Cleave rooks"

CB78OlCB784
hstdlation and Operating Instructions
The Cleaver-Brooks CB78O/CB784 is a microprocessor
based integrated burner control for automatically fired
gas, oil, or combinationfuel single burner applications. The
CB780 consists of a Relay Module and Keyboard Display
Module. The CB784 consistsof the Relay Module only. The
Keyboard Display Module is optional with the CB784. Sub-
base, AmpliJier,and Purge Card are required to complete the
system. Options include Personal Computer Inte~ace,Control
Bus, Remote Display Mounting, First-Out Expanded Annun-
ciator and Combustion System Managment software.
The CB78O/CB784 is programmed to provide a level of
safety, functional capability
and features beyond the capacity
of conventional controls.
Functions provided by the CB780KB784 include auto-
matic burner sequencing, .flame supervision, system status

W 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 timeof fault.
-Internal hardware status monitoring. Sequence status at timeof fault.
-Low Fire Start Switch test. Sequence time at timeof fault.
-Tamper resistant timing and logic. -Diagnostic information:
Access for external electrical voltage checks. Devicetype.
Application flexibility. Flameamplifiertype.
Communication interface capability. Flame failure response time.
Dependable, long-term operation provided by microcom- Manufacturingcode.
puter technology. OdOff status of all digital inputs and outputs.
First-out annunciation and system diagnostics provided by Selectedprepurgetime.
a 2 row by20 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.
Localorremoteannunciation of operationandfault 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.

CB-7803
CB780/CB784
SPECIFICATIONS

Specifications
ELECTRICAL
RATINGS,
Table
see 1: Dissipation:
Power
Voltage and Frequency: 120 Vac (+lo/-15%), 50 or CB780/CB784: 1OW maximum.
60 HZ (+I- 10%)~. Module:
Display 3W maximum.
KeyboardDisplayModule: 13 Vdc peak full wave Maximum Total Connected Load: 2000 VA.
(+20/-15%).
rectified
Fusing: Total Connected Load: 20A maximum, type
FRN or equivalent.

TABLE 1-TERMINAL RATINGS,

I

Terminal No. Description Ratings

G Flame Sensor Ground
GI Earth I Earth Ground1 I
L2(N) Line Voltage Common
3 120 Vac, 1A pilot duty. Alarm
4 I Line Voltage supply
(LI) I 120 Vac (+lo/-15%),or50 60 Hz (flO%).Z5
5 Burner Motor 120 Vac, 9.8AFL, 58.8ALR (inrush).
6 Burner Controller and Limits 120 Vac, 1 mA.
I 7 I LockoutRunning Interlock I 120 Vac, 9A.
8 Pilot ValveAgnition 120 Vac, 4.5A ignition and 50VA pilot duty.3
9 Main Fuel Valve 120 Vac, 2A pilot dutye4
I 10 I Ignition I 120 Vac, 4.5A Ignition.
F(11) Flame Sensor 60 to 220 Vac, current limited.
12 Firing Rate High Fire 120 Vac, 75 VA pilot duty.
I 13 I Firing Rate Common I 120 Vac, 75
pilot
VA duty.
14 Firing Rate Low Fire 120 Vac, 75 VA pilot duty.
15 Firing Rate Modulate 120 Vac, 75 VA pilot duty.
I 16 I Unused I
17 Unused
18 Low Fire Switch Input 120 Vac, 1 mA.
I 19 I High Fire Switch Input I 120 vac, 1 m ~ .
20 Preignition Interlock Input 120 Vac, 1 mA.
21 IntenuptedPilot ValveFirstStage Oil Valve 120 Vac, 2A pilot duty.
I 22 I Shutter 0.5A.I 120 Vac,
The CB780/CB784must 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 interna
The CB780/CB784 needs a low impedance ground connection to the equipment frame which, in turn, needs a low impedance
RF frequencies,
connection to earth ground. For a ground path to be low impedance at 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 fastener
free of nonconductive coatings and are protected against mating surface corrosion.
2000 VA maximum connected load to CB780/CB784 Assembly.
Can also be 120 Vac, 1A pilot duty.
Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.
Operating frequency chosen by CB780/CB784 selection.

CB-7803 2
 CB780/CB784
SPECIFICATIONS

ENVIRONMENTAL
WEIGHT: RATINGS:
Temperature:
Ambient
CB780/CB784: 1 pound unpacked.
10 ounces,
Operating: -40°F
140°F.
Keyboard
ounces,
unpacked.
Display
to
Module:
4
Storage: -40°F to 150°F.
Humidity: 85% RH continuous, noncondensing. IMPORTANT: Flame Detection System available for use
Vibration: 0.5G environment. with CB78O/CB784. To select your Plug-in Flame
DIMENSIONS: Refer to Figs. 1 and-2. Signal Ampl@er and matching Flame Detector, see
Table 2.

TABLE 2-FLAME DETECTION SYSTEMS (FIGS. 3.4.5).

Plug-In Flame Amplifiers
Flame
3
Applicable Flame Detectors

II I I
Failure
Part Response
Type Color Self-checking Time Number
Infrared Red No 833-2722 3 sec. Gas, oil, Infrared 817-1742
coalfiel (Lead Sulfide)
Type part
Number
833-2723' Gas, oil, Infrared
Dynamic Auto-Check coal (Lead Sulfide)

Self-check Check
I I I I
Peeper)
aThe 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 8 17-1121 Flame Detector with the 833-2741 Amplifier
as the ultraviolet flame detection system.
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.
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 Approval Energy
Period Purge Interlock Rate Saving Code
~~~i~~ Idtiate standby hrgePilot R~ Timing Circuit Circuits
Prepurge Bodies
CB 780/ 10 sec * ** 401. lOor * 15 sec Preignition, 4-wire No FM/IRI
CB 784 10 sec 15 sec Lockout, modulating Modulating
High and
, LowFire ,
* STANDBY and RUN can be an infinite time period.
** PURGE will be determined by which purge card is selected.
The MFEP will be determined by which terminal is used, see Figs. 7 and 18.
The operating sequence of the CB780 and CB784 Relay Modules are identical.The only difference between the Relay
Modules is that the Keyboard Display Moduleis standard with the CB780 andoptional with the CB784.

JIlV9AO.AF.
No.
APPROVAL
Report
approved,
Mutual
Factory
BODIES:
Underwriters
Laboratories Inc. listed, File
No.
MP268,
IRIacceptable.
Communications
Federal
MCCZ.
No.
Guide
Commission,
Part 15,Class B-
Canadian
Standards
Association
certified,
LR9S329-3.
Emissions.

3 CB-7803
CCB780lCB784
SPECIFICATIONS

MOUNTING: 833-2725 for panel mount. ACCESSORIES:

REQUIRED COMPONENTS: Optional:
CB780: 120 Vac160 Hz, 833-2718. Control Bus-part no. 833-2729. Provides
CB780: 120 Vac150 Hz, 833-2719. communication and remote reset capabilities on
CB784: 120 Vac160 Hz, 833-2720. CB784; remote display capabilities on CB780
CB784: 120 Vacl50 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 MountingKit for the Keyboard Display,
833-2732 90 sec. NEMA 4-part no. 833-2740.
833-2733 2-112 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)

I I

0 ALARM l
5-1/4 (133) I
5 (127) c

A REMOVE ONLY FOR TERMINALTESTACCESS. M7399

CB-7803 4
 CB780/CB784
SPECIFICATIONS

Fig. 2-Mounting dimensions of Keyboard

Display Module, in inches (mm).
--
Fig. 4-Ultraviolet

-1
(102) 4

3-1/2 (89)
detector.

6 FOOT (1.83 METER)

LEADWIRES (2)

2-3/4

I
-LCOLLAR WITH 1/2-14 NPSM M7419
INTERNALTHREADS

817-1743
7

4-3/32 (1 04) 4 Fig. 5-Infrared detector.

I HEATBL7K
CELL MOUNT
1-5/8 (41)

1- 1 -1/16 (27) +

FLEXIBLE CONDUIT
BUSHING WITH NPSM INTERNAL
MAGNIFYING LENS COLLAR, 3/4-14 NPSM THREADS
INTERNAL THREADS Ml9EPA

81 7-1 742
833-2727
(Standard with CB780, optional with CB784)

Fig. 3-Ultraviolet Self-check detector.

MOUNTING FLANGE
+7-7/32 ,7\ 3/4-14 ““7

817-1121

5 CB-7803
PRINCIPALTECHNICALFEATURES

Princiml Technical Features

The CB780KB784 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. Ignitiordpilotvalvehntennittent pilot valve terminal
b. Purge card is bad. is not energized.
c.Configurationjumperswerechanged(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 endof PFEP.
e. Four minute INITIATE periodis 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 Interlockis open an accumulative time 5. MAIN FLAME ESTABLISHING Period (MFEP)
of 30 seconds. a. Low Fire Switch opens.
c. Interlock checkfeature is enabled andthe Inter- b. Lockout Interlock opens.
lock String (including the airflow switch)is closed c. Ignition/pilot valvehntennittent pilot valve termi-
for 120 seconds withcontroller closed. nal is not energized.
d. Ignition/pilot valvehntennittent pilot valve termi- d. Main valve terminal is not energized.
nal is energized. e. No flame is present at endof MFEP.
e. Main valve terminal is energized. f. Internal system fault.
f. Internal system fault. g. Purge card is not installedor removed.
g. Purge card is not installedor removed. h. Purge card is bad.
h. Purge card is bad. 6. RUN Period
3. PREPURGE Period a. No flame is present.
a. PreignitionInterlockopensanytimeduring 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 afterf i n g rate motor is commanded 7. POSTPURGE Period
to drive to high fire position at of PREPURGE.
start 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.
fitken seconds after firing rate motor is commanded b. Ignition/pilot valvehntennittent pilot valve termi-
to drive to lowfire 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 valvehntennittent pilot valve termi- e. Purge card is removed.
nal is energized. f. Purge card is bad.
h. Main valve terminal is energized.

CB-7803 6

INTERNAL HARDWARESTATUS MONITORING
The CB780KB784 checks the purge card for correct
parity to prevent purge timingshifts and circuitry failures. It
also analyzes the integrity of the configuration jumpers and
internal hardware.ThePOWERLED blinks everyfour
seconds, signifying an internal hardware check.
