volt- If Operation is Abnormal, Check the
No. Jumpers meter Normal Operation Items Listed Below
WARNING
Make 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).
None 4-L2 Line voltage at terminal 4. 1 1. Master switch.
2. Power connected to the master
switch.
3. Overload protection (fuse, circuit
breaker, etc.) has not opened the
power line.
2 None 6-L2 Line voltage at terminal 6. 1. Limits.
2. Burner controller.
3 None 20-L2 Line voltage at terminal 20. 1. Preignition interlocks.
4 4-5 7-L2 1. Burner motor (fan or blower) starts. 1. Burner 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.
c. Burner motor.
2. Running or Lockout Interlocks
(including Airflow Switch).
5 4-10 — Ignition spark (if ignition transformer is 1. Watch for spark or listen for buzz.
connected to terminal 10). a. Ignition electrodes are clean.
b. Ignition transformer is okay.
6 4-8 — 1. Ignition spark (if ignition transformer is 1. Watch for spark or listen for buzz.
connected to terminal 8). a. Ignition electrodes are clean.
2. Automatic pilot valve opens (if con- b. Ignition transformer is okay.
nected to terminal 8). 2. Listen for click or feel head of valve
NOTE: Refer to wiring diagram of system for activation.
being tested. a. Actuator if used.
b. Pilot valve.
7 4-21 — Same as test no. 6 for connections to terminal 8. Same as test no. 6. If using direct spark
If using direct spark ignition, check the first ignition, check the first stage fuel valve(s)
stage fuel valve(s) instead of pilot valve. isntead of the pilot valve.
8 4-9 — Automatic main fuel valve(s) open. If using 1. Listen for and observe operation of
direct spark ignition with intermittent pilot on the main fuel valve(s) and actuator(s).
terminal 21, check the optional second stage 2. Valve(s) and actuator(s).
fuel valve, if used.
9 4-3 — Alarm (if used) turns on. 1. Alarm.
10. 4-5 and 18-L2 Firing rate motor drives open; zero volts at 1. Low Fire Start Switch.
12-13 terminal 18 after motor starts driving open. 2. Firing rate motor and transformer.
11 4-5 and 18-L2 Firing rate motor drives closed; line voltage at 1. Low Fire Start switch.
14-13 terminal 18 after motor is in Low Fire position. 2. Firing rate motor and transformer.
12 4-5 and 19-L2 Firing rate motor drives open; line voltage at 1. High Fire Purge Switch.
12-13 terminal 19 after motor is in High Fire position. 2. Firing rate motor and transformer.
13 4-5 and 19-L2 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.
(Continued)
1-26 750-166
CB780/CB784
STATIC CHECKOUT • CHECKOUT
TABLE 8—STATIC CHECKOUT (Continued).

Test Test Volt- If Operation is Abnormal, Check the
No. Jumpers meter Normal Operation Items Listed Below
WARNING
Make 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).
14 15-13 — 1. Raise set point of Series 90 controller— 1. Series 90 Controller.
firing rate motor should drive toward open. 2. Firing rate motor and transformer.
2. Lower setpoint of Series 90 controller—
firing rate motor should drive toward
closed.
Final
CAUTION
On completing these tests, open the master switch and remove all test jumpers from the subbase
terminals. Also remove bypass jumpers from the low fuel pressure limits (if used).
Checkout
IMPORTANT:
WARNING 1. If the system fails to perform properly, note the fault
Do not allow fuel to accumulate in the combus- code, fault message, equipment status, and sequence
tion chamber. If fuel is allowed to enter the time on the display. Refer to the Troubleshooting sec-
chamber for longer than a few seconds without tion of the CB780/CB784 Operation and Maintenance
igniting, an explosive mixture could result. It is Manual, Manual Number 750-166.
recommended that you limit the trial for pilot to 2. Repeat ALL required Checkout tests after all adjust-
ten seconds, and limit the attempt to light the main ments are made. ALL tests must be satisfied with the
burner to two seconds from the time the fuel has flame detector(s) in its FINAL position.
reached the burner nozzle. In any case, do not
exceed the nominal lightoff time specified by the EQUIPMENT RECOMMENDED
equipment manufacturer; close the manual fuel Volt-ohmmeter (20 kohm/volt minimum sensitivity) with:
shutoff valve(s) if the flame is not burning at the • 0-300 Vac capability.
end of the specified time. • 0-6000 ohm capability.
• 0-10 Vdc capability.
CHECKOUT SUMMARY
CAUTION • Preliminary inspection—all installations.
1. Use extreme care while testing the system. Line • Flame signal measurement—all installations.
voltage is present on most terminal connections • Initial lightoff check for proved pilot—all installations
when power is on. using a pilot.
2. Open the master switch before removing or in- • Initial lightoff check for direct spark ignition of oil—
stalling the CB780/CB784 or Keyboard Dis- all burners using DSI.
play Module connector. • Pilot turndown test—all installations using a pilot.
3. Make sure all manual fuel shutoff valve(s) are • Hot refractory saturation test—all installations using
closed before starting the initial lightoff check Infrared (lead sulfide) Flame Detectors.
and the Pilot Turndown tests. • Hot refractory hold-in test—all installations.
4. Do not put the system in service until you have • Ignition interference test—all installations using flame
satisfactorily completed all applicable tests in rods.
this section and any others required by the • Ignition spark pickup—all installations using Ultra-
equipment manufacturer. violet Flame Detectors.
• Response to other ultraviolet sources—all installa-
tions using Ultraviolet Flame Detectors.
750-166 1-27
CB780/CB784
CHECKOUT
• Flame signal with hot combustion chamber—all 7. Power is connected to the system disconnect switch,
installations. (master switch).
• Safety shutdown tests—all installations. 8. Lockout is reset (push in reset button) only if the Relay
See Figs. 1 and 2 for location of component parts and Module is powered; see Figs. 1 and 2.
Fig. 7 or wiring subbase specifications for terminal locations. 9. Run/Test Switch is in RUN position.
10. System is in the STANDBY condition. STANDBY
PRELIMINARY INSPECTION message is viewable in the VFD.
Perform the following inspections to avoid common 11. All limits and interlocks are reset.
problems. Make certain that:
1. Wiring connections are correct and all terminal screws FLAME SIGNAL MEASUREMENT
are tight. (TABLE 9 AND FIG. 26)
2. Flame detector(s) is clean, and installed and positioned Measure the flame signal at the appropriate times as
properly. Consult the applicable instructions. defined in the following Checkout tests. Read the flame
3. Correct combination of amplifier and flame detec- signal in volts dc at the flame amplifier test jacks + and
tor(s) is used. See Table 2 in the Specifications section. (Com) or at the Keyboard Display Module.
4. Plug-in amplifier and purge card are securely in place. 1. Use 1M ohm/volt meter with a 0 to 10 Vdc capability.
5. Burner is completely installed and ready to fire; con- 2. Set the 1M ohm/volt meter to the 0 to 10 Vdc range.
sult equipment manufacturer instructions. Fuel lines are 3. Insert the positive (red) probe into the + jack of the
purged of air. flame amplifier. Insert the negative (black) probe into the
6. Combustion chamber and flues are clear of fuel and (Com) jack of the flame amplifier; see Fig. 26.
fuel vapor. 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 dc Voltage a dc Voltage
817-1121 833-2741 b 1.25 Vdc 5.0 Vdc at Keyboard
817-1742 833-2722 or Display Module
833-2723c or
817-1743 833-2724 5.0 Vdc at 1M ohm/volt meter
a
This minimum or stronger signal should easily be obtained if the detector is correctly installed and positioned to properly sense
the flame. This voltaged must be obtained before completing checkout.
b
The flame signal amplifier circuitry istested one-half second every five seconds during burner operation and shuts down the
burner if the amplifier fails (all installations).
c
This flame amplifier is Auto-Check type.
5. If using Auto-Check or shutter check amplifiers, read