CLOSED LOOP LOGIC TEST
The test verifies the integrity of all safety critical loads,
terminals 8, 9, 10 and 21. If the loads are not energized
properly; i.e., the main valve terminal is powered during
PREPURGE, the CB780KB784 will lockout on safety shut-
down. The CB780KB784 must react to input changes but
avoid the occurrence of nuisance shutdown events. Signal
conditioning is applied to line voltage inputs to verify proper
operation in the presence of normal electricalline noise such
as transient high voltage spikes orshortperiodsof line
dropout.Signal conditioningis tolerant of synchronous noise
(line noise eventsthat occur at the same time during each line
cycle).
DYNAMIC AUTO-CHECK
DynamicAuto-Check circuitry tests the flame signal
amplifier during burner operation shuts
and down the CB780/
CB784 if the flame amplifier fails.
DYNAMIC FLAMEAMPLIFIER AND SHUTTER
CHECK
Self-checking circuitry tests
all electroniccomponents in
the flame detection system andamplifier 10 to 12 times per
minute and shuts down the CB780KB784 if the detection
system fails.
DYNAMIC INPUT CHECK
All system inputcircuits are examined to verify that the
CB780KB784 is capable of recognizing the true status of
external controls, limits and interlocks.If anyinput fails this
test, a safety shutdown occurs andthe fault is annunciated.
DYNAMIC SAFETY RELAY TEST
Checks the ability ofthe dynamic safetyrelay contacts to
open andclose. It also verifies that the safety critical loads,
terminals 8,9,10and 21, can be de-energized, asrequired,by
the Dynamic Self-check logic.
7 CB-7803
CB780/CB784
SAFETYPROVISIONS
Safety Provisions
DYNAMIC SELF-CHECK SAFETY CIRCUIT
The microcomputer tests itself and related hardware
while atthe same timethe safety relay system tests
the micro-
computer operation. If amicrocomputerorsafety relay
failure occurs and does not allow proper execution of the
self-checkroutine, safety shutdown will occur andall safety
critical loads will be de-energized.
EXPANDED SAFE-STARTCHECK
The conventionalsafe-startcheck, which prevents burner
start-up ifflame is indicated at start-up, is expanded to
include a flamesignal check during STANDBY, preigni-
a
tion interlock check, aninterlock check, and a safety
critical
load check.
HIGH FIRE PURGE ANDLOW FIRE START
SWITCH TESTS
High Fire Purge Switch Testexamines the Purge Posi-
tion Interlock Switch atthe moment the firing rate motor is
commanded to the high fire position. If the switch is by-
passed, welded or otherwise closed prematurely, the system
will automatically add 30 secondsto allow additional drive
time for the firing rate motor to reach or near the open
position before starting the purge timing; otherwise, purge
timing starts when the High Fire Switch is closed. This
switch will also cause a hold (four minutes, fifteen seconds)
condition when the switch is open before purge or opens
during purge. The CB780KB784 will lockout and annunci-
ate an alarm ifthe switch fails to close within the hold time
period.
Low Fire Start Switch Testexamines the Low Fire Start
Switch at the moment PREPURGE is completed. If the
switch is bypassed, welded or otherwise prematurelyclosed,
the system automatically adds 30 seconds to allow the firing
rate motor additional time to reach or nearthe low fire start
position before ignition trials; otherwise, ignition trials start
after the Low Fire Switch closes. The test also is used to prove
that the firing rate motor is at low fire position throughout
the ignition trial period. This switch will also cause a hold
(four minutes, fifteen seconds) condition the if switch opens
after purging is complete. The CB780KB784 will lockout
and annunciate an alarm theifswitch fails to close within the
hold timeperiod.
CB780/CB784
SAFETYPROVISIONS

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

If lockout occurs after the initiation of ignition trials, down or identifiesthe cause of a failure to start or continue
(or at anytime duringa sequence whenthe 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 flamedetection 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 CB780KB784 to distinguish between field
ing condition or an actualflame 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 fist 40 seconds of STANDBY, a safety shut- CB780KB784 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 detectorare energized forthe first tics and Troubleshooting section of the CB780KB784 Op-
40 seconds during STANDBY and the last two seconds eration and Maintenance Manual, Manual Number 750- 166.
before exiting STANDBY.If a flameexists, a safety shut-
down occurs. An Auto-Check Amplifier is energized con- INTERLOCK REQUIREMENTS
tinually throughSTANDBY and PREPURGE to detect any The following interlock inputsare provided:
possibility of a runaway detector ora flame. If either situa-
tion happens,a safety shutdown occurs. A standard amplifier Low Fire Interlock
isenergizedcontinuallythroughSTANDBYand This interlock verifiesthe firing rate motoris 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 signifiesa Lockout Interlock.
If the Lockout Interlockis open for more than ten seconds
if any of the safety critical loads are powered, safety shut-
down occurs andis annunciated. into PREPURGE, the CB780KB784 will lockout. After
entering PREPURGE,if the Lockout Interlock opens during
TAMPER RESISTANT TIMINGAND 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
InterlockopensanytimeaftertensecondsintoPURGE,
VERIFIED SPARK TERMINATION during the Ignition Trialsor Run,it causes a lockout.
The ignition terminal is monitored to verify early spark A typical Lockout Interlock string contains an airflow
switch (see Fig. 7). The Interlock Check is asite configur-
termination (five seconds ignition and pilot and five seconds
pilot only). able option (see Table 7).If this feature is enabled, the
CB780KB784 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 programsequence: POWER, PILOT, Preignition Interlock
FLAME, MAIN and ALARM. The green POWER LED The Preignition Interlock inputis typically connected to
blinksevery four secondstosignify the CB780KB784 proof-of-closure switchesfor 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 duringSTANDBY, it causes a
CB780, optional with CB784) shows elapsed time during hold (30 seconds). The CB780KB784 will lockout if the
PREPURGE, PILOTIGN, 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 sec-
is open after five
expanded annunciator information when a safety shutdown onds into POSTPURGE, the CB780KB784 will lockout.
or holdor normal operation occurs. The Preignition Interlockis ignored duringthe ignition trials
state and during RUN.

CB-7803 8

A WARNINGFIRE OR EXPLOSION HAZARD
CAN CAUSE PROPERTY DAMAGE,
SEVERE INJURY, OR DEATH.
To prevent possible hazardous burner operation,
verification of safety requirememts must be per-
formed each timecontrol
a is installed on aburner.
WHEN INSTALLING THIS PRODUCT.. . own expense maybe required to take whatever mea-
1. Read these instructions carefully. Failure to follow
themcoulddamage the product or causeahazardous
condition.
2. Checkthe ratings givenintheinstructionsand
marked on the product to make sure the product is suitable
for the application.
3. Installer must be a trained, experienced, flame safe-
guard service technician.
4. After installation is complete, check out the product
operation as providedin these instructions.
CAUTION
1. Disconnect the power supply before beginning
installation to prevent electrical shock, equip-
ment andcontrol damage. More than one power
supply disconnect maybe involved.
2. Wiring connections for the CB780KB784 are
unique; therefore, refer to Figs. 6 , 7 , 8 or 9 or
the correct Specifications for proper subbase
wiring.
3. Wiring must comply withall applicable codes,
ordinances andregulations.
4. Wiring, whererequired,must comply with NEC MOUNTING WIRING SUBBASE
Class 1 (Line Voltage) wiring.
5. Loads connectedto the CB780KB784 must not
exceed thoselisted on the CB780KB784 label
or the Specifications, see Table 1.
6. Limits and interlocks must be rated to simulta-
neously carry and breakcurrent to the ignition
transformer,pilot valve, and mainfuel valve(s).
7. All externaltimers mustbe listed or component
recognized byauthoritieswho havejurisdiction
for the specificpurpose for which theyare used.
IMPORTANT:
1. For on-off gas-fired systems, some authorities who
have jurisdiction prohibit the wiringof any limit or
operating contacts in series between the flame safe-
guard control andthe main fuel valve(s).
2. Two Flame Detectors can be connectedinparallel with
the exception of Infrared Flame Detector(817-1742).
9 CB-7803
CB780/CB784
INSTALLATION
Installation
3. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in
accordance withthe instructions, may causei n t e ~ e r -
ence to radio communications. It has been tested and
found tocomply withthe limitsfor a ClassB comput-
ing device of Part 15 ofFCC rules which are designed
to provide reasonable protection against such inter-
ference when operated in a commercial environment.
Operation of this equipment in a residential area may
cause inte~erence;in which case, the users at their
sures arerequired to correctthis inte~erence.
4. This digital apparatus does not exceed the Class B
limits for radio noisefor digital apparatus set out in
the Radio Inte~erenceRegulations of the Canadian
Department of Communications.
HUMIDITY
Install the CB780KB784 where the relative humidity
never reaches the saturation point. The CB780KB784 is
designed to operate in a maximum 85% RH continuous,
noncondensing, moisture environment. Condensing mois-
ture may cause a safety shutdown.
VIBRATION
Do not install the CB780KB784 where it could be sub-
jected to vibration in excess of 0.5G continuous maximum
vibration.
WEATHER
The CB780KB784 is not designedto be weather tight. If
installed outdoors, the CB780KB784 must be protected by
an approved weather-tightenclosure.
NOTE: For installation dimensions, seeFig. 1.
1. Mount the subbase in any position except horizontally
with the bifurcated contacts pointing down. The standard
vertical position is recommended. Any other position de-
creases the maximum ambient temperaturerating.
2. The 833-2725 Wiring Subbase can be mounted di-
rectly inthe control cabinet. Be sure to allow adequateclear-
ance for servicing, installation,access or removal of the
CB780KB784, ExpandedAnnunciator,KeyboardDis-
play Module, flame amplifier,flame amplifiersignal voltage
probes, R u f l e s t Switch, electrical signal voltage probes
and electrical field connections.
3. For surface mounting, usethe back of the subbase as a
template to mark the four screw locations. Drill the pilot
holes.
4. Securely mount the subbase using four no.6 screws.
CB780/CB784
INSTALLATION

Fig. 6-Internal block diagram of the CB780KB784 (see Figs.7,8,9, or 10 for detailed wiring instructions).

L1
(HOT)
L2

CONFIGURATION

FLAME SIGNAL

STATUSLEDs

R PRE-IGNITION

INTERLOCK
LOCKOUT

+@+&LOW FIRE SWITCH

w
PILOT

HIGH FIRE SWITCH

MAIN VALVE
I
I-

3K1
ALARM

RS485
t INDICATES FEEDBACKSENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLT INPUTS
DDL
COMMUNICATIONS
-FIELD WIRING
RESET INTERNAL WIRING

CB-7803 10

1. a. For proper subbasewiring, refer to Fig. 7.
b. For proper remote wiring of the Keyboard Dis-
play Module, refer to Fig. 8, 9 or 10 or to the
Specifications for the Keyboard Display Module,
Communication Interface Base Unit or Control
Bus.
2. Disconnect the power supply from the main discon-
nect beforebeginning installation toprevent electrical
shock and equipment damage. Morethan one disconnect
may be involved.
3. All wiring must comply with all applicable electrical
codes, ordinances and regulations. Wiring, where required,
must comply with NEC, Class1 (Line Voltage) wiring.
4. Recommended wire size and type:
a. All Line Voltageterminals use no. 14 or 16 cop-
per conductor (9OOC or higher) 600 volt insula-
tion wire (wire size must be coordinated with fuse
protection). For high temperature installations,
use wireselected for a temperaturerating above
the maximum operating temperature. All leadwires
should be moisture resistant.
b. KeyboardDisplay Module-For communica-
tions purposes, use an unshielded 22 AWG 2-wire
twistedcableandonewire for groundif the
leadwire run and noise conditions permit; how-
ever, some installations may need up to five wires,
three for communications and two for remote reset
(in eithera single cable or separate cablesfor com-
munications or remotereset) or useBelden 8771
shielded cable or equivalent. The Keyboard Dis-
play Module, Control Bus (for remote mounting or
communications)orCommunication Interface
ControlBus Module must be wired in a daisy chain 5. Recommended grounding practices:
configuration, (l(a)-l(a),2(b)-2(b), 3(c)-3(c)).The
order of interconnection of all the devices listed
above is not important. Be awarethat moduleson
the closest and farthest end of the daisy chain
configuration string require a 120 ohm (1/4 watt
minimum) resistor termination across terminals
1 and 2 of the electrical connectors, for connec-
tions over 100 feet, see Fig. 8,9 and 10.
c. Control Bus-For communicationspurposes,
use an unshielded 22 AWG 2-wire twisted cable
if the leadwire run and noise conditions permit;
however, some installations may need up to five
wires, three for communications and two for re-
motereset(ineither a single cable or separate
cables) or use a Belden 8771 shielded cable or
equivalent. The Keyboard Display Module, Con-
trol Bus (for remote mounting or communications)
or Communication Interface ControlBus Module
mustbewired in a daisy chain configuration,
(l(a)-l(a), 2(b)-2(b),3(c)-3(c)). Theorderofinter-
connection of all the devices listed above is not
11
CB780/CB784
WIRING
Wiring
important. Be aware that modules on the closest
and farthest end of the daisy chain configuration
string requirea 120 ohm (1/4 watt minimum) resis-
tor termination across terminals1 and 2 of electri-
cal connectors, for connections over 100 feet, see
Fig. 8 , 9 and 10.
Remote Reset-Use no. 22AWGor greater
twisted pair wire, insulated for low voltage; see
Fig. 8,9 and 10.
Communication Interface ControlBus Module-
For communications purposes, use an unshielded
22 AWG 2-wire twisted cable if the leadwire run
and noise conditions permit or use a Belden 8771
shieldedcable orequivalent.TheKeyboard
Display Module,Control Bus(for remote mount-
ing or communications) or Communication Inter-
face ControlBus Module must be wiredin a daisy
chainconfiguration, (l(a)-l(a),2@)-2@),3(c)-3(c)).
The order of interconnection of all the devices
listed aboveisnotimportant.Beaware that
modules on the closest and farthest end of the
daisy chain configuration string require a 120
ohm (1/4 watt minimum) resistor termination
across terminals1 and 2of the electrical connec-
tors, for connections over 100 feet, see Fig. 8,9
and 10.
Use the recommended wire size for the 13 Vdc
full wave rectified transformer power input of
no. 18 AWG wire insulatedfor voltages and tem-
peratures encountered in the application. Sug-
gested wire types include TTW(60C), THW(75C)
and THHN(90C).
a. The earth ground provides for a connection be-
tween the subbase and the control panel of the equip-
ment. 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/CB784needs a lowimpedanceground
connection to the equipmentframewhich,in
turn, needs a low impedance connection to earth
ground. For a ground path to be low impedance
at RF frequencies, the connectionmust be made
with minimum length conductors that have a
maximum surface area. Wide straps or brackets
are preferred rather than leadwires. Be careful to
ensure thatmechanically tightenedjoints along
the ground path, suchas pipe or conduitthreads
or surfaces held together with fasteners, are free
of nonconductivecoatingsand are protected
against corrosion on mating surfaces.
b. KeyboardDisplayModule,ControlBus, or
Communication Interface ControlBus Module-
CB-7803
CB780/CB784
WIRING
The shield, if used, should be connected to the
signal ground terminal 3(c) provided as ofpart the
CB780/CB784deviceControlBusconnection.
Connect the shield at both ends to earth ground.
c.CB780/CB784-Each CB780KB784 willhave
an earth ground terminal that must be grounded to
the metal control panel with wire as short as prac-
tical. Each ground wire must be of capable
carrying
a fault current equal to the rating of the protec-
tive fuse (20A).A number 14 copper conductor
is adequate, but widestraps or brackets are pre-
ferred rather than leadwires.
6. Recommended wire routing:
a. Flame detector leadwires:
1. Do not run high voltageignition transformer
wires in the same conduit with the flamedetec-
tion wiring.
2. Do not route scanner wiresin conduit with line
voltage circuits.
3. Enclose scanner wires without armor cable in
metal cable or conduit.
4. Follow directionsin flame detector Instructions.
b. Control Bus:
1. Do not run high voltage ignition transformer Specifications; see Table1.
wires in the same conduit orclose proximity
with the Control Buswiring.
2. Do not route Control Bus inwires conduit with line separate power supply circuit may be required for the
voltage circuits.
c.KeyboardDisplayModule (VFD): Because the
VFD is powered from alow voltage, energy lim-
ited source, it can be mounted outside of a control
panel if it is protected from mechanical damage.
d. Remote Reset:
1.Donotrunhighvoltageignitiontransformer
wires in the same conduit with the Remote Reset
wiring.
CB-7803 12
2. Do not route Remote Reset wires in conduit
with line voltage circuits.
NOTE: A 13 Vdc power supply must be used any time more
than one Keyboard Display Module is used.
7. Maximum wire lengths:
a. CB780KB784 leadwires-The maximum length
of leadwire is300 feet to terminal inputs (Control,
Preignition Interlock,RunningLockout Interlock,
High Fire Switch and Low Fire Switch).
b. Flame Detectorleadwires-The maximum flame
sensor leadwire length is limited by the flame
signal strength.
c. Remote Reset leadwires-The maximum length
of wire is 1000 feet toa Remote Reset pushbutton.
d. Control Bus-The maximum Control Bus cable
length depends onthe number of system modules
connected, the noise conditions and the cable used.
The maximum length of all interconnecting wire
is 1000 feet.
8. Make sure loads do not exceed the terminal ratings.
Refer to the label onthe CB780KB784 or to the ratingsin
9. Check the power supply circuit. The voltage and fre-
quency tolerance must matchthose of the CB780KB784.A
CB78O/CB784. Add the required disconnect means and
overload protection.
10. Check all wiring circuits and complete the Static
Checkout, see Table 8, before installing the CB780KB784
on the subbase.
11. Install all electrical connectors.
12. Restore power tothe panel.
 CB780/CB784
WIRING

FIG. 7-WIRING CB780/CB784

r
I
I
I
I
I I MODULATE I
I
I BURNER MOTOR
I (BLOWER)

I
I
I
I
BURNER
CONTROLLER/LIMITS

LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)
1
I
I 10 SEC. INTERRUPTED
PILOT/IGNITION PURGE SWITCH
I
I
I
5 SECOND IGNITION
I 15 SEC.
INTERRUPTED
ERMINATION)
I PILOT VALVE
-
I 'I
I 817-1742 L1
A- - INFRARED
(LEAD SULFIDE) (HOTA
L2
I FLAME DETECTOR

FOR DIRECT SPARK IGNITION (OIL

OR GAS)

I
I
OR
- I I

t
b

I
---I
YELLOW 817-1121
ULTRAVIOLET
FLAME DETECTOR
BLUE- J
2ND STAGE
FUEL VALVE
(OPTIONAL)

A 1 2 O V , 60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED

M7408
A D O NOT WIRE TO ANY UNUSED TERMINALS.

13 CB-7803
CB780/CB784
WIRING

Fig. 8-Wiring the Keyboard Display Module with Fig. 9-Wiring multiple Keyboard DisplayModules.
Communication Interface ControlBus Module.
833-2727 KEYBOARD DISPLAY MODULE
833-2727 KEYBOARD DISPLAY MODULE (MOUNTED ON CB 780/CB 784)
(MOUNTED ON CB 780/CB784)

I
MOMENTARY
MOMENTARY PUSH B U T O N
PUSH B U T O N
SWITCH

120 OHM POWER SUPPLY

833-2734
COMMUNICATIONS
INTERFACE
CONTROLBUS

I I
833-2727 REMOTE KEYBOARD DISPLAY MODULE

WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

A T H R E E 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
WIRE MUST BE USED. M7406 M7409

Fig. 10-Wiring the Control Bus with remote Keyboard Display Module.

833-2729 CONTROL BOX (MOUNTED ON CB780/CB784)

h rn
MOMENTARY
PUSH B U T O N
SWITCH

1
120 OHM
P P
RESISTOR

120 OHM
RESISTOR

I I
833-2727 REMOTE KEYBOARD DISPLAY MODULE

WIRE SHIELDED CABLE MAY BE REQUIRED. T w o 120

OHM TERMINATING RESISTORS ARE REQUIRED FOR
CONNECTIONSOVER 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.

A w H E N CONNECTING THE KEYBOARD DISPLAY MODULE

CONTROL BUS,OR REMOTE RESET MODULE
EXTERNAL FROM THE CONTROL CABINET, APPROPRIATE
MEASURES MUST BE TAKEN TO MEET EN60730 SAFETY
LOWVOLTAGE REQURIEMENTS(SEE APPROVALS). ~7407

CB-7803 14
 CB780/CB784
ASSEMBLY

Assembly
MOUNTING CB780KB784
Fig. 1l-Electrical panel installation.
NOTE: For installation dimensions, seeFig. 1.