Fig. 26—Flame signal measurement. the average stable voltage, disregarding the peaks and val-
leys caused by the self-checking operation.
POSITIVE (+)
6. The meter reading must be as specified in Table 8 after
METER LEAD all tests are completed and all adjustments made.
ONE
NEGATIVE (-) MEGOHM/VOLT As an option, the flame signal can be checked by using the
METER LEAD METER Keyboard Display Module.
If the signal is unstable or less than the minimum accept-
able voltage, check flame detector installation and circuitry.
1. Check 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.
M7383 • Short circuits.
• Leakage paths caused by moisture, soot or accu-
mulated dirt.
1-28 750-166
CB780/CB784
CHECKOUT
3. For all optical detectors, clean the detector viewing g. After a continuous spark is obtained, open the master
window and inside of the sight pipe as applicable. switch and add a jumper on the subbase from
4. With the burner running, check temperature at the de- terminal 4 (L1) to the pilot terminal 8 or 21. Recon-
tector. If it exceeds the detector maximum rated temperature: nect the leadwire from the pilot valve if it was
• Add a heat block to stop conducted heat traveling disconnected in step b.
up the sight pipe. h. Close the master switch to energize both the igni-
• Add a shield or screen to reflect radiated heat. tion transformer and the pilot valve.
• Add cooling (refer to sight pipe ventilation in the i. If the pilot does not ignite and if the ignition spark
detector Instructions). is still continuous, adjust the pressure regulator until
5. Make sure the flame adjustment is not too lean. a pilot is established.
6. Make sure the detector is properly sighting the flame. j. When the pilot ignites properly and stays ignited,
7. If necessary, resight or reposition the detector. open the master switch and remove the jumper(s)
from terminals 4-8, 4-10 and 4-21 of the subbase.
INITIAL LIGHTOFF CHECK FOR PROVED k. Check for adequate bleeding of the fuel line.
PILOT l. Reinstall the CB780/CB784 on the subbase, close
Perform this check on all installations that use a pilot. It the master switch, and then return to step 4.
should immediately follow the preliminary inspection. 7. When pilot ignites, measure the flame signal. If the
pilot flame signal is unsteady or approaching the 1.25 Vdc
NOTE: Low fuel pressure limits, if used, could be open. If minimum value, adjust the pilot flame size or detector
so, bypass them with jumpers during this check. sighting to provide a maximum and steady flame signal.
8. Recycle the system to recheck lightoff and pilot flame
1. Open the master switch. signal.
2. Make sure that the manual main fuel shutoff valve(s) 9. When the MAIN IGN period is displayed on the VFD,
is closed. Open the manual pilot shutoff valve. If the pilot make sure the automatic main fuel valve is open; then
takeoff is downstream from the manual main fuel shutoff smoothly open the manual main fuel shutoff valve(s) and
valve(s), very slightly open the manual main valve to supply watch for main burner flame ignition. When the main burner
pilot gas flow. Make sure the main fuel is shut off just up- flame is established, proceed to step 15.
stream from the burner inlet, or disconnect power from the 10. If the main burner flame is not established within
automatic main fuel valve(s). ten seconds, close the manual main fuel shutoff valve(s).
3. Close the master switch and start the system with a 11. Recycle the system to recheck the lightoff and pilot
call for heat by raising the set point of the operating control- flame signal.
ler; see Fig. 19 or CB780/CB784 sequence. The program 12. Smoothly open the manual fuel shutoff valve(s) and
should start the ten second INITIATE sequence. try lightoff again. (The first reattempt may have been re-
4. Let the sequence advance through PREPURGE. When quired to purge the lines and bring sufficient fuel to the
the PILOT IGN status is displayed on the Keyboard Display burner.)
Module, ignition spark should occur and the pilot should 13. If the main burner flame is not established within
light. If the pilot ignites, the FLAME LED will be energized. five seconds or the normal lightoff time specified by the
Proceed to step 7. equipment manufacturer, close the manual main fuel shutoff
5. If the pilot flame is not established in ten seconds, safety valves(s). Check all burner adjustments.
shutdown occurs. Let the sequence complete its cycle. Consult 14. If the main burner flame is not established after two
the equipment operating manual for further information. attempts:
6. Push the reset pushbutton, and let the system recycle a. Check for improper pilot size.
once. If the pilot still does not ignite, make the following b. Check for excess combustion air at low fire.
ignition/pilot adjustments: c. Check for adequate low fire fuel flow.
a. Open master switch and remove the CB780/CB784 d. Check for proper gas supply pressure.
from the subbase. e. Check for proper valve operation.
b. On the subbase, temporarily jumper terminal 4 to f. Check for proper pilot flame positioning.
ignition terminals 8, 10 or 21; refer to the appropri- 15. Repeat steps 10 through 14 to establish the main
ate wiring diagram to determine the proper termi- burner flame; then proceed to step 16.
nal. Disconnect the leadwire to the pilot valve if it 16. With the sequence in RUN, make burner adjustments
is connected to the same terminal. for flame stability and Btu input rating.
c. Close the master switch to energize only the igni- 17. Shut down the system by opening the burner switch or
tion transformer. by lowering the set point of the operating controller. Make
d. If the ignition spark is not strong and continuous, sure the main flame goes out. There may be a delay due to gas
open the master switch and adjust the ignition trapped between the valve(s) and burner. Make sure all
electrode spark gap setting to the manufacturer automatic fuel valve(s) close.
recommendations.
e. Make sure the ignition electrodes are clean.
f. Close the master switch and observe the spark.
750-166 1-29
CB780/CB784
CHECKOUT
18. Restart the system by closing the burner switch and/or 12. Wait about three minutes. Close the master switch,
raising the set point of the operating controller. Observe that open the manual fuel shutoff valve(s), and try to lightoff the
the pilot is established during PILOT IGN and the main burner again. The first attempt may have been required to
burner flame is established during MAIN IGN within the purge the lines and bring sufficient fuel to the burner.
normal lightoff time. 13. If the first stage burner flame is not established within
19. Measure the flame signal. Continue to check for the ten seconds, close the manual fuel shutoff valve(s), and open
proper signal, see Table 9, through the RUN period. Check the master switch.
the signal at both High and Low Firing Rate positions and 14. If necessary, repeat steps 11 through 13 to establish the
while modulating. first stage burner flame. Then proceed to step 15.
20. Run the burner through another sequence, observing 15. When the first stage burner flame is established, the
the flame signal for: sequence will advance to RUN. Make burner adjustments
a. Pilot flame alone (DSI). for flame stability and input rating. If a second stage is used,
b. Pilot and main flame together. proceed to step 18.
c. Main flame alone (unless monitoring an intermit- 16. Shut down the system by opening the burner switch or
tent pilot). Also observe the time it takes to light the by lowering the set point of the operating controller. Make
main flame. Ignition of main flame should be smooth. sure the burner flame goes out and all automatic fuel valve(s)
21. Make sure all readings are in the required ranges close.
before proceeding. 17. If used, remove the bypass jumpers from the low fuel
22. Return the system to normal operation. pressure limit and subbase.
18. If a second stage is used, make sure the automatic sec-
NOTE: After completing these tests, open the master switch ond stage fuel valve(s) has opened. Check the lightoff as
and remove all test jumpers from the subbase terminals, follows (otherwise proceed to step 19):
limits/controls or switches. a. Open the manual second stage fuel valve(s).
b. Restart the system by raising the set point of the
INITIAL LIGHTOFF CHECK FOR DIRECT operating controller.
SPARK IGNITION c. When the first stage burner flame is established,
This check applies to gas and oil burners not using a pilot. watch for the automatic second stage fuel valve(s)
It should immediately follow the preliminary inspection. to open. Observe that the second stage lights off
Refer to the appropriate sample block diagram of field properly.
wiring for the ignition transformer and fuel valve(s) hookup. d. Make burner adjustments for flame stability and
input rating.
NOTE: Low fuel pressure limits, if used, could be open. If so, e. Shut down the system by lowering the set point of
bypass them with jumpers during this check. the operating controller. Make sure the burner
flame goes out and all automatic fuel valve(s)
1. Open the master switch. close.
2. Complete the normal ready-to-fire checkout of the f. Proceed to step 19.
fuel supply and equipment as recommended by the equip- 19. Restart the system by closing the burner switch and/or
ment manufacturer. raising the set point of the operating controller. Observe that
3. Close all manual main fuel shutoff valve(s). Check the burner flame is established during PILOT IGN, within the
that the automatic fuel valve(s) are closed. Make sure fuel is normal lightoff time specified by the equipment manufacturer.
not entering the combustion chamber. 20. Measure the flame signal. Continue to check for the
4. Close the master switch and start the system with a call proper signal, see Table 9, through the RUN period. Check
for heat by raising the setpoint of the operating controller, the signal at both high and low firing rate positions and while
see Fig.18 for CB780/CB784 sequencing. The program modulating. Any pulsating or unsteady readings will require
sequence should start the ten second INITIATE sequence. further attention.
5. Let the sequence advance through PREPURGE. Igni- 21. Make sure all readings are in the required ranges
tion spark should occur after PREPURGE period. Listen for before proceeding.
the click of the first stage fuel solenoid valve(s).
6. Let the program sequence complete its cycle. NOTE: Upon completing these tests, open the master
7. Open the manual fuel shutoff valve(s). switch and remove all test jumpers from the subbase
8. Push the reset button and recycle the program se- terminals, limits/controls or switches.
quence through PREPURGE.
9. When PILOT IGN status is displayed , watch that the 22. Return the system to normal operation.
first stage burner flame is established. If it is established,
proceed to step 15. PILOT TURNDOWN TEST (ALL INSTALLATIONS
10. If the first stage burner flame is not established within USING A PILOT)
ten seconds, close the manual fuel shutoff valve(s), and open Perform this check on all installations that use a pilot. The
the master switch after POSTPURGE is completed. purpose of this test is to verify that the main burner can be lit
11. Check all burner adjustments. by the smallest pilot flame that will hold in the flame
1-30 750-166
CB780/CB784
CHECKOUT
amplifier and energize the FLAME LED. Clean the flame

detector(s) to make sure that it will detect the smallest Fig. 27—Flame-out timer lockout.
acceptable pilot flame. If using Auto-Check or Self-Check-
ing Amplifier and 1M ohm/volt meter, the flame signal will
fluctuate every time the amplifier does a self-check or a LOCKOUT #16 PFEP
shutter check. * Flame-out Timer*
NOTE: Low fuel pressure limits, if used, could be open. If