RELAY MODULE MOUNTING

1. Mount the CB780KB784 vertically, see Fig. 11, or
mount horizontally with the knife blade terminals pointing
downward.The CB780KB784 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 CB780KB784, Keyboard Display Module,
flame amplifier,flame amplifier signal voltage probes, elec-
trical signal voltage probes, and electrical connections.
a. Allow an additionaltwo inches below the CB780KB784
for the flame amplifier mounting.
d. Allow an optional three-inch minimum to both sides
of the CB780KB784 for electrical signal voltage
probes.
3. Make sure no subbase wiringis projectingbeyond the
terminal blocks. Tuck wiring in against the back of the sub-
base so it does notinterfere with the knife blade terminals or
bifurcated contacts.

IMPORTANT: The CB78O/CB784 must be installed with a

plug-in motionrather than a hingeaction. IMPORTANT: The CB780will notfunctionproperly with-
out one of thefollowing mountedcorrectly: Keyboard
4. MounttheCB780/CB784byaligningthefourLshaped Display Module, or Control Bus.
corner guides and knife blade terminals with the bifurcated
contactson the wiring subbase and tighteningthe two screws MOUNTING KEYBOARD DISPLAY MODULE
securely without deformingthe plastic. (VFD)
1. Align the two interlocking ears of the Keyboard Dis-
INSTALLING THE PURGE CARD play Module with the two mating slots the CB780KB784;
on
1. Remove the Keyboard Display Module or Control see Fig. 13.
Bus, see Fig. 13 or 14. 2. Insert the two interlocking earsintothe two mating slots
2. Remove the current Purge Card from the CB780KB784 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 CB780KB784.
3. Make sure that the Purge Cardselectedhas the desired 3. Verify the KeyboardDisplay Modulef iisi y in place.
timing.
4. Insert Purge Card into the opening of the CB780KB784MOUNTING 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 CB780KB784; see Fig. 14.
Busonto the CB780KB784 and restore power tothe 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 atleast one complete secure it to the CB780KB784.
cycle to verify the system is operating asdesired. 3. Be sure the Control Busis firmly in place.

15 CB-7803
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 mountingthe Keyboard Display Module the on
face of a door panel, closely follow these instructions:
a. Select the location on the door panelfor flush mount-
ing. Pay attention to the insertion dimension
of the two
Keyboard Display Module screws, two interlocking
earsand the twoplug-inconnectorstoallow for
sufficient clearance, 1/4 inch minimum inwardfrom
the surfaceof the door panel.
b. Use the Keyboard Display Module asa template; see
Fig. 28. Mark the two screw locations, two interlock-
ing ear locations and two plug-in connector locations.
Drill the pilot holesfor 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 receptacleon the CB780KB784. 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 CB780KB784 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 CB780KB784. Make sure the correct
Fig. 14-Control Bus mounting. combination of amplifier andflame detector(s) is used.

REMOTE MOUNTING OF KEYBOARD DISPLAY Proper flame detector installationis 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 theflame 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 Table9.

CB-7803 16
 ASSEMBLY

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

Display Module.
INFRARED (817-1742)

G
-
ULTRAVIOLET (817-1743)

SOLID STATE SELF-CHECKING

uL l'RAVIOLET (81
7-1
121)
7
-

Fig. 16-Flame signal amplifier mounting.

A-22
BLUE
YELLOW
WHITE

L2 WHITE I
L, BLACK
L2 BLACK

A 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.

A 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.

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

CONNECTTO THE CB 780/CB 784 WIRING SUBBASE, COLOR
NOT IMPORTANT. KEEP WIRES AS SHORT AS POSSIBLE
M7410
AND TWIST THEM.

17 CB-7803
CB780/CB784
OPERATION
SEQUENCE OF OPERATION
The CB780/CB784 has the following operating sequence,
see Fig. 18 and Table4.
INITIATE
The CB780/CB784enters the INITIATE sequence when
the Relay Moduleis powered. The CB780/CB784 canalso
enter the INITIATE sequenceif the Relay Moduleverifies
voltage fluctuations of +1O/- 15% or frequencyfluctuations
of +/-lo% during any part of the operating sequence. The
INITIATE sequencelasts for ten seconds unlessthe voltage
or frequencytolerances are not met. When the tolerances are
notmet,aholdconditionwill be initiated andwill be
displayed on the VFD for at least five seconds. When the
tolerances are met, the INITIATE sequence will restart. If
the condition is not corrected and the hold condition exists
for four minutes,the CB780/CB784 willlockout. Causes for
hold conditionsin the INITIATE sequence:
a. AC line dropout is detected.
b. AC line frequency error caused by using 60 Hz
a device
on a50 Hz line, or vice versa.
c. AC line noise that can prevent asufficient reading of
the line voltage inputs.
[y]
d. Brownouts caused by a lowline voltage.
The INITIATE sequence
also delays the burner motor
starterfrom being energized $ Diagnostic Info
andde-energizedfroman
intermittent AC line input or control input.
[ T
STANDBY
The CB780/CB784 is
+Total Cycles
ready to start an operating
sequence whenthe operat-
ing control determines acall for heat is present. The burner
switch, limits,operating controland all microcomputer moni-
tored circuits must be in the correct state for the CB780/
CB784 to continueinto the PREPURGE sequence.
NORMAL START-UP
PREPURGE $ TotalHours 396
The CB780KB784 pro-
vides a PREPURGE timing
selectable from 30 seconds to 2-1/2 minutes with power
applied andthe CB780/CB784 operatingcontrol indicating
a call for heat:
a.Running Interlocks, Preignition Interlocks, Burner
Switch, Run/Test Switch, Lockout Interlocks and all
microcomputer monitoredcircuits must be inthe cor-
rect operating state.
b. The blower motor output, terminal 5 , is powered to
start the PREPURGE sequence. The firing rate motor
is driven to the high fire position. The PREPURGE
timing does not begin until the Lockout Interlock
String and HighFire Switch are both closed.
c. The Preignition Interlock input must remain closed
throughout PREPURGE;otherwise, safety shutdown
occurs.
CB-7803
Operation
The Lockout Interlock or Running Interlock inputs
(interlockcircuitincluding Airflow Switch) must close
by ten seconds into PREPURGE; otherwise, a safety
shutdown occurs.
After the firing rate motor reaches the PREPURGE
rate position and PREPURGE timing is completed, the
firing rate motor willdrive to the low fire position.
When the firing rate motor reaches lowfire position,
the Low Fire Switch,terminal 18, inputmust be
energized beforeentering the Ignition Trial state.
IGNITION TRIALS
a PilotFlameEstablish-
ing Period (PFEP): Fault History
1. Withthefiring
rate motor at the low fire position:
a. The pilot valve and the ignition transformer,
terminals 8, 10 and 21, are energized. The
CB780/CB784 has afifteen second interrupted
pilot valve, terminal 21 and a ten secondinter-
rupted pilot valvehgnition, terminal 8.
b. During PFEEthe Low Fire Switch must remain
closed. If it opens, a safety shutdown occurs.
c. ThePreignitionInterlockinputisignored
throughout the Ignition Trial state.
2. Flame mustbe proven bythe end of the four or ten
second PFEPto allow the sequence tocontinue. If
flame is not proven by the end of PFEP, a safety
shutdown occurs.
I
3. With flame proven,the ignition, terminal 10, is de-
energized for early spark termination.
b.MainFlameEstablish-
ing Period (MFEP): 3 FlameSignal 2.7V
1. The CB78O/CB784
hasa selectable ten second or fifteen second
MFEP. Afterthe Ignition Trials, and withthe pres-
ence of flame, the main fuel valve, terminal 9, is
powered. If a flameoutoccurs, the CB780/CB784
will lockout within 3 seconds.
RUN
1. A ten second stabilizationperiod occurs atthe begin-
ning of the RUN period.
2. The firing rate motor releases to modulation.
3. The CB780/CB784is now in RUN andwill remain in
RUN until the controllerinput, terminal 6 , opens, indicating
that the demand is satisfied or alimit has opened.
POSTPURGE
TheCB780KB784pro-
vides a fifteensecond
POST-PURGE following +
Expanded Annun. b
the completion of the RUN
period. The blower motor output is powered to drive all
products of combustion and any unburned fuel from the
18
 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
shutoff valve. fist five secondsof
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 thelowf i i position to begin the POSTPURGE pleted, the CB780/CB784 reenters STANDBY.
period.

Fig. 18-CB780EB784 sequence.

CB 780lCB 784
VFD
DISPLAY

LED
DISPLAY

BURNER

OPERATING
CONTROLS
AND
INTERLOCKS

FLAME
SIGNAL

FIRING
RATE
MOTOR

19 CB-7803
OPERATION

message will replace a selectable message to support the available. The CB780/CB784 LEDs provide positive visual
sequence status information.
It will also replacea selectable indication of the program sequence: POWER, PILOT,
message after 60 seconds if it or a lockoutmessage is FLAME, MAIN andALARM.

TABLE 4-SEQUENCE STATUS DISPLAY INFORMATION (SeeFig. 19).

NOTE: Normal seauences are in BOLD TYPE, while abnormal seauences are notin bold twe. --
Burner Seauence LEDs Energized
INITIATE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
:selectable-message
INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(AC Freqmoise)
INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(AC Line Dropout)
INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(AC Frequency)
INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(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)
STANDBY HOLD: T7 POWER, PILOT, FLAME, MAIN AND ALARM
(Running ILK)
STANDBY HOLD: T7 POWER, PILOT, FLAME, MAIN AND ALARM
(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)
PURGE HOLD: T18 POWER, PILOT, FLAME, MAIN AND ALARM
(Low Fire Switch)
PURGE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
:selectable-message
PURGE HOLD: T7 POWER, PILOT, FLAME, MAIN AND ALARM
(Running ILK)
PILOT IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
:selectable-message
PILOT HOLD: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
MAIN IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
:selectable-message
RUN POWER, PILOT, FLAME, MAIN AND ALARM
:selectable-message
RUN POWER, PILOT, FLAME, MAIN AND ALARM
:selectable-message
RUN LOWFIRE: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)

CB-7803 20
 OPERATION

TABLE &SEQUENCE STATUS DISPLAY INFORMATION (SeeFig. 19) (Continued).

NOTE: Normal sequences are in BOLD TYPE,while abnormal sequencesare not in bold type.
Burner Sequence LEDs Energized
POSTPURGE minutemeconds POWER, PILOT, FLAME,MAIN AND ALARM
:selectable-message
Waiting for connection... POWER, PILOT, FLAME,MAIN AND ALARM
RESET/AL,ARM TEST POWER, PILOT, FLAME,MAIN AND ALARM
:selectable-message
Additioanl sequencestatus information when an Expanded Annunciator
is connected to the relay module. Alsosee
CB780/CB784 Operating and Maintenance Manual, Manual Number 750-166.
BURNER OFF: T6 I POWER,PILOT,
FLAME, MAIN AND ALARM
(Burner Switch)
STANDBY HOLD: T6 POWER, PILOT, FLAME,MAIN AND ALARM
(Expanded Annunciator hold message)
HOLD: T6 POWER, PILOT, FLAME,MAIN AND ALARM STANDBY
(Circuit Fault)

KEYBOARD FUNCTIONS
The keyboard contains four pushbuttons and each has
separate functions (SCROLL-Down, SCROLL-Up, MODE
and Change-Level). The MODE and Change-Level push-
buttons, when pressed together, provide a SAVE function.
1. SCROLL Down-Up pushbuttons(:), see Fig. 20.
TheSCROLLDown-Uppushbuttons )(: are used to
scroll through the selectable messages. The double-headed
arrow (:), which is located in the lower leftposition of the
second line of the display, represents the SCROLL Down-
Up pushbuttons. The SCROLL Down-Up pushbuttons )(:
can be pressed to display selectablemessages one at a time or
held downto scroll through the selectablemessages at a rate
of two per second. When the last item of the selectable
message is viewed, the display wraps around and displays
the first selectable message again.

Fig. 20-(:) SCROLL pushbutton function.

BURNER CONTROL

r-.-- t Total Hours 1332

M7401

2. Change-Level pushbutton (e), see Fig. 21. MODE

3. pushbutton, see Fig. 22.
TheChange-Levelpushbutton is used to changebetweenTheMODEpushbuttoninstantaneouslyswitches the
the first hierarchy of selectable messages to asubsetof display froma second-line-selectable message to second-
selectablemessages. The Change-Level pushbutton canalso 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 lockoutmessage.
level hierarchy of selectable messages.Thesymbol (e)
located on the second line in the lower right corner of the
VFD represents a subsetof selectable messages.

21 CB-7803
CB780/CB784
OPERATION

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

I1 I 1\/II 11 I 1\/II

I I /
///

PILOT IGN 00:05 PILOTIGN 0O:lO rlH1

rn+
SCROLL
SCROLL
4-p 4-p
m-sAvE-m
MODE MODE

J P 2

M7402

Fig. 22-MODE pushbutton function.

BURNER CONTROL BURNER CONTROL

LOCKOUT #17 MFEP LOCKOUT #17 MFEP

3 MainValve T9 Off I *Main Flame Fail*

Q-SAVE-nm m; m-sAvE4-p-m
SCROLL SCROLL
MODE 4-p MODE
4
J 1 3

/ \ M7403

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

The SAVE function enablesusers 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
I
key and then pressing the Change-Level pushbutton (e). I
///
The second line of the display will briefly note ‘‘.. .SAV-
ING.. .” to confirm the key press.
... SAVING ...
SELECTABLE MESSAGES
SCROLL
VFD Second Line Display, Two-Level Hierarchy, see
Table 5 .
The display values are as follows:
Q-SAVE-m
@
MODE

3 1

n represents a numberedvalue.
T represents the terminal number. M7404

x represents the suffix letter of the Relay Module.

CB-7803 22
 CB780/CB784
OPERATION

TABLE 5- ELECTABLE MESSAGES.

Selectable Message Display Value First Line
(Second Line) (Second Line) Message
:Flame Signal
:Total Cycles
:Total Hours
:Fault History-
:Fault Cycle
:Fault Hours
:Fault Code LH1
:*fault -message*< LH1
"sequence-message< LH1
A

:(second-line-msg)< LH1
:Fault Cycle
:Fault Hours
:Fault Code LH2
:*fault -message*< LH2
"sequence-message< LH2
A

:(second-line-msg)< LH2
:Fault Cycle
:Fault Hours
:Fault Code LH3
:*fault -message*< LH3
"sequence-message< LH3
A

:(second-line-msg)< LH3
:Fault Cycle
:Fault Hours
:Fault Code LH4
:*fault -message*< LH4
"sequence-message< LH4
A

:(second-line-msg)< LH4
:Fault Cycle
:Fault Hours
:Fault Code LH5
:*fault -message*< LH5
"sequence-message< LH5
A

:(second-line-msg)< LH5
:Fault Cycle
:Fault Hours
:Fault Code LH6
:*fault -message*< LH6
"sequence-message< LH6
A

:(second-line-msg)< LH6
:Diagnostic Info-
:Device RM78nnx < LDI
:Device Suffix nnnn < LDI
:Run/Test Sw. RUNorTEST < LDI
Coperating Control (Opercontrol) T6 ONor OFF < LDI
:Interlock T7 ONor OFF < LDI
:Pilot Valve T8 ONor OFF < LDI
:Main Valve T9 ONor OFF < LDI
:Ignition T10 ONor OFF < LDI
CLowFire Sw T18 ONor OFF < LDI
CHighFireSw T19 ONor OFF < LDI
:Preignition Interlock (PreIgn ILK) T20 ONor OFF < LDI
:Pilot VdveDirst Stage Oilvalve (Valv/Start,V25) T21 ONor OFF < LDI
:Jumper 1 INTACT or CLIPPED < LDI
:Jumper 2 INTACT or CLIPPED < LDI
:Jumper 3 INTACT or CLIPPED < LDI
:Amplifier Type (Amp Type) NORMAL or AMP-CHECK or SHUTTER LDI
:Flame Response 0.8s or 3s < LDI
:Purge Time mm:ss < LDI
:Manufacturing Code (Mfg Code) nnnn < LDI
:Software Revision (SW Rev.) nnndnnnn < LDI
:Expanded Annun.- (see Table 5)
:Remote Command NONE/HOLD/HFLF

23 CB-7803
CB780/CB784
OPERATION

EXPANDED ANNUNCIATOR MESSAGES, shown, seeTable 6 andthe Diagnostic and Troubleshooting

SEE TABLE 6 section of the CB780KB784 Operation and Maintenance
The Expanded Annunciator (EA) may or may not be Manual, Manual No. 750-166, Tables 6 andfor7fault codes.
connected becauseit is an optional device. If the EA is not When accessing Expanded Annunciator Messages, follow
connected, adisplay message of “(EA not connected)” will the same operations as used with
the Selectable Messages.
be shown. Ifthe EA is connected, display messages willbe
TABLE 6-EXPANDED iNNUNCIATOR MESSAGES.
Selectable Message Display Value First Line
(Second Line) (Second Line) Message
$Expanded Annun.-
$Expanded Annunciator(EA not connected)<
$Current Status (CS:)” EA Message< LEA
$Valve Closure (Valve Close) T4 ON or OFF< LEA
$Burner Switch@ m e r Sw.) T5 ON or OFF< LEA
toperating Control (Opecontrol) T6 ON or OFF< LEA
$Auxiliary Limit (Aux Limit1) T7 ON or OFF< LEA
$Auxiliary Limit (Aux Limit2) T8 ON or OFF< LEA
$LOW water Cutoff (LwCO) T9 ON or OFF< LEA
$High Limit (High Limit) T10 ON or OFF< LEA
$Auxiliary Limit (AuxLimit 3) T11 ON or OFF< LEA
$Oil Selection Switch (Oil Select) T12 ON or OFF< LEA
$High Oil Pressure Switch (Hi OilPres) T13 ON or OFF< LEA
$Low Oil Pressure Switch (LowOilPres) T14 ON or OFF< LEA
$High Oil Temperature Switch (Hi OilTemp) T15 ON or OFF< LEA
$Low Oil Temperature Switch (LowOilTemp) T16 ON or OFF< LEA
$Atomizing Switch (Atomize Sw) T19 ON or OFF< LEA
$Gas Selection Switch (Gas Select) T17 ON or OFF< LEA
$High Gas Pressure Switch (Hi GasPres) T18 ON or OFF< LEA
$Low Gas Pressure Switch (LowGasPres) T19 ON or OFF< LEA
$Airflow Switch (Airflow Sw) T20 ON or OFF< LEA
$Auxiliary Interlock (Aux ILK 4) T2 1 ON or OFF< LEA
$Auxiliary Interlock (Aux ILK5) T22 ON or OFF< LEA
$EA Fault Code nnn< LEA
$Software Revision (SW Rev.) nnnn< LEA
a Expanded Annunciator Diagnostic Current
Status Messages canbe reviewed inCB780KB784 Operating and Maintenance
Manual, Manual Number 750-166.

RUN/TEST SWITCH FUNCTIONS
The Run/Test Switch is located on the top side of the
CB780KB784; see Fig. 19.The Run/Test Switch allows the
burner sequenceto be altered as follows:
1. In Prepurge Drive To High Fire Position,the Run/Test
Switch, when placed in the TEST position, will hold in
PREPURGE with the firing rate motor in the High Fire
position.
2. In the measured PREPURGE sequence,the Run/Test
Switch, when placed in the TEST position, will cause the
PREPURGE timingto stop. Thefiring rate motor will be in
the High Fire position.
3. In Prepurge Driveto Low Fire position, the Run/Test
Switch, when placed in the TEST position, will hold the
burner sequencein PREPURGE withthe firing rate motor in
the Low Fire position.
4. In PFEP, the Run/Test Switch, when placed in the
TEST position, will stop the timer during the first eight
seconds when aten second PFEP is selected or during the
first three seconds when a four second PFEP is selected,
allowing pilot-turn-downtest and other burner adjustments
to be made. This activates a fifteen second flameout timer
that permits pilot flame adjustment without nuisance safety
shutdowns. The Run/Test Switch will be ignored during
PFEP for the CB780KB784 if terminals 8 and 9 or 9 and 21
are jumpered.
5. During RUN,the Run/Test Switch, when place din the
TEST position, will drive the firing rate motor to the Low
Fire position.
NOTE: WhenCB780/CB784isswitchedtotheTESTmode,
it will stop and hold atthe next Run/Test Switch point in
the operatingsequence. Make sure that the Ruflest
Switch is in the RUNposition before leaving the installa-
tion.