Condition at the
so, bypass them with jumpers during this test.
time of lockout . . .
1. Open the master switch.
2. Close the manual main fuel shutoff valve(s). PILOT HOLD:
3. Connect a manometer (or pressure gauge) to measure (Run/Test Sw)
pilot gas pressure during the turndown test.
4. Open the manual pilot shutoff valve(s). M5001
5. Close the master switch and start the system with a

call for heat. Raise the set point of the operating control-
ler. The program sequence should start, and PREPURGE 10. Set the Run/Test Switch in the RUN position and let
should begin. the sequence proceed. At ten seconds into the Ignition Trial
6. When the PILOT IGN begins, set the Run/Test Switch period, make sure the automatic main fuel valve(s) open;
to TEST position to stop the sequence. The FLAME LED then smoothly open the manual main fuel shutoff valve(s) (or
will come on when the pilot ignites. any other manually opened safety shutoff valve(s), if used)
and watch for main burner ignition. If the main burner flame
NOTE: If the sequence does not stop, reset the system and is established, proceed to step 18.
make sure you set the Run/Test Switch to TEST within
the first eight seconds of the PILOT IGN sequence. NOTE: This step requires two people, one to open the
manual valve(s) and one to watch for ignition.
IMPORTANT: You have eight seconds or three seconds,
depending on PFEP selected, to position the Run/Test 11. If the main burner flame is not established within ten
Switch to the TEST position to stop the sequence after seconds, close the manual main fuel shutoff valve(s) and
the start of the PILOT IGN period. open the master switch. If the lightoff was rough, the pilot
flame size is too small.
7. Turn the pilot pressure down very slowly, reading the 12. Recycle the burner and stop the sequence in the PI-
manometer (or pressure gauge) as it drops. Stop instantly LOT IGN period by using the Run/Test Switch.
when the FLAME LED goes out. Note the pressure at the 13. Increase the pilot flame size by increasing its fuel flow
CB780/CB784 flame relay dropout point. The pilot is at the until a smooth main flame is accomplished.
minimum turndown position. Immediately turn up the pilot 14. Reposition the flame scanner sight tube or use orifices
pressure until the FLAME LED comes on again or the flame until the pilot flame signal voltage is in the range of 1.25 to
signal increases to 1.25 Vdc. 1.50 Vdc.
15. When the main burner lights reliably with the pilot at
NOTE: If there is no flame for fifteen seconds with the turndown, disconnect the manometer (or pressure gauge)
sequence stopped at this point, the CB780/CB784 will and turn the pilot gas flow up to that recommended by the
lockout and flash a lockout message; see Fig. 27. equipment manufacturer.
16. If used, remove the bypass jumpers from the sub-
8. Repeat step 7 to verify the pilot gas pressure reading at base terminals, limits/controls, or switches.
the exact point the FLAME LED light goes out. 17. Run the system through another cycle to check for
9. Increase the pilot pressure immediately until the normal operation.
FLAME LED comes on, and then turn it down slowly to 18. Return the system to normal operation.
obtain a pressure reading just above the dropout point or until
the flame signal increases to 1.25 Vdc.
750-166 1-31
CB780/CB784
CHECKOUT
HOT REFRACTORY SATURATION TEST aware that it must also properly sight the flame. For an infrared
(ALL INFRARED DETECTORS) detector, try lengthening the sight pipe or decreasing the pipe
Test to make certain that radiation from hot refractory size (diameter). For details, refer to the detector Instructions
does not mask the flickering radiation of the flame itself. and the equipment Operating Manual. Continue adjustments
Start the burner and monitor the flame signal during the until hot refractory hold-in is eliminated.
warmup period. A decrease in signal strength as the refrac-
tory heats up indicates hot refractory saturation. If saturation ULTRAVIOLET SENSOR, IGNITION SPARK RE-
is extreme, the flame signal will drop below 1.25 Vdc and the SPONSE TEST (ALL ULTRAVIOLET DETECTORS)
system will shut down as though a flame failure occurred. Test to make certain that the ignition spark is not actuating
If hot refractory saturation occurs, the condition must be the FLAME LED.
corrected. Add an orifice plate in front of the cell to restrict 1. Close the pilot and main burner manual fuel shut-off
the viewing area, lengthen the sight pipe or decrease the pipe valve(s).
size (diameter). Continue adjustments until hot refractory 2. Start the burner and use the Run/Test Switch to stop
saturation is eliminated. the sequence in the PILOT IGN period. Ignition spark should
occur, but the flame signal should not be more than 0.5 Vdc.
HOT REFRACTORY HOLD-IN TEST 3. If the flame signal is higher than 0.5 Vdc and the
(ALL INFRARED DETECTORS) FLAME LED does come on, consult the equipment operat-
Test to make certain hot refractory will not delay the ing manual and resight the detector farther out from the
flame detection system response to a flameout. This condi- spark, or away from possible reflection. It may be necessary
tion can delay response to flame failure and also can prevent to construct a barrier to block the ignition spark from the
a system restart as long as hot refractory is detected. detector view. Continue adjustments until the flame signal
Infrared (lead sulfide) detectors can respond to infrared due to ignition spark is less than 0.5 Vdc.
rays emitted by a hot refractory, even when the refractory has
visibly ceased to glow. Infrared radiation from a hot refrac- RESPONSE TO OTHER ULTRAVIOLET
tory is steady, but radiation from a flame has a flickering SOURCES
characteristic. The infrared detection system responds only Some sources of artificial light, such as incandescent or
to flickering infrared radiation; it can reject a steady signal fluorescent bulbs, mercury sodium vapor lamps and day-
from hot refractory. The refractory steady signal can be made light, produce small amounts of ultraviolet radiation. Under
to fluctuate if it is reflected, bent or blocked by smoke or fuel certain conditions, an ultraviolet detector will respond to
mist within the combustion chamber. Be careful when ap- these sources as if it is sensing a flame. To check for proper
plying an infrared system to verify its response to flame only. detector operation, check the Flame Failure Response Time
To check infrared (lead sulfide) detectors for hot refrac- (FFRT) and conduct Safety Shutdown Tests under all oper-
tory hold-in, operate the burner until the refractory reaches ating conditions.
its maximum temperature. If the installation has a multi-fuel
burner, burn the heavier fuel that is most likely to reflect, FLAME SIGNAL WITH HOT COMBUSTION
bend or obscure the hot refractory steady infrared radiation. CHAMBER (ALL INSTALLATIONS)
When the maximum refractory temperature is reached, close With all initial start-up tests and burner adjustments com-
all manual fuel shutoff valve(s), or open the electrical circuits pleted, operate the burner until the combustion chamber is at
of all automatic fuel valve(s). Visually observe when the the maximum expected temperature. Observe the equipment
burner flame or FLAME LED goes out. If this takes more manufacturer warm-up instructions. Recycle the burner un-
than three seconds, the infrared detector is sensing hot der these hot conditions and measure the flame signal. Check
refractory. Immediately terminate the firing cycle. (Lower the pilot alone, the main burner flame alone, and both
the set point to the operating controller, or set the Burner together (unless monitoring only the main burner flame
Switch to OFF. Do not open the master switch.) when using DSI). Check the signal at both High and Low
Firing Rate positions and while modulating, if applicable.
NOTE: Some burners continue to purge oil lines between the Check the FFRT of the Flame Amplifier. Lower the set
valve(s) and nozzle(s) even though the fuel valve(s) are point of the operating controller and observe the time it takes
closed. Terminating the firing cycle (instead of opening for the burner flame to go out. This should be within 3 sec-
the master switch) will allow purging the combustion onds maximum.
chamber. This will reduce a buildup of fuel vapors in the If the flame signal is too low or unsteady, check the flame
combustion chamber caused by oil line purging. detector temperature. Relocate the detector if the tempera-
ture is too high. If necessary, realign the sighting to obtain the
If the detector is sensing hot refractory, the condition must proper signal and response time. If the response time is still
be corrected. Add an orifice plate in front of the cell to restrict too slow, replace the Plug-in Flame Signal Amplifier. If the
the viewing area of the detector. If this does not correct the detector is relocated or resighted, or the amplifier is replaced,
problem, resight the detector at a cooler, more distant part of repeat all required Checkout tests.
the combustion chamber. While resighting the detector, be
1-32 750-166
CB780/CB784
CHECKOUT
SAFETY SHUTDOWN TESTS 5. Failure to ignite main.

(ALL INSTALLATIONS) a. Open the manual pilot valve(s); leave the main fuel
Perform these tests at the end of Checkout, after all other manual shutoff valve(s) closed.
tests have been completed. If used, the external alarm should b. Depress the reset button.
turn on. Press the CB780/CB784 reset pushbutton to restart c. Start the system.
the system. d. The pilot should ignite and the flame signal should
1. Opening a Preignition Interlock during STANDBY or be at least 1.25 Vdc but the main burner cannot light.
PREPURGE period. e. The flame signal should drop below 1.25 Vdc with-
a.*Preignition ILK* fault will be displayed on the in 3 seconds after the interrupted pilot goes out.
VFD. Fault code 10 or 33 will be displayed to f. *Main Flame Ign.* fault will be displayed on the
denote the fault. VFD. Fault code 19 will be displayed to denote
b. Safety shutdown will occur. the fault.
2. Opening a Lockout Interlock during PREPURGE, g. Safety shutdown will occur.
PILOT IGN, MAIN IGN or RUN period. 6. Loss of flame during RUN.
a. *Lockout ILK* fault will be displayed on the VFD. a. Open the main fuel manual shutoff valve(s) and open
Fault code 11 or 12 or 21 or 29 will be displayed to manual pilot shutoff valve(s).
denote the fault. b. Depress the reset button.
b. Safety shutdown will occur. c. Start the system. Start-up should be normal and the
3. Detection of flame 40 seconds after entry to STAND- main burner should light normally.
BY, fault code 9. Detection of flame ten seconds into Drive d. After the sequence is in the normal RUN period for
to Purge Rate or during measured PREPURGE time. at least ten seconds with the main burner firing,
a. Simulate a flame to cause the flame signal voltage close the manual main fuel shutoff valve(s) to extin-
level to be at least 1.25 Vdc for 40 seconds after guish the main burner flame.
entry to STANDBY and also simulate a flame e. The flame signal should drop below 1.25 Vdc within
signal for 10 seconds during PREPURGE. 3 seconds after the main flame goes out.
b.*Flame Detected* fault will be displayed on the f. *Main Flame Fail* fault will be displayed on the
VFD. Fault code 9 or 15 or 18 will be displayed to VFD. Fault code 17 will be displayed to denote
denote the fault. the fault.
c. Safety shutdown will occur. g. Safety shutdown will occur.
4. Failure to ignite pilot. 7. Opening a Preignition Interlock after the first five
a. Close pilot and main fuel manual shutoff valve(s). seconds of POSTPURGE.
b. Depress the reset button. a. *Preignition ILK* fault will be displayed on the
c. Start the system. VFD. Fault code 33 will be displayed to denote
d. The automatic pilot valve(s) should be energized the fault.
but the pilot cannot ignite. b. Safety shutdown will occur.
e. *Pilot Flame Fail* fault will be displayed on the
VFD. Fault code 28 will be displayed four or ten IMPORTANT:
seconds (depending on the jumper configuration 1. If the CB780/CB784 fails to shut down on any of these
selection for PFEP) after the pilot valve(s) is tests, take corrective action; refer to CB780/CB784
energized to denote the fault. Troubleshooting and diagnostics manual and return
f. Safety shutdown will occur. to the beginning of all Checkout tests.
2. When all Checkout tests have been completed, reset
all switches to original status.
750-166 1-33
CB780/CB784
TROUBLESHOOTING
Troubleshooting
CB780/CB784 SYSTEM DIAGNOSTICS Diagnostic Information Index
Troubleshooting control system equipment failures is The CB780/CB784 monitors input/output terminals and
made easier with the CB780/CB784 self-diagnostics and can display the status of the terminal at the VFD (example:
first-out annunciation. In addition to an isolated spst alarm Pilot Valve T8 ON<). See Table 5 for a complete terminal
relay (audible annunciation), the CB780/CB784 provides description and number. The display will show the actual
visual annunciation by displaying a fault code and fault or status of the terminal. If voltage is detected at the terminal,
hold message at the Keyboard Display Module 2 row by ON is displayed, but if no voltage is detected at the terminal,
20 column VFD. The CB780/CB784 provides118 diag- OFF is displayed; see Table 5.
nostic messages for troubleshooting the system (see the
CB780/CB784 Operating and Maintenance Manual, Manual Historical Information Index
Number 750-166). The CB780/CB784 has nonvolitile memory that allows
Self-diagnostics of the CB780/CB784 enables it to detect the Relay Module to retain Historical Information for the six
and annunciate both external and internal system problems. most recent lockouts. Each of the six lockout files retains the
Internal faults and external faults such as interlock failures, cycle when the fault occurred, the hour of operation when the
flame failures and false flame signals are annunciated by the fault occurred, a fault code, a fault message and burner status
CB780/CB784, which energizes the ALARM LED or visu- when the fault occurred; see Table 4.
ally displayed at the Keyboard Display Module VFD.
The VFD displays a sequence status message indicating: IMPORTANT: The CB780 will not operate without a Key-
STANDBY, PREPURGE, PILOT IGN, MAIN IGN, RUN board Display Module or a Control Bus installed.
and POSTPURGE. The selectable messages also provide
visual indication of current status and historical status of the SERVICE NOTE: If the Keyboard Display Module VFD
equipment such as: Flame Signal, Total Cycles, Total Hours, is scrambled, remove and reinstall the Keyboard Display
Fault History, Diagnostic Information and Expanded An- Module, and reset the CB780/CB784 Relay Module.
nunciator terminal status (if used). With this information,
most problems can be diagnosed without extensive trial and SERVICE NOTE: Reset CB780/CB784 by pressing the
error testing. reset pushbutton on the CB780/CB784, or pressing a
Table 4 provides the sequence and status hold messages. remote reset pushbutton wired through the Keyboard
Table 10 provides a summary of all CB780/CB784 fault Display Module or Control Bus. A power-up reset will
messages and fault codes. In addition, Diagnostic Informa- cause an electrical reset of the CB780/CB784, but will not
tion and History Data are available to assist in troubleshoot- reset a lockout condition.
ing the CB780/CB784, see Table 6.
The CB780/CB784 provides diagnostic information to SERVICE NOTE: Use the access slots on the sides of the
aid the service mechanic in obtaining information when Wiring Subbase to check the terminal voltage of the
troubleshooting the system, see Tables 4, 5, 6 and 10. Informa- CB780/CB784.
tion available in the Diagnostic Information includes Device
Type, Device Suffix, Software Revision, Manufacturing SERVICE NOTE: Maximum ambient operating tempera-
Code, Flame Amplifier Type, Flame Failure Response Time, ture of an 817-1121 flame sensor, Series 1 through 6 will
Selectable Jumper Configuration Status, Run/Test Switch be reduced to 125°F because of the duty cycle operation
Status and Terminal Status. of the CB780/CB784 Relay Module.
1-34 750-166
CB780/CB784
TROUBLESHOOTING
TABLE 10—HOLD AND FAULT MESSAGE SUMMARY.
Fault Number Annunciation Message

Fault 1 *No Purge Card*
Fault 2 *AC Frequen/Noise*
Fault 3 *AC Line Dropout*
Fault 4 *AC Frequency*
Fault 5 *Low Line Voltage*
Fault 6 *Purge Card Error*
Fault 7 *Flame Amplifier*
Fault 8 *Flame Amp/Shutr*
Fault 9 *Flame Detected*
Fault 10 *Preignition ILK*
Fault 11 *Running ILK On*
Fault 12 *Lockout ILK On*
Fault 14 *High Fire Sw.*
Fault 16 *Flame-Out Timer*
Fault 17 *Main Flame Fail*
Fault 19 *Main Flame Ign.*
Fault 20 *Low Fire Sw. Off*
Fault 21 *Running ILK*
Fault 24 *Call Service*
Fault 28 *Pilot Flame Fail*
Fault 29 *Lockout ILK*
Fault 33 *Preignition ILK*
Fault 35 - 40 *Call Service*
Fault 41 *Main Valve On*
Fault 42 *Pilot Valve On*
Fault 43 *Ignition On*
Fault 44 *Pilot Valve 2 On*
Fault 45 *Low Fire Sw. Off*
Fault 46 *Flame Amp Type*
Fault 47 *Jumpers Changed*
Fault 50 *Jumpers Wrong*
Fault 51 *Flame Too Strong*
Fault 71 - 75 *Device Specific*
Fault 76 - 93 *Accessory Fault*
750-166 1-35
,
CB780/CB784

TROUBLESHOOTING
Fig. 28—Flush mounting of a Keyboard Display Module template.