SELECTABLE SITE-CONFIGURABLEJUMPERS
The CB780KB784 hastwo site-configurable jumper
options; see Fig. 24andTable 7. The site-configurable
jumpers shouldbe clipped withside cutters and the resistors
removed fromthe Relay Module.

CB-7803 24
 OPERATION STATICCHECKOUT

TABLE 7-SITE CONFIGURABLE

n
JUMPER OPTIONS. Fig. 24-Selectable site-configurable jumpers.
Jumper SELECTABLE CONFIGURATION JUMPERS
Number Description Intact Clipped
J RUN/TEST SWITCH
JR1 Pilot Flame 10 Seconds 4 Seconds
Establishing
Period (PFEP)
JR3 Enabled
Start-up Disabled
Interlock Check
NOTE: For allstandard installations, these jumpers
should be left intact, unless otherwise indicated on
wiring diagram.

/"/, CAUTION
1. Use extreme care while testing the system.Line
voltage is present on most terminal connections
when poweris on.
2.Openthemasterswitchbeforeinstallingor
removing a jumperon the subbase.
3. Before continuing to the next test, be sure to
remove testjumper(s) used in the previous test.
4. Replace all limits and interlocks that are not
operating properly. Do not bypass limits and
interlocks.
5. Close all manual fuel shutoff valve(s) before
starting these tests.
After checking all wiring, perform this checkout before
installing the CB780KB784 on the subbase. These tests
verify the Wiring Subbase is wired correctly, andthe exter-
nal controllers, limits, interlocks, actuators, valves, trans-
formers, motors and other devices are operating properly. last column.
NOTE: Do not performa dielectric test with theCB780KB784 nal screws, correct wire, and proper wiring techniques. Re-
installed. Internal surge protectors will break down and
conduct a current. This could cause the CB780KB784 to
fail the dielectric test or possibly destroy the internal valves, transformers, motors and other devices as required.
lightning and high current protection.
Static Checkout
EQUIPMENT RECOMMENDED
1. Voltmeter (20 kohm/volt minimum sensitivity) set on
the 0-300 Vac scale.
2. Two jumper wires; no. 14 wire, insulated, 12 inches
[304.8 mm] long with insulated alligator clips at both ends.
GENERAL INSTRUCTIONS
1. Perform all applicable tests listedin Static Checkout,
Table 8, in the order listed.
2. Make sure all manualfuel shutoffvalve(s) are closed.
3. Raise the setpoint of the operating controller to simu-
late a call for heat.
4. For each test, open the master switch and install the
jumper wire(s) betweenthe subbase wiring terminals listed
in the Test Jumpers column.
5. Close the master switch before observing operation.
6. Read the voltage between the subbase wiring termi-
nals listedin the Voltmeter column.
7. If there is no voltage or the operation is abnormal,
check the circuits and external devices as described inthe
8. Check all wiring for correct connections, tight termi-
place all damaged or incorrectly sized wires.
9. Replace faulty controllers, limits, interlocks, actuators,
10. Ensure normal operation is obtained for each required
test before continuingthe checkout.
11. After completing each test, be sure to remove the
test jumper(s).

25 CB-7803
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

A WARNING
Make sureall manual fuel shutoff valves are closed.

IMPORTANT: Low fuelpressure limits, ifused, could be open. Bypass themwith jumpersfor the remaining Static
Tests (if restaired).
None 4-L2 Line voltage at terminal 4. 1. Master switch.
2. Power connected to the master
switch.
3.Overloadprotection (fuse, circuit
breaker, etc.) has not opened the
power line.
2 None 5-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. Burnermotor 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. Burnermotor.
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 Actuatorifused.
- 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 fuelvalve(s)
- stage fuelvalve(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; linevoltage at 1. Low Fire Start switch.
14-13 terminal 18 after motor is in Low Fireposition. 2. Firing rate motor and transformer.
12
4-5 and 19-L2 Firing rate motor drives open; linevoltage 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)

CB-7803 26
 STATICCHECKOUT CHECKOUT

TABLE 8-STATIC CHECKOUT (Continued).

Test If Operation is Abnormal, Check the Volt-
No. Jumpers meter Normal Operation Items Listed Below

A WARNING
Make sure all manual fuel shutoff valves are closed.

IMPORTANT: Low fuel pressure limits,

i f used, could be open. Bypass them with
jumpers forthe remaining Static
Tests (ifrequired).
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
A CAUTION
On completing thesetests, open the master switch and remove all test jumpers from thesubbase
terminals. Also remove bypass jumpers fromthe low fuelpressure limits (if used).

/
A WARNING
9 \
Do not allow fuel to accumulatein the combus-
tionchamber. If fuelisallowedtoenterthe
chamber for longer than a few seconds without
igniting, an explosive mixture could result. It is
recommended that you limit the trial for pilot to
ten seconds, andlimit the attempt to light the main
burner to two seconds from the time the fuel has
reached the burner nozzle. In any case, do not
exceed the nominal lightoff time specified by the
equipment manufacturer; close the manual fuel
shutoff valve(s) if the flameis not burning at the
end of the specified time.
Checkout
IMPORTANT:
1. If the system fails topeg?orm properly, note the fault
code, fault message, equipmentstatus, and sequence
time on the display. Refer to the Troubleshooting sec-
tion of the CB780KB784 Operation and Maintenance
Manual, Manual Number 750-166.
2. Repeat ALL required Checkout tests after all adjust-
ments are made.ALL tests must be satisfied with the
flame detector(s) inits FINAL position.
EQUIPMENT RECOMMENDED
Volt-ohmmeter (20 kohrdvolt minimum sensitivity) with:
0-300Vac capability.
0-6000 ohm capability.
0-10 Vdc capability.

A CAUTION
/ - \

1. Use extremecare while testing the system. Line

CHECKOUT SUMMARY
voltage is present on most terminal connections
when poweris on.
2. Open the master switch before removing orin-
stalling the CB780KB784 or Keyboard Dis-
play Module connector.
3. Make sure all manual fuel shutoff valve(s) are
closed before starting the initial lightoff check
and the Pilot Turndown tests.
4. Do not putthe system in service until you have
satisfactorily completed all applicable tests in
this section andany others requiredby the
equipment manufacturer.
Preliminary inspection-all installations.
Flame signal measurement-all installations.
Initial lightoff checkfor proved pilot-all installations
using apilot.
Initial lightoff checkfor direct spark ignition of oil-
all burners using DSI.
Pilot turndown test-all installations using apilot.
Hot refractory saturation test-all installations using
Infrared (lead sulfide) Flame Detectors.
Hot refractory hold-in test-all installations.
Ignitioninterferencetest-all installationsusing flame
rods.
Ignition spark pickup-all installations using Ultra-
violet Flame Detectors.
Response to other ultraviolet sources-all installa-
tions using Ultraviolet Flame Detectors.

27 CB-7803
CB780/CB784
CHECKOUT

Flame signal withhotcombustion chamber-all
installations.
Safety shutdown tests-all installations.
See Figs. 1 and 2 for location of component parts and
Fig. 7 or wiring subbase specifications for terminal locations. 9. R u f l e s t Switch is in RUN position.
PRELIMINARY INSPECTION
Performthefollowinginspectionstoavoidcommon
problems. Make certain that:
1. Wiring connections are correct and all terminal screws FLAME SIGNAL MEASUREMENT
are tight.
2. Flame detector(s) is clean, and installed and positioned
properly. Consult the applicable instructions.
3. Correct combination of amplifier and flame detec-
tor(s) is used. See Table 2in the Specifications section.
4. Plug-in amplifier and purge card are securely in place.
5. Burner is completely installed and ready tofire; con-
sultequipmentmanufacturerinstructions.Fuellinesare
purged of air.
6. Combustion chamber and flues are clear of fuel and
fuel vapor.
7. Power is connected to the system disconnect switch,
(master switch).
8. Lockout is reset (pushin reset button) onlyif the Relay
Module is powered; see Figs.1 and 2.
10. System is in the STANDBY condition. STANDBY
message is viewable in the VFD.
11. All limits and interlocks are reset.
(TABLE 9 AND FIG. 26)
Measure the flame signal at the appropriate times as
defined in the following Checkout tests. Read the flame
signal in volts dc at the flame amplifier test jacks + and
(Com) or atthe Keyboard Display Module.
1. Use 1M ohm/volt meter with 0ato 10 Vdc capability.
2. Set the 1M ohm/volt meter to the0 to 10 Vdc range.
3. Insert the positive (red) probe into the +jack of the
flame amplifier. Insert the negative (black) probe into the
(Com) jack of the flame amplifier; see Fig. 26.
4. Allow a few seconds for the meter reading to stabilize.

TABLE 9-FLAME SIGNAL.

Flame Flame Signal Minimum Acceptable Maximum Expected
Detector Amplifier Steady dc Voltagea dc Voltage
817-1121 833-2741b
833-2722 or 817-1742
833-2723' or
1.25 Vdc
I 5.0 Vdc at Keyboard
Disdav Module
I .

817-1743 ,
5.0 Vdc at 1M ohdvolt meter 833-2724
a This minimum or stronger signal shouldbeeasily obtainedifthe detectoris correctly installed and positioned to properly sense
the flame. This voltaged must be obtained before completing checkout.
The flamesignal amplifier circuitry istested one-half second every five seconds during burner operation and shuts the down
burner if the amplifier fails (all installations).
This flame amplifieris Auto-Checktype.

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.
j
POSITIVE (+)
6. The meter reading must be as specifiedin Table 8 after
METER LEAD all tests are completed and all adjustments made.
As an option, the flame signal can be checked by the using
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(Ll)and L2
(N). Make surethe master switch isclosed, connections are
correct, and the power supply is of the correct voltage, fre-
quency andis sinusoidal.
2. Check the detector wiringfor defects including:
Incorrectconnections.
Wrong type of wire.
Deterioratedwire.
Opencircuits.
Shortcircuits.
Leakage paths caused by moisture, soot or accu-
mulated dirt.

CB-7803 28
 CB780/CB784
CHECKOUT

3. For all optical detectors, clean the detector viewing g. Afteracontinuous sparkis obtained,openthemaster
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(Ll)to the pilot terminal8 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 boththe igni-
Add a shield or screen to reflect radiated heat. tion transformer andthe pilot valve.