1/8 DIA. (2)
M5082A
Section 2 - CB780/CB784
System Annunciation
Diagnostics and Troubleshooting
FIVE WIRE CONNECTOR FOR
COMMUNICATIONS, REMOTE DI = DIAGNOSTICS
KEYBOARD DISPLAY AND REMOTE RESET* H1 = HISTORY
EA = EXPANDED
RUN/TEST SWITCH ANNUNCIATOR
CAPTIVE
SEQUENCE MOUNTING
STATUS SCREW
SELECTABLE PLUG-IN
MESSAGE OR PURGE
PREEMPTIVE CARD
MESSAGE
KEYBOARD
DISPLAY
SEQUENCE MODULE
STATUS
LEDs
RELAY
MODULE
RESET FLAME
PUSHBUTTON AMPLIFIER
FLAME
SIMULATOR INPUT FLAME CURRENT
TEST JACKS M7395
CB780/CB784 SYSTEM DIAGNOSTICS Table 1 provides the sequence and status hold messages.
Troubleshooting control system equipment failures is Table 6 provides a summary of all CB780/CB784 fault
made easier with the CB780/CB784 self-diagnostics and messages and fault codes. In addition, Diagnostic Informa-
first-out annunciation. In addition to an isolated spst alarm tion and History Data are available to assist in troubleshoot-
relay (for audible annunciation), the CB780/CB784 pro- ing the CB780/CB784, see Table 2.
vides visual annunciation by displaying a fault code and fault The CB780/CB784 provides diagnostic information to
or hold message at the Keyboard Display Module (standard aid the service mechanic in obtaining information when
on CB780, optional on CB784) 2 row by 20 column Vacuum troubleshooting the system, see Tables 1, 2, 3 and 4. Infor-
Fluorescent Display (VFD). The CB780/CB784 provides mation available in the Diagnostic Information includes
127 different diagnostic messages for troubleshooting the Device Type, Device Suffix, Software Revision, Manufac-
system. turing Code, Purge Time, Flame Amplifier Type, Flame
Self-diagnostics of the CB780/CB784 enables it to detect Failure Response Time, Selectable Jumper Configuration
and annunciate both external and internal system problems. Status, Run/Test Switch Status and Terminal Status.
Internal faults and external faults (e.g., interlock failures,
flame failures, and false flame signals) are annunciated by Diagnostic Information Index
the CB780/CB784, through the Device ALARM LED Alarm The CB780/CB784 monitors input/output terminals and
output, and can be visually displayed at the Keyboard Dis- can display the status of the terminal at the KDM (example:
play Module (KDM). Pilot Valve T8 1 (one), see Table 3. A complete terminal
The KDM displays a sequence status message indicat- description and terminal number are provided. The display
ing: STANDBY, SAFE START CHECK, PREPURGE, shows the actual status of the terminal. If voltage is detected
PILOT IGN, MAIN IGN, RUN and POSTPURGE. The at the terminal, 1 (one) is displayed; but if no voltage is
selectable messages also provide visual indication of current detected at the terminal, 0 is displayed; see Table 3.
status and historical status of the equipment such as: Flame
Signal, Total Cycles, Total Hours, Fault History, Diagnostic
Information and Expanded Annunciator terminal status (if
used). With this information, most problems can be diag-
*NOTE: Remote Reset must be mounted within sight
nosed without extensive trial and error testing.
of the boiler control panel.
750-166 2-1
Historical Information Index SERVICE NOTE: Reset the CB780/CB784 by pressing
The CB780/CB784 retains historical information for the reset button on the CB780/CB784, or pressing a re-
the six most recent lockouts. Each of the six lockout records mote reset pushbutton wired through the Keyboard Dis-
retain the cycle when the fault occurred, the hour of opera- play Module or Control Bus. A power-up reset causes an
tion when the fault occurred, a fault code, a fault message and electrical reset of the CB780/CB784 but does not reset a
burner status when the fault occurred; see Table 2. lockout condition.
SERVICE NOTE: The CB780 Relay Module will not SERVICE NOTE: Use the access slots on the sides of the
operate without a Keyboard Display Module or Control 833-2725 wiring subbase to check terminal voltage.
Bus installed. (These devices are optional with CB784
control.) SERVICE NOTE: Maximum ambient operating tempera-
ture of the 817-1121 UV self-check scanner, Series 1
SERVICE NOTE: If the Keyboard Display Module KDM through 6, is reduced to 125°F because of the duty cycle
is scrambled, remove and remount the Keyboard Dis- operation of the CB780/CB784 Relay Module.
play Module, and reset the CB780/CB784 Relay Mod-
ule. SERVICE NOTE: Configuration jumpers must be selected
prior to 200 hours of operation. If configuration jumpers
are changed after 200 hours, lockout 110 occurs.
TABLE 1—SEQUENCE AND STATUS HOLD MESSAGES FOR ALL CB780/CB784 CONTROLS.
NOTE: Normal sequences are in BOLD type, while abnormal sequences are not in bold type.
Sequence Burner Control Status
INITIATE mm:ss The KDM indicates the burner status, INITIATE, which is a stabilization period for the
CB 780/CB 784 to check for any fluctuations in ac line voltage on POWER UP or
control/recycle limit contact bounce during normal operation. The timing of the
INITIATE period is ten seconds before entering STANDBY.
INITIATE HOLD: AC The KDM indicates the burner status, INITIATE, and that it is waiting for excess line
(ac Frequency/Noise) noise to clear up. The burner sequence will not advance into STANDBY until the excess
line noise, which prevents sufficient reading of the line voltage inputs ceases or a line
frequency error is corrected (perhaps caused by using a 60 Hz device on a 50 Hz line, or
vice versa).
INITIATE HOLD: AC The KDM indicates the burner status, INITIATE, and that ac line power has momentarily
(ac Line Dropout) dropped out. The burner sequence will not advance into STANDBY until the ac line
voltage has stabilized throughout the INITIATE period.
INITIATE HOLD: AC The KDM indicates the burner status, INITIATE, and that line frequency is faster than
(ac Frequency) the expected value. The burner sequence will not advance into STANDBY until the line
frequency returns to the proper value (perhaps caused by using a 50 Hz device on a
60 Hz line).
INITIATE HOLD: AC The KDM indicates the burner status, INITIATE, and that low line voltage has occurred.
(Low Line Voltage) The burner sequence will not advance into STANDBY until the line voltage is at a
sufficient level for proper operating parameters.
STANDBY The KDM indicates the burner status, STANDBY. The burner can be placed in
STANDBY by opening the burner switch or if the operating controller indicates setpoint
has been satisfied. A demand could be present for burner operation, but the burner
sequence will not advance from STANDBY to PURGE until the recycle limits close. If
an Expanded Annunciator is connected, the display messages will be enhanced.
STANDBY HOLD: F/G The KDM indicates the burner status, STANDBY, and that a flame is detected. A
(Flame Detected) demand is present for burner operation. The burner sequence will not advanced to
prepurge because a flame is detected as being present. The sequence will not advance to
prepurge until the flame signal clears. If the flame signal does not clear within
40 seconds the CB 780/CB 784 will lockout.
STANDBY HOLD: T20 The KDM indicates the burner status, STANDBY, and that the Preignition Interlock is
(Preignition Interlock) not closed. If a demand is present for burner operation, the burner sequence will not
advance to PREPURGE until the Preignition Interlock proves closed. If this time exceeds
a 30 second hold, the CB 780/CB 784 will lockout.
(Continued)
2-2 750-166
TABLE 1—SEQUENCE AND STATUS HOLD MESSAGES FOR ALL CB780/CB784 CONTROLS (Continued).
STANDBY HOLD: T7 The KDM indicates the burner status, STANDBY, and that the Lockout Interlock is
(Lockout Interlock) closed. If a demand is present for burner operation, the burner sequence will not advance
to PREPURGE until the Lockout Interlocks prove open. If this time exceeds the
120 second hold, the CB 780/CB 784 will lockout.
PURGE HOLD : T19 The KDM indicates the burner status, PURGE, and that the High Fire Switch is not
(High Fire Switch) closed. The firing rate motor is driving to its PURGE rate position. If this time exceeds
two minutes and 15 seconds, the CB 780/CB 784 will lockout.
PURGE DELAY: T19 The KDM indicates the burner status, PURGE, and that the High Fire Switch is
(High Fire Jumpered) jumpered. The High Fire Switch is bypassed, welded or otherwise prematurely closed.
The system will automatically add 30 seconds to allow the firing rate motor additional
drive time to reach or near the open damper position before starting the PURGE
sequence.
PURGE mm:ss The KDM indicates the burner status, PURGE, which is the period of time before the
ignition period when the blower motor is running. The timing of the PURGE period is
selectable. PREPURGE is counted in minutes and seconds.
PURGE HOLD:TEST The KDM displays the burner status, PURGE, and that the Run/Test Switch is in the
(Run/Test Switch) TEST position. The sequence will not continue until the Run/Test switch is placed in the
RUN position.
PURGE HOLD :T18 The KDM displays the burner status, PURGE, and that the Low Fire Switch is jumpered.
(Low Fire Jumpered) The Low Fire Switch is bypassed, welded or otherwise prematurely closed. The system
will automatically add 30 seconds to allow the firing rate motor additional drive time to
reach or near the closed damper position before starting the ignition sequence.
PURGE HOLD: F/G The KDM indicates the burner status, PURGE, and that a flame is detected. The burner
(Flame Detected) sequence will not advance through PREPURGE because a flame is detected as being
present. The sequence will hold waiting for the flame signal to clear. If the time exceeds
30 seconds, the CB 780/CB 784 will lockout.
PURGE HOLD : T18 The KDM indicates the burner status, PURGE, and that the Low Fire Switch is not
(Low Fire Switch) closed. The firing rate motor is driving to its low fire position in preparation for ignition
trials. If this time exceeds two minutes and 15 seconds, the CB 780/CB 784 will lockout.
PILOT IGN mm:ss The KDM indicates the burner status, PILOT IGN, and the timing of the PILOT IGN
trial begins, in seconds. During this period of time, the CB 780/CB 784 permits the pilot
valve to be open and the pilot flame to be established.
PILOT HOLD: TEST The KDM indicates the burner status, PILOT IGN, and that the Run/Test Switch is in the
(Run/Test Switch) TEST position. The sequence will not continue until the Run/Test switch is placed in the
RUN position.
MAIN IGN mm:ss The KDM indicates the burner status, MAIN IGN, and the timing of the MAIN IGN trial
begins, in seconds. During this period of time, the CB 780/CB 784 permits the main
valve to be open and the main flame to be established.
RUN The KDM indicates the burner status, RUN, which is the period of time after the ignition
trials and before the operating controller setpoint is reached. During this time the burner
is firing under the control of the firing rate controller.
RUN LOWFIRE:TEST The KDM indicates the burner status, RUN, and that the Run/Test Switch is in the TEST
(Run/Test Switch) position. The firing rate motor will drive to the low fire position. Normal modulation or
operation will not resume until the Run/Test Switch is placed in the RUN position.
POSTPURGE mm:ss The KDM indicates the burner status, POSTPURGE, which is the period of time after the
RUN period during which the blower motor continues to run. The timing of the
POSTPURGE period is 15 seconds.
Waiting for connection… The display has power but is waiting to receive a signal from the CB 780/CB 784 to
continue operation.
(Continued)
750-166 2-3
TABLE 1—SEQUENCE AND STATUS HOLD MESSAGES FOR ALL CB780/CB784 CONTROLS (Continued).
RESET/ALARM TEST The KDM indicates the burner status, RESET/ALARM TEST. This display indicates
that the reset button is pressed. If it is held for more than four seconds, the alarm output
is energized. The alarm output will be deenergized when the reset button is released.
ADDITIONAL SEQUENCE STATUS INFORMATION IF AN EXPANDED ANNUNCIATOR IS
CONNECTED TO THE RELAY MODULE.
BURNER OFF: T6 The KDM indicates the Burner Switch is not closed. The burner sequence will not
(Burner Switch) advance to PREPURGE until the Burner Switch closes.
STANDBY The KDM indicates the burner status, STANDBY, and the Operating Control is not
closed. The burner sequence will not advance to PREPURGE until the Operating Control
closes.
STANDBY HOLD: T6 The KDM indicates the burner status, STANDBY, and a limit is not closed. The burner
(EA Hold Message) sequence will not advance to PREPURGE until one or all limits close downstream from
the Operating Control.
STANDBY HOLD: T6 The KDM indicates the burner status, STANDBY, and the control input is not closed.
(Circuit Fault) The burner sequence will not advance to PREPURGE until the control input closes.
TABLE 2—ACCESSING HISTORICAL AND DIAGNOSTIC SELECTABLE MESSAGES.

Step Operation Press Display Comments
1. Press scroll key to access (↕) STANDBY Use the down/up scroll keys to access the
Diagnostic Information Diagnostic Info> selectable message. The second line will
display Diagnostic Information.
2. Press change level key to (↔) STANDBY Use the change key to access the
access Diagnostic Diagnostic Info> Diagnostic Information.
Information
3. Continue display of (↕) STANDBY⁄DI Push the (↕) scroll key to scroll to the next
Diagnostic Information. Device RM7800< Diagnostic message.
4. Continue through remaining Diagnostic Information display following step 3 as required.
5. Press change level key to (↔) STANDBY Another display can be selected or
return to the first level of Diagnostic Info> discontinue accessing Diagnostic
Diagnostic Information Information review.
data prompt or to other
selectable messages.
NOTE: Historical Files may be selected similarly.
2-4 750-166
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 Vdc Flame Flame relay pull-in and drop-
Amp (+ and - (Com)) out value 1.25 Vdc.
Total Cycles Total number of equipment 0 - 99,999 cycles Cycle counter will be updated
operating cycles each time the main valve is
energized.
Total Hours Total number of equipment 0 - 99,999 hours Hour counter will be updated
operating hours. each time the main valve output
is energized for 60 minutes.
Fault History> (six most First level prompt for
recent faults) history information. Has
subset level.
Fault Cycle ÂH1 Cycle when the fault 0 - 99,999 cycles
occurred.
Fault Hours ÂH1 Run hour when the fault 0 - 99,999 hours
H1 occurred.
Fault Code ÂH1 Number that identifies the 0 - 999
reason for the lockout.
*Fault Message* ÂH1 Indicates lockout cause.
Sequence Message ÂH1 Indicates where the lockout
occurred in the sequence.
(Second Line Message) Second Line Message
ÂH1 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 RM7840x
Device Suffix Device suffix number. nnnn
Run/Test Sw Position of Run/Test RUN or TEST Indicates if CB 780/CB 784 is
switch. in RUN or TEST mode.
OperControl T6 Operating Control Input. 1 or 0 Indicates if input is on or off,
energized or de-energized.
Interlock T7 Running/Lockout Interlock. 1 or 0 Indicates if input is on or off,
energized or de-energized.
Pilot Valve T8 Pilot Valve. 1 or 0 Indicates if output terminal is
on or off, energized or
de-energized.
Main Valve T9 Main Fuel Valve. 1 or 0 Indicates if output terminal is
de-energized.
Ignition T10 Ignition. 1 or 0 Indicates if output terminal is
de-energized.
(Continued)
750-166 2-5
TABLE 3—SELECTABLE MESSAGES (Continued).
Selectable Possible States/Range
Message/Display Description (Terminals) Comments
LowFire Sw T18 Low Fire Switch. 1 or 0 Indicates if input is on or off,
energized or deenergized.
HighFire Sw T19 High Fire Switch. 1 or 0 Indicates if input is on or off,
PreIgn ILK T20 Preignition Interlock. 1 or 0 Indicates if input is on or off,
Valv/Start T21 Interrupted/Intermittent 1 or 0 Indicates 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 a 4 second PFEP.
Jumper 2 NOT USED
JUMPER 3 Interlock Check (IC). INTACT Disabled/ Display shows state of Start-
CLIPPED Enabled Up Interlock Check (IC)
jumper. If jumper is clipped,
CB 780/CB 784 IC check is
enabled. If jumper is intact,
IC is disabled.
Amp Type Defines type of amplifier NORMAL/AMP - Display shows type of flame
installed. CHECK/SHUTTER detection system installed (i.e.,
as NORMAL/Standard, 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
Mfg Code Manufacturing code is five nnnnn
digit code representing date
code.
SW Rev Software revision and nnnn/nnnn First four digits represent the
version code for Keyboard software revision of the
Display Module and Keyboard Display Module.
CB 780/CB 784. Second four digits represent the
software revision of the relay
module.
Expanded Annunciator First level 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.
2-6 750-166
LOCKOUT MESSAGES (TABLE 4) 3. STATE 3, see Fig. 3: Display of the third state mes-
When the CB780/CB784 is locked out, it displays a sage lasts three seconds. It is a replica of the burner status as
repeating cycle of messages (in English text); see Table 4. it existed at the time of lockout. The second line will be blank
In addition to the lockout messages, Table 4 provides the if the burner status at the time of lockout did not include a
system failure and recommended troubleshooting. There pre-emptive message (in parentheses) for the second line.
are four states in the cycle: 4. STATE 4: In the fourth state, both lines are blanked for
1. STATE 1, see Fig. 1: First state message display lasts one-half second, then sequence to the first state.
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 Fig. 2—Lockout message state 2.
of the Relay Module at the time of lockout is shown on the
right side of the first 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 BURNER CONTROL
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 Condition at the
code supplied by the Expanded Annunciator. time of lockout ...
2. STATE 2, see Fig. 2: Display of the second state
SCROLL
message lasts two seconds. MODE
SAVE
Fig. 1—Lockout message state 1. M7415
Fig. 3—Lockout message state 3.
BURNER CONTROL
LOCKOUT #23p PURGE BURNER CONTROL