Add cooling (refer to sight pipe ventilation in the i. If the pilot does notignite and if the ignition spark
detector Instructions). is still continuous, adjust the pressure regulator until
5. Make sure theflame adjustment is not too lean. a pilotis established.
6. Make surethe detector is properly sightingthe flame. j. When the pilot ignites properly and stays ignited,
7. If necessary, resight or repositionthe detector. open the master switch and removethe jumper(s)
from terminals4-8,4-10 and 4-21of the subbase.
INITIAL LIGHTOFF CHECK FOR PROVED k. Check for adequate bleedingof the fuel line.
PILOT 1. Reinstall the CB780KB784 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 followthe 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 minimumvalue,adjust the pilot flame sizeordetector
so, bypass themwith jumpers duringthis check. sighting to provide a maximum and steady flame signal.
8. Recyclethe system to recheck lightoff and flame pilot
1. Open the master switch. signal.
2. Make sure that the manual main fuel shutoff valve(s) 9. Whenthe MAIN IGN periodis displayed onthe VFD,
is closed. Open the manual pilot shutoff valve. If the pilot makesuretheautomaticmainfuelvalve 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 burnerflame ignition. When the main burner
pilot gas flow. Make sure the main fuel is shut off just up- flame is established, proceed to step15.
stream fromthe burner inlet, or disconnect power from the 10. If the main burner flame is not established within
automatic mainfuel 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 raisingthe set pointof the operating control- flame signal.
ler; see Fig. 19 or CB780KB784 sequence. The program 12. Smoothly open the manual fuel shutoff valve(s) and
should startthe 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 step7. 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 lowfire fuel flow.
a. Open master switch and remove the CB780KB784 d. Check for proper gas supply pressure.
from the subbase. e. Check for proper valve operation.
b. On the subbase, temporarilyjumper terminal 4 to f. Check for proper pilot flame positioning.
ignition terminals8,lO or 21; refer to the appropri- 15.Repeatsteps 10 through14toestablishthemain
ate wiring diagram to determine the proper termi- burner flame; then proceed to step 16.
nal. Disconnect the leadwire the to pilot valveif it 16. With the sequence in RUN, make burner adjustments
is connected tothe same terminal. for flame stability and Btu input rating.
c. Close the master switch to energize onlythe igni- 17. Shut downthe 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 be a may
delay due to gas
open the master switch and adjust the ignition trappedbetweenthevalve(s)andburner.Makesureall
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 observethe spark.

29 CB-7803
CB780/CB784
CHECKOUT
18. Restart the system by closingthe burner switch and/or
raising the set pointof the operating controller. Observe that
the pilot is established during PILOT IGN and the main
burner flame is established during MAIN IGN within the
normal lightoff time.
19. Measure the flame signal. Continue to check for the
proper signal, see Table9, through the RUN period. Check
the signal at both High and Low Firing Rate positions and
while modulating.
20. Run the burner through another sequence, observing
the flame signal for:
a. Pilot flame alone @SI).
b. Pilot and main flame together.
c. Main flame alone (unless monitoring an intermit-
tent pilot). Also observe the time ittakes to light the
mainflame. Ignition of mainflame shouldbe smooth.
21.Makesureallreadingsare in the requiredranges
before proceeding.
22. Return the system to normal operation.
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,
limitskontrols or switches.
INITIAL LIGHTOFF CHECK FOR DIRECT
SPARK IGNITION
This check applies to gas and oil burners not a pilot.
It should immediately follow the preliminary inspection.
Referto the appropriatesampleblockdiagram of field
wiring for the ignition transformer and fuel valve(s) hookup.
NOTE: Lowfuelpressurelimits, ifused, couldbeopen. If so,
bypass them with jumpers during this check.
1. Open the master switch.
2. Complete the normal ready-to-fire checkout of the
fuel supply and equipment as recommended bythe equip-
ment manufacturer.
3. Close all manual main fuel shutoff valve(s). Check
that the automatic fuel valve(s) are closed. Make sure is
not enteringthe combustion chamber.
4. Closethe master switch and start the system withacall
for heat by raising the setpoint of the operating controller,
see Fig.18 for CB780KB784 sequencing. The program
sequence should start the ten second INITIATE sequence. further attention.
5. Let the sequence advance through PREPURGE. Igni-
tion spark should occur after PREPURGE period. Listenfor
the clickof the first stage fuel solenoid valve(s).
6. Let the program sequence complete its cycle.
7. Open the manual fuel shutoff valve(s).
8. Push the reset button and recycle the program se-
quence through PREPURGE.
9. When PILOT IGN status is displayed, watch thatthe
first stage burner flame is established. If it is established,
proceed to step 15.
10. If the first stage burnerflame is not established within
ten seconds, close the manual fuel shutoff valve(s), and open
the master switch after POSTPURGE is completed.
11. Check all burner adjustments.
CB-7803
12. Wait about three minutes. Close the master switch,
open the manualfuel shutoff valve(s), and try to lightoffthe
burner again. The first attempt may have been required to
purge the lines and bring sufficient fuel the to burner.
13. If the first stage burner flame is not established within
ten seconds, close the manual fuel shutoff valve(s), and open
the master switch.
14. If necessary, repeat steps 11through 13to establishthe
first stage burner flame. Then proceed to step 15.
15. When the first stage burner flame is established, the
sequence will advance to RUN. Make burner adjustments
for flame stability and input rating. If a second stageis used,
proceed to step 18.
16. Shut downthe system by opening the burner switch or
by lowering the set point of the operating controller. Make
sure the burner flame goes out and all automatic fuel valve(s)
close.
17. If used, remove the bypass jumpers from the low fuel
pressure limit and subbase.
18. If a second stageis used, make sure the automatic sec-
follows (otherwise proceed to step19):
a. Open the manual second stagefuel valve(s).
b. Restart the system by raising the set point of the
operating controller.
c. When the first stage burner flame isestablished,
using watch for the automatic second stage fuel valve(s)
to open. Observe that the second stage lights off
properly.
d. Make burner adjustments for flame stability and
input rating.
e. Shut down the system by lowering the set point of
theoperatingcontroller.Makesure the burner
flame goesoutandallautomaticfuelvalve(s)
close.
f. Proceed to step 19.
19. Restart the system by closingthe burner switch and/or
raising the set point of the operating controller. Observe that
the burner flame is established during PILOT IGN, within the
fuel normal lightoff time specified by the equipment manufacturer.
20. Measure the flame signal. Continue to check for the
proper signal, see Table9, through the RUN period. Check
the signal at both high and low firing rate positions and while
modulating. Any pulsating or unsteady readings will require
21.Makesureallreadingsare in the requiredranges
before proceeding.
NOTE: Upon completing these tests, open the master
switch and remove all test jumpers from the subbase
terminals, limitdcontrols or switches.
22. Return the system to normal operation.
PILOT TURNDOWN TEST (ALL INSTALLATIONS
USING A PILOT)
Perform this check on all installations usethat
apilot. The
purpose of this testis to verify that the main burner can be lit
by the smallestpilot flame thatwillhold in the flame
30
 CB780/CB784
CHECKOUT

amplifier and energize theFLAME LED. Clean the flame

detector(s)tomakesurethat it willdetectthesmallest Fig. 27-Flame-out timer lockout.
acceptable pilot flame.If using Auto-Check or Self-Check-
ing Amplifier and1M ohdvolt meter, the flame signal will
LOCKOUT #16 PFEP
fluctuate every time the amplifier does a self-check or a
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
pilot gas pressure during the turndown test.
4. Open the manual pilot shutoff valve(s). M5001

5. Close the master switch andstart the system with a

call f o r heat. Raise the set point of the operatingcontrol-
ler. The program sequence should start, and PREPURGE
should begin.
6. When the PILOT IGN begins,theset Run/Test Switch
to TEST position to stop the sequence. The FLAME LED
will comeon when the pilot ignites.
NOTE: If the sequence does not stop, resetthe system and
make sure you setthe Run/Test Switch to TEST within
the first eight seconds
of the PILOT IGN sequence.
IMPORTANT: You have eight secondsor three seconds,
depending on PFEP selected, to position the
Ruflest
Switch tothe TESTposition to stop the sequence
after
the start of the PILOTIGNperiod.
7. Turn the pilot pressure down very slowly, reading the
manometer (or pressure gauge) as it drops. Stop instantly
when the FLAME LEDgoes out. Note the pressure at the
CB780KB784 flamerelay dropout point. The pilot is at the until a smooth mainflame is accomplished.
minimum turndown position. Immediately turn the up pilot
pressure untilthe FLAME LED comes on again the or flame
signal increases to1.25 Vdc.
NOTE: If there is no flame for fifteen seconds with the
sequence stopped at this point, the CB780KB784 will
lockout and flasha lockout message; see Fig. 27.
8. Repeat step7 to verify the pilot gas pressure reading at base terminals, limitdcontrols, or switches.
the exact point theFLAME LED light goes out.
9. Increase the pilot pressureimmediately until the
FLAME LED comes on, and then turn it down slowly to
obtain apressure readingjust above the dropout point or until
the flame signal increases to 1.25 Vdc.
10. Set the Run/Test Switchin the RUN position and let
the sequence proceed. At ten seconds into the Ignition Trial
period, make sure the automatic main fuel valve(s) open;
then smoothly open the manual main fuel valve(s) shutoff (or
any other manually opened safety shutoff valve(s), if used)
and watchfor main burner ignition. If the main burnerflame
is established, proceed to step 18.
NOTE:Thissteprequirestwopeople,onetoopen the
manual valve(s) and one to watchfor ignition.
11. If the main burnerflame is not established within ten
seconds, close the manual main fuel shutoff valve(s) and
open the master switch. If the lightoff was rough, the pilot
flame size is too small.
12. Recycle the burner and stop the sequence in the PI-
LOT IGN period by using the Run/Test Switch.
13. Increase the pilot flame size by increasing its fuel flow
14. Reposition the flame scanner sight tube or use orifices
until the pilotflame signal voltageis in the range of 1.25to
1.50 Vdc.
15. When the main burner lights reliably with the pilot at
turndown, disconnect the manometer (or pressure gauge)
and turn the pilot gas flow up to that recommended by the
equipment manufacturer.
16. If used, remove the bypass jumpers from thesub-
17. Run the system through another cycle to check for
normal operation.