*Airflow Sw.*
SCROLL
MODE
PURGE HOLD: T7
SAVE (Airflow Sw.)
SCROLL
M7416 MODE
SAVE
M7414
750-166 2-7
TABLE 4—FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING.
Fault Code System Failure Recommended Troubleshooting
Fault 01 No card is plugged into the 1. Assure the purge card is seated properly.
*No Purge Card* purge card slot. 2. Inspect the purge card and the connector on the
relay module for damage or contaminants.
3. Reset and sequence the CB 780/CB 784.
4. If fault code reappears, replace the purge card.
6. If fault persists, replace the relay module.
Fault 02 Excess noise or device running 1. Check the relay module and display module
*AC Frequen/Noise* on slow AC. connections.
3. Check the CB 780/CB 784 power supply to
assure that both frequency and voltage meet
specifications.
4. Check the backup power supply as appropriate.
Fault 03 AC Line dropout detected. 1. Check the relay module and display module
*AC Line Dropout* connections.
specifications.
Fault 04 Device running on fast AC. 1. Check the relay module and display module
*AC Frequency* connections.
specifications.
Fault 05 Low AC line detected. 1. Check the relay module and display module
*Low Line Voltage* connections.
specifications.
Fault 06 The purge card timing has 1. Assure that the purge card is seated properly.
*Purge Card Error* changed from the original 2. Inspect the purge card and the connector on the
configuration. relay module for any damage or contaminants.
4. If fault code reappears, replace the purge card.
6. If code persists, replace relay module.
Fault 07 Flame not sensed when checked 1. Check wiring; correct any errors.
*Flame Amplifier* for a nonself-check version. 2. Assure that the flame detector and flame
amplifier are compatible.
3. Remove the flame amplifier and inspect its
connections. Reseat the amplifier.
5. If the code reappears, replace the flame amplifier
and/or the flame detector.
(Continued)
2-8 750-166
TABLE 4—FAULT MESSAGE AND RECOMMENDED TROUBLESHOOTING (Continued).
Fault 08 Flame sensed when checked for 1. Check wiring; correct any errors.
*Flame Amp/Shutr* shutter-check or ampli-check 2. Assure that the flame detector and flame
versions. amplifier are compatible.
Fault 09 Flame sensed when shutter open 1. Check that flame is not present in the combustion
*Flame Detected* and no flame is expected during chamber; correct any errors.
Standby. 2. Check wiring; correct any errors.
Fault 10 Preignition interlock fault during 1. Check wiring; correct any errors.
*Preignition ILK* Standby. 2. Check Preignition Interlock switches to assure
proper functioning.
3. Check fuel valve operation.
4. Reset and sequence the CB 780/CB 784; monitor
the Preignition interlock status.
5. If code persists, replace the relay module.
Fault 12 Lockout Interlock powered at 1. Check wiring to assure that the Lockout
*Lockout ILK On* improper point in sequence. Interlocks are connected properly between
terminals 6 and 7. Correct any errors.
3. 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.
4. 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
Interlock or Airflow switch. Correct any errors.
5. If steps 1 through 4 are correct and the fault
persists, replace the relay module.
(Continued)
750-166 2-9
Fault 14 High fire interlock switch failure 1. Check wiring; correct any errors.
*High Fire Sw.* to close during prepurge. 2. Reset and sequence the CB 780/CB 784.
3. Use either the manual motor potentiometer to
drive the motor to the High Fire position or use
the Run/Test switch option (if available)
sequence to Prepurge Drive to High Fire and
place in the TEST position. Adjust the High Fire
switch while in this state to assure that it is
closing properly.
4. 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.
5. Reset and sequence the CB 780/CB 784. If
120 Vac was present between the High Fire
switch and terminal 18, and the fault still persists,
replace the relay module.
*Flame Detected* and no flame is expected. chamber; correct any errors.
2. Assure that the flame amplifier and flame
detector are compatible.
3. Check wiring and correct any errors.
connectors. Reseat the flame amplifier.
Fault 16 Integrated no-flame time 1. Measure the flame signal. If one exists, does it
*Flame-Out Timer* exceeded the limit during Pilot meet specifications? Make appropriate burner
Flame Establishing Period. adjustments.
2. Assure that the flame amplifier and the flame
3. Replace the flame amplifier and/or the flame
detector, if necessary.
4. If the fault persists, replace the relay module.
Fault 17 Main flame failure during Run 1. Inspect the main fuel valve(s) and its
*Main Flame Fail* after flame was established and connection(s).
on for at least 10 seconds. 2. 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.
3. Inspect the Airflow Switch and assure that it is
functioning properly.
4. 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.
(Continued)
2-10 750-166
*Flame Detected* and no flame is expected during chamber. Correct any errors.
Prepurge. 2. Assure that the flame amplifier and flame
3. Check wiring; correct any errors.
4. Remove the flame amplifier and inspect the
connectors. Reseat the flame amplifier.
Fault 19 Flame was lost during MFEP or 1. Inspect the main fuel valve(s) and connections.
*Main Flame Ign.* the first 10 seconds of the Run 2. Verify that the fuel pressure is sufficient to
state. supply fuel to the combustion chamber. Inspect
the connections to the fuel pressure switches to
assure proper functioning.
3. Inspect the Airflow Switch to assure proper
functioning.
4. 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 interlock switch failure 1. Check wiring; correct any errors.
*Low Fire Sw. Off* to close during Prepurge. 2. Reset and sequence the CB 780/CB 784.
3. Use either the manual motor potentiometer to
drive the motor to the Low Fire position, or use
the Run/Test switch option (if available)
sequence to Prepurge Drive to Low Fire and
place in the TEST position. Adjust the Low Fire
switch while in this state to assure that it is
closing properly.
4. 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.
120 Vac was present between the Low Fire
switch and terminal 19 and the fault still persists,
Fault 22 Lockout Interlock fault during 1. Check wiring; correct any errors.
*Lockout ILK* Prepurge. 2. Inspect the fan; assure that there is no blockage
of the air intake and that it is supplying air.
3. Assure that the Lockout Interlock switches are
functioning properly and that the contacts are
free from contaminants.
4. 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.
(Continued)
750-166 2-11
Fault 24 The Flame Interlock (relay 1. Reset and sequence the CB 780/CB 784.
*Call Service* module) was on when it should 2. If fault persists, replace the relay module.
have been off.
Fault 25 The Flame Interlock (relay 1. Reset and sequence the CB 780/CB 784.
*Call Service* module) was off when it should 2. If fault persists, replace the relay module.
be on.
Fault 28 Pilot flame failure. 1. Check pilot valve wiring and operation. Correct
*Pilot Flame Fail* any errors.
2. Check fuel supply.
3. Check pilot pressure and repeat pilot turndown
test.
4. Check ignition transformer electrode, flame
detector, flame detector sighting, and flame
amplifier.
Fault 29 Lockout Interlock fault. 1. Check wiring; correct any errors.
*Lockout ILK* 2. Inspect the fan; assure that there is no blockage
of the air intake and that it is supplying air.
3. Assure that the Lockout Interlock switches are
functioning properly and that the contacts are
free from contaminants.
4. Reset and sequence the CB 780/CB 784 to
Prepurge (place the Run/Test Switch into the
TEST position, if available). Measure the voltage
should be present.
Fault 31 Low Fire Interlock switch 1. Check wiring; correct any errors.
*Low Fire Sw. Off* failure to close during Run. 2. Reset and sequence the CB 780/CB 784.
3. Use either the manual motor position to drive the
motor to the LOW FIRE position, or use the Run/
Test switch option (if available) sequence to Run
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.
4. While in Run 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 needs replacement.
120 Vac was present between the Low Fire
switch and terminal 19 and the fault still persists,
(Continued)
2-12 750-166
Fault 33 Preignition Interlock fault. 1. Check wiring; correct any errors.
*Preignition ILK* 2. Inspect the Preignition Interlock switches and
assure proper funcitoning.
3. Check fuel valve operation. Valve must close
within five seconds.
4. Reset and sequence the CB 780/CB 784. During
Standby or Prepurge, measure the voltage
should be present. If not, the Preignition
Interlock switches may be defective and need
replacement.
Fault 35 Safety relay was off when it 1. Reset and sequence the CB 780/CB 784.
*Call Service* should be on or fuse has blown. 2. If fault persists, replace the relay module.
Fault 36 Main valve terminal was off 1. Reset and sequence the CB 780/CB 784.
*Call Service* when it should be on. 2. If fault persists, replace the relay module.
Fault 37 Pilot (ignition) valve terminal 1. Reset and sequence the CB 780/CB 784.
*Call Service* was off when it should be on. 2. If fault persists, replace the relay module.
Fault 38 Ignition terminal was off when it 1. Reset and sequence the CB 780/CB 784.
*Call Service* should be on. 2. If fault persists, replace the relay module.
Fault 39 V2S valve terminal was off 1. Reset and sequence the CB 780/CB 784.
*Call Service* when it should be on. 2. If fault persists, replace the relay module.
Fault 40 Safety relay was on when it 1. Reset and sequence the CB 780/CB 784.
*Call Service* should be off. 2. If fault persists, replace the relay module.
Fault 41 Main valve terminal was on 1. Warning! Remove system power; turn off fuel
*Main Valve On* when it should be off. supply.
2. Check wiring to terminal 9; correct any errors.
3. Inspect the Main Fuel Valve(s) and connections.
Assure that switches are functioning correctly
and are not jumpered or welded.
Fault 42 Pilot (ignition) valve terminal 1. Warning! Remove system power; turn off fuel
*Pilot Valve On* was on when it should be off. supply.
3. Inspect the Pilot Fuel Valve(s) and connections.
Assure that switch is functioning correctly and is
not jumpered or welded.
Fault 43 Ignition terminal was on when it 1. Warning! Remove system power; turn off fuel
*Ignition On* should be off. supply.
3. Inspect the Ignition terminal and connections.
(Continued)
750-166 2-13
Fault 44 V2S valve terminal, used as a 1. Warning! Remove system power; turn off fuel
*Pilot Valve 2 On* pilot, was on when it should be supply.
off. 2. Check wiring to terminal 21; correct any errors.
3. Inspect the Pilot Fuel Valve 2 and connections.
Fault 45 Low fire interlock switch failure 1. Check wiring; correct any errors.
*Low Fire Sw. Off* to close or stay closed. 2. Reset and sequence the CB 780/CB 784.
3. Use either the manual motor position to drive the
motor to the LOW FIRE position, or use the
Run/Test switch option, if available. Sequence to
the LOW FIRE position and place the switch in
the TEST position. Adjust the Low Fire switch
while in this state to assure that it is closing
properly.
4. While in the Drive to Low Fire state, measure the
voltage between terminals 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. If steps 1 through 4 are correct and the fault still
Fault 47 The configuration jumpers differ 1. Inspect the jumper connections. Assure that
*Jumpers Changed* from the sample taken at startup. clipped jumpers were completely removed.
Fault 50 The sequence logic detected a 1. Inspect jumpers and consult the instruction and
*Jumpers Wrong* combination of jumpers that is installation guide for compatible jumper
illegal for the sequence (e.g., if it 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 3. 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.
connectors. Reset the flame amplifier.
4. Check the flame detector sighting position, reset
and cycle. Measure flame strength. Does it meet
specifications? If not, refer to flame detector
and/or flame amplifier checkout procedures in
installation instructions.
Fault 52 Pilot Valve 2 terminal was off 1. Inspect Pilot terminal 21 and connections. Assure
*Internal Fault* when it should be on. that Pilot is functioning properly.
(Continued)
2-14 750-166
Fault 67 L1 and L2 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.
*Call Service* 2. If fault reappears, remove power from the device,
CB 780/CB 784.
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,
CB 780/CB 784.
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 line voltage phase.
Fault 110 Configuration jumpers differ 1. Inspect the jumper connections. Assure they
*Call Service* from stored values. match the original selection and clipped jumpers
were completely removed.
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.
*Call Service* 2. If fault persists, replace the relay module.
(Continued)
750-166 2-15
Fault 127 Safety relay feedback circuit 1. Reset and sequence the CB 780/CB 784.
*Call Service* was in an improper state. 2. If fault persists, replace the relay module.
2-16 750-166
TABLE 5—CB783 EXPANDED ANNUNCIATOR HOLD CODES.
Annunciation Message Symbol System Holds
BURNER OFF: T6 EA Burner switch is open.
(Burner Switch)
STANDBY HOLD: T6 EA Auxiliary limit #1 is open.
(Aux. Limit #1)
(Aux. Limit #2)
STANDBY HOLD: T6 EA Open low water cutoff.
(LWCO)
STANDBY HOLD: T6 EA High limit (pressure or temperature) exceeded.
(High Limit)
(Aux. Limit #3)
STANDBY HOLD: T6 EA No fuel selected.
(FuelSelect Off)
STANDBY HOLD: T6 EA Both fuels selected.
(BothFuelSelect)
STANDBY HOLD: T6 EA Oil pressure is above high oil pressure limit.
(High Oil Pres.)
STANDBY HOLD: T6 EA Oil pressure is below low oil pressure limit.
(Low Oil Pres.)
STANDBY HOLD: T6 EA Oil temperature is above high oil temperature limit.
(High Oil Temp.)
STANDBY HOLD: T6 EA Oil temperature is below low oil temperature limit.
(Low Oil Temp.)
STANDBY HOLD: T6 EA Atomizing switch is open.
(Atomizing Sw.)
STANDBY HOLD: T6 EA Gas pressure is above high gas pressure limit.
(High Gas Pres.)
STANDBY HOLD: T6 EA Gas pressure is below low gas pressure limit.
(Low Gas Pres.)
STANDBY HOLD: T6 EA Control input is not energized.
(Circuit Fault)
750-166 2-17
TABLE 6—CB783 EXPANDED ANNUNCIATOR FAULT CODES.
Annunciation Message Symbol System Faults
LOCKOUT nna EA Auxiliary limit #1 is open.
*Aux. Limit #1*
LOCKOUT nnb EA Auxiliary limit #2 is open.
*Aux. Limit #2*
LOCKOUT nnc EA Open low water cutoff.
*LWCO*
LOCKOUT nnd EA High limit (pressure or temperature) is exceeded.
*High Limit*
LOCKOUT nne EA Auxiliary limit #3 is open.
*Aux. Limit #3*
LOCKOUT nnf EA No fuel is selected.
*FuelSelect Off*
LOCKOUT nng EA Both fuels are selected.
*BothFuelSelect*
LOCKOUT nnh EA Oil pressure is above high oil pressure limit.
*High Oil Pres.*
LOCKOUT nni EA Oil pressure is below low oil pressure limit.
*Low Oil Pres.*
LOCKOUT nnj EA Oil temperature is above high oil temperature limit.
*High Oil Temp.*
LOCKOUT nnk EA Oil temperature is below low oil temperature limit.
*Low Oil Temp.*
LOCKOUT nnm EA Atomizing switch failed to close.
*Atomizing Sw.*
LOCKOUT nnn EA Gas pressure is above high gas pressure limit.
*High Gas Pres.*
LOCKOUT nno EA Gas pressure is below low gas pressure limit.
*Low Gas Pres.*
LOCKOUT nnp EA The airflow switch is open when it should be closed or vice versa.
*Airflow Switch*
LOCKOUT nnq EA Auxiliary interlock #3 is open.
*Aux. ILK #4*
LOCKOUT nnr EA Auxiliary interlock #4 is open.
*Aux. ILK #5*
LOCKOUT nns EA Other Auxiliary Interlocks are open.
*Other ILKs*
LOCKOUT nny EA Preignition Interlock or other valve closure switch is open.
*Valve Closure*
LOCKOUT nnz EA Other Preignition Interlocks are open.
*Other PIIs*
2-18 750-166
CB783 EXPANDED ANNUNCIATOR DIAGNOS- TABLE 7—CB783 EXPANDED ANNUNCIATOR
TIC CURRENT STATUS MESSAGES (TABLE 7) DIAGNOSTIC CURRENT STATUS MESSAGES.
These messages are used to provide information from the
Display Description
CB783 Expanded Annunciator to the Keyboard Display
Module in the EA Diagnostic section under Current Status; Burner Sw. Burner Switch
see Table 7. This information explains the first limit or Oper. Control Operating Control
interlock in the system that is de-energized.
Aux. Limit #1 Auxiliary Limit #1
LWCO Low Water Cutoff
High Limit High Temperature or High
Pressure Limit
FuelSelectOff Fuel Select Off
BothFuelSelect Both Fuels Selected
High Oil Pres. High Oil Pressure
Low Oil Pres. Low Oil Pressure
High Oil Temp. High Oil Temperature
Low Oil Temp. Low Oil Temperature
Atomizing Sw. Atomizing Switch
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
750-166 2-19
NOTES
2-20 750-166
Tecnnology Proven Worldwide