18. Return the system to normal operation.

31 CB-7803
CB780/CB784
CHECKOUT

HOT REFRACTORYSATURATION TEST aware thatit 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 maskthe flickering radiationof the flame itself. and the equipment Operating Manual. Continue adjustments
Start the burner and monitor the flame signal duringthe 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, IGNITIONSPARK RE-
is extreme, the flame signal will drop below 1.25Vdc andthe SPONSE TEST (ALL ULTRAVIOLET DETECTORS)
system will shut down as though a flame failure occurred. Test to make certain the that
ignition sparkis not actuating
If hot refractory saturationoccurs, 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 manualfuel shut-off
the viewing area, lengthen the sight pipeor decrease the pipe valve(s).
size (diameter). Continue adjustments until hot refractory 2. Start the burner and usethe R u f l e s t Switch to stop
saturation is eliminated. the sequencein the PILOT IGN period. Ignition spark should
occur, butthe flame signal should not be more 0.5 thanVdc.
HOT REFRACTORYHOLD-IN TEST 3.If the flame signal is higher than 0.5 Vdc and the
(ALL INFRARED DETECTORS) FLAME LED does come on, consultthe 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. Itbemay necessary
tion can delay responseflame to 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 untilthe flame signal
Infrared (lead sulfide) detectors can respond to infrared due to ignition spark is less than0.5 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 be canmade light, produce small amountsof ultraviolet radiation. Under
to fluctuateif 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 asif it is sensing a flame. To check for proper
plying an infrared system to verify its response flame only.
to 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 obscurethe 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 manualfuel shutoff valve(s),or openthe electrical circuits pleted, operate the burner until the combustion chamberis 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-
thanthreeseconds, the infrareddetector is sensinghot der these hot conditions and measure the flame signal. Check
refractory. Immediately terminate the firing cycle. (Lower thepilotalone, the mainburner flame alone,andboth
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 theCheck the FFRT of the Flame Amplifier. Lowerthe set
valve(s) and nozzle(s) even thoughthe fuel valve(s) are point of the operating controller and observe the ittime 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, checkflame the
combustion chamber caused by oil line purging. detector temperature. Relocatethe detector if the tempera-
tureis too high. If necessary, realign the sighting to the obtain
If the detector is sensing hot refractory, the condition must proper signal and response time. If the response timeis still
be corrected. Add an orifice plate in front of the cell to restrict too slow, replacethe 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 amplifieris replaced,
problem, resight the detector at a cooler, more distantofpart repeat all required Checkout tests.
the combustion chamber. While resighting the detector, be

CB-7803 32

SAFETY SHUTDOWN TESTS
(ALL INSTALLATIONS)
Perform these tests the at end of Checkout, after all other
tests have been completed. If used, the externalalarm should
turn on. Pressthe CB780/CB784 reset pushbutton to restart
the system.
1. Openinga Preignition Interlock during STANDBYor
PREPURGE period.
a. *Preignition ILK*fault will be displayed on the
VFD. Fault code 10 or 33 will be displayed to
denote the fault.
b. Safety shutdown will occur.
2. Opening a LockoutInterlockduringPREPURGE,
PILOT IGN, MAIN IGN or RUN period.
a. "Lockout ILK* fault will be displayed the VFD.
on
Fault code11 or 12 or 21 or 29 will be displayed to
denote the fault.
b. Safety shutdown will occur.
3. Detection of flame 40 seconds after entry to STAND-
BY, fault code9. Detection of flame ten seconds into Drive
to Purge Rateor during measured PREPURGE time.
a. Simulate a flameto cause theflame signal voltage
level to be at least 1.25 Vdc for 40 seconds after
entryto STANDBY and also simulate a flame
signal for 10 seconds during PREPURGE.
b.*Flame Detected* fault will be displayed on the
VFD. Fault code 9or 15 or 18 will be displayedto
denote the fault.
c. Safety shutdown will occur.
4. Failure to ignite pilot.
a. Close pilot and main fuel manual shutoff valve(s). secondsbf POSTPURGE.
b. Depress the reset button.
c. Start the system.
d. The automatic pilot valve(s) should be energized
but the pilot cannot ignite.
e. *Pilot Flame Fail* fault will be displayed on the
VFD. Fault code 28 will be displayed four orten
seconds (depending on the jumper configuration
selection for PFEP) after the pilot valve(s) is
energized to denote the fault.
f. Safety shutdown will occur.
33
CB780/CB784
CHECKOUT
Failure toignite main.
a. Open the manual pilot valve(s); leave the main fuel
manual shutoff valve(s) closed.
b. Depress the reset button.
c. Start the system.
d. The pilot shouldignite and the flame signal should
be at least 1.25 Vdc but the main burner cannot light.
e. The flame signal should drop below 1.25Vdc with-
in 3 seconds afterthe interrupted pilot goes out.
f. *Main Flame Ign.* fault will be displayed on the
VFD. Fault code 19will be displayed to denote
the fault.
g. Safety shutdown will occur.
Loss of flame during RUN.
a. Open the main fuel manual shutoff valve(s) and open
manual pilot shutoff valve(s).
b. Depress the reset button.
c. Start the system. Start-up should be normal the and
main burner should light normally.
d. Afterthe sequence is in the normal RUN period for
at least ten seconds with the main burner firing,
close the manual main fuel shutoff valve(s) to extin-
guish the main burner flame.
e. The flame signal should drop below 1.25Vdc within
3 seconds after the main flame goes out.
f. *Main Flame Fail* fault will be displayed on the
VFD. Fault code17 will be displayed to denote
the fault.
g. Safety shutdown will occur.
Opening a Preignition Interlock after the first five
a. *Preignition ILK* fault will be displayed on the
VFD. Fault code 33 will be displayed to denote
the fault.
b. Safety shutdown will occur.
IMPORTANT:
1. Ifthe CB78O/CB784fails to shut down onofthese any
tests,takecorrectiveaction;refertoCB78O/CB784
Troubleshooting and diagnostics manual and return
to the beginning of all Checkout tests.
2. When all Checkout tests have been completed, reset
all switches to original status.
CB-7803
CB780/CB784
TROUBLESHOOTING

Troubleshooting
CB780KB784 SYSTEM DIAGNOSTICS Diagnostic Information Index
Troubleshootingcontrolsystemequipmentfailures is The CB780KB784monitors input/output terminals and
made easier with the CB780KB784 self-diagnostics and can displaythe status of the terminal at the VFD (example:
first-out annunciation. In addition to an isolated spst alarm Pilot Valve T8 ON<). SeeTable 5 for a complete terminal
relay (audible annunciation), the CB780KB784 provides description and number. The display will show the actual
visual annunciation by displayinga fault code and fault or status of the terminal. If voltage is detected atthe terminal,
hold message at the Keyboard Display Module2 row by ON is displayed, butif no voltageis detected atthe terminal,
20 column VFD. The CB780KB784 provides118 diag- OFF is displayed; see Table5.
nostic messages for troubleshooting the system (see the
CB780KB784 Operating andMaintenanceManual, Manual Historical Information Index
Number 750-166). The CB780KB784 has nonvolitile memory that allows
Self-diagnostics of the CB780KB784 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 whenthe fault occurred, the hour of operation whenthe
flame failures andfalse flame signals are annunciated the by fault occurred,a fault code, a fault message and burner status
CB780KB784, which energizesthe ALARM LED or visu- when the fault occurred; see Table 4.
ally displayed atthe Keyboard Display Module VFD.
The VFD displaysa sequence status message indicating: IMPORTANT: The CB780 will not operate withouta Key-
STANDBY, PREPURGE, PILOT IGN,MAIN IGN, RUN board Display Module or a Control Bus installed.
and POSTPURGE. The selectable messages also provide
visual indicationof current status and historical statusof 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 CB780KB784 Relay Module.
nunciator terminal status (if used). With this information,
most problems can be diagnosed without extensive trial andSERVICE NOTE Reset CB780KB784 by pressing the
error testing. reset pushbutton on the CB780KB784, 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 CB780KB784 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 CB780KB784, but will not
tion and History Data are available to in assist
troubleshoot- reset a lockout condition.
ing the CB780KB784, see Table6.
The CB780KB784 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
troubleshootingthe system, see Tables 4,5,6 and 10. Informa- CB780KB784.
tion available the
in Diagnostic Information includes Device
Type,Device Suffix, SoftwareRevision,Manufacturing SERVICE NOTE: Maximum ambient operating tempera-
Code,Flame Amplifier Type, Flame Failure Response Time, ture of an 817-1121flame sensor, Series1through 6 will
Selectable Jumper Configuration Status, Run/Test Switch be reduced to125°Fbecause of the duty cycle operation
Status and Terminal Status. of the CB780KB784 Relay Module.

CB-7803 34
 CB780/CB784
TROUBLESHOOTING
TABLE 10-HOLD AND FAULT MESSAGE SUMMARY,

Fault Number Annunciation Message

Fault 1 *No Purge Card*
2 I Fault I
Freauen/Noise* *AC I
Fault 3 *AC Line Dropout"
Fault 4 *AC Frequency"
I Fault 5 I
Voltage" *Low Line I
Fault 6 *Purge Card Error*
Fault 7 *Flame Amplifier*
Fault 8 *Flame AmdShutr"
9 I Fault Detected* I *Flame I
Fault 10 *Preignition ILK*
Fault 11 "Running ILK On*
I Fault 12 On* ILKI "Lockout I
Fault 14 *High FireSw.*
Fault 15 *Flame Detected*
Fault 16 *Flame-Out Timer*
Fault 17 *Main Flame Fail*
Fault 18 *Flame Detected*
Fault 19 *Main FlameIgn.*
20 I Fault I *Low Fire Sw. Ofpi: I
Fault 21 "Running ILK*
Fault 24 *Call Service*
Fault 25 *Call Service*
Fault 28 *Pilot Flame Fail*
Fault 29 "Lockout ILK*
Fault 33 "Preignition ILK*
I Fault 35 - 40 I *Call Service* I
Fault 41 *Main Valve On*
Fault 42 *Pilot Valve On*
43 I Fault On* I "Ignition I
Fault 44 *Pilot Valve2 On*
Fault 45 *Low Fire Sw. Ofpi:
Fault 46 *Flame Amp Type*
Fault 47 "Jumpers Changed*
Fault 50 *Jumpers Wrong*
Fault 5 1 *Flame Too Strong*
I Fault 52 - 70 I *Call Service* I
Fault 71 - 75 *Device Specific*
Fault 76 - 93 *Accessory Fault*
Fault 94 - 108 *Call Service*
Fault 109 *Call Service*
Fault 110 - 127 *Call Service*

35 CB-7803
CB780/CB784
TROUBLESHOOTING

Fig. 28-Flush mounting of a Keyboard Display Module template.

1/8 DIA. (2)

U u M5082A

Cleave rooks
Printed in U S A .