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$25.

DIVISION OF AQUA-CHEM, INC.

© Aqua-Chem, Inc., 1995

Please direct purchase orders for replacement manuals to your local

Manual Part Number 750-166

Section 1 – Installation and Operating Instructions

Section 2 – System Annunciation Diagnostics and Troubleshooting

TABLE 1—TERMINAL RATINGS.

ENVIRONMENTAL RATINGS: WEIGHT:

TABLE 2—FLAME DETECTION SYSTEMS (FIGS. 3, 4, 5).

TABLE 3—SEQUENCE TIMING FOR NORMAL OPERATION.2

APPROVAL BODIES: Factory Mutual approved, Report No. JI1V9A0.AF.

MOUNTING: 833-2725 for panel mount. ACCESSORIES:

1 REMOVE ONLY FOR TERMINAL TEST ACCESS. M7399

Fig. 2—Mounting dimensions of Keyboard Fig. 4—Ultraviolet detector.

Fig. 3—Ultraviolet Self-Check detector.

Principal Technical Features

MANDATORY PURGE First-out Annunciation reports the cause of a safety shut-

1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M7420

*Note: Remote Reset must be mounted within sight

FIG. 7—WIRING CB780/CB784

LOCKOUT INTERLOCKS LOW FIRE

10 SEC. INTERRUPTED 8 19 HIGH FIRE

WHITE 817-1743 BLUE FOR DIRECT SPARK IGNITION (OIL

YELLOW 817-1121 BLUE 8 L2

1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

833-2727 REMOTE KEYBOARD DISPLAY MODULE

1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

2 WHEN CONNECTING THE KEYBOARD DISPLAY MODULE DATA

3 REMOTE RESET MUST BE MOUNTED WITHIN SIGHT OF

RELAY MODULE MOUNTING

IMPORTANT: The CB780/CB784 must be installed with a

Fig. 13—Keyboard Display Module mounting. INSTALLING PLUG-IN FLAME SIGNAL

INSTALLING THE FLAME DETECTOR

NOTE: Table 2 lists the flame detection systems available

Fig. 15—Remote mounting of Keyboard Fig.17—Flame detector wiring.

SOLID STATE SELF-CHECKING

Fig. 16—Flame signal amplifier mounting.

1 FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD

2 FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD

3 1 BROWN WIRE AND 1 WHITE WIRE FROM THE 817-1742,

combustion chamber. It also supplies combustion air to burn 2. The Preignition

Fig. 18—CB780/CB784 sequence.

BURNER BURNER/BLOWER MOTOR 5

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18

MOTOR OUTPUT SWITCHING 13 TO 15

KEYBOARD DISPLAY MODULE (VFD) Fig. 19—Keyboard Display Module and

sage to support the sequence status information. A preemp-

TABLE 4—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 19).

TABLE 4—SEQUENCE STATUS DISPLAY INFORMATION (See Fig. 19) (Continued).

Fig. 20—(↕) SCROLL pushbutton function.

BURNER CONTROL BURNER CONTROL

Fig. 21 (↔)—Change-Level pushbutton function.

BURNER CONTROL BURNER CONTROL

PILOT IGN 00:05 PILOT IGN 00:10 H1

Fig. 22—MODE pushbutton function.

BURNER CONTROL BURNER CONTROL

LOCKOUT #17 MFEP LOCKOUT #17 MFEP

4. SAVE function; see Fig. 23. Fig. 23—SAVE function.

x represents the suffix letter of the Relay Module.

TABLE 5—SELECTABLE MESSAGES.

TABLE 7—SITE CONFIGURABLE