CB780/CB784 Relay Modules: Features

CB780/CB784
Relay Modules
INSTALLATION INSTRUCTIONS
FEATURES
• Safety features:
— Interlock check.
— Closed loop logic test.
— Dynamic AMPLI-CHECK™.
— Dynamic input check.
— Dynamic safety relay test.
— Dynamic self-check logic.
— Expanded safe-start check.
— High Fire Purge Switch test.
— Internal hardware status monitoring.
— Low Fire Start Switch test.
— Tamper resistant timing and logic.
• Access for external electrical voltage checks.

• Application flexibility.
• Communication interface using Modbus Module
833-2820.
• Dependable, long-term operation provided by
APPLICATION microcomputer technology.
• First-out annunciation and system diagnostics
The Cleaver-Brooks CB780/CB784 (833-2718/833- provided by a 2 row by 20 column Vacuum
2720) is a microprocessor based integrated burner control Fluorescent Display (VFD) located on the Keyboard
for automatically fired gas, oil, or combination fuel single Display Module (Optional on CB784).
burner applications. The CB780 consists of a Relay
Module and Keyboard Display Module. The CB784
consists of the Relay Module only. The Keyboard Display Contents
Module is optional with the CB784. Subbase, Amplifier, Application ..................................................................................... 1
and Purge Card are required to complete the system. Features .......................................................................................... 2
Options include DATA CONTROLBUS MODULE™*, Remote Specifications ............................................................................... 2
Display Mounting, First-Out Expanded Annunciator or Principal Technical Features .................................................. 6
Modbus™ Module. Safety Provisions ......................................................................... 6
Installation ..................................................................................... 7
The CB780/CB784 is programmed to provide a level of Wiring ............................................................................................... 10
safety, functional capability and features beyond the Assembly ......................................................................................... 13
capacity of conventional controls. Operation ........................................................................................ 17
Functions provided by the CB780/CB784 include Static Checkout ............................................................................ 26
automatic burner sequencing, flame supervision, system Troubleshooting ........................................................................... 26
status indication, system or self-diagnostics and
troubleshooting
SIL3
Capable 32-00207-01
CB780/CB784 RELAY MODULES
• Hours of operation at time of fault.

• First-out expanded annunciation with 26 Light • Sequence status at time of fault.
Emitting Diodes (LEDs) for limits and interlocks • Sequence time at time of fault.
(optional).
— Diagnostic information:
• Five sequence information Light Emitting Diodes
(LEDs). • Device type.
• Five function Run/Test Switch. • Flame amplifier type.
• Interchangeable plug-in flame amplifiers. • Flame failure response time.
• Local or remote annunciation of operation and fault • Manufacturing code.
information.
• On/Off status of all digital inputs and outputs.
• Nonvolatile memory for retaining history files and
sequencing status after loss of power. • Selected prepurge time.
• Remote reset (optional). • Software revision and version of CB780/CB784
and Keyboard Display Module.
• Report generation (optional).
• Status of configuration jumpers.
• Burner controller data:
• Status of Run/Test Switch.
— Sequence status.
— Sequence time.
—
—
Hold status.
Lockout/alarm status.
SPECIFICATIONS
— Flame signal strength. Electrical Ratings (see Table 1):
— Expanded annunciator status. Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz
— Total cycles of operation. (±10%).
— Total hours of operation. Keyboard Display Module: 13 Vdc peak full wave rectified
— Fault history of six most recent faults: (+20/-15%).
Power Dissipation:
• Cycles of operation at time of fault. CB780/CB784: 10W maximum.
• Expanded annunciator data at time of fault. Display Module: 3W maximum.
Maximum Total Connected Load: 2000 VA.
• Fault message and code. Fusing: 15A maximum, Type SC or equivalent—fast blow.
32-00207—01 2
Table 1. Terminal Ratings.

Terminal No. Description Ratings
G Flame Sensor Grounda —
Earth G Earth Grounda —
L2(N) Line Voltage Common —
3 Alarm 120 Vac, 1A pilot duty.
4 Line Voltage Supply (L1) 120 Vac (+10%/-15%), 50 or 60 Hz (±10%).b
5 Burner Motor 120 Vac, 9.8AFL, 58.ALR (inrush).
6 Burner Controller and Limits 120 Vac, 1 mA.
7 Lockout/Running Interlock 120 Vac, 8A.
8 Pilot Valve/Ignition 120 Vac, 4.5A ignition and 50VA pilot duty.c
9 Main Fuel Valve 120 Vac, 2A pilot duty.d
10 Ignition 120 Vac, 4.5A ignition.c
F(11) Flame Sensor 60 to 220 Vac, current limited.
12 Firing Rate High Fire 120 Vac, 75VA pilot duty.
13 Firing Rate Common 120 Vac, 75VA pilot duty.
14 Firing Rate Low Fire 120 Vac, 75VA pilot duty.
15 Firing Rate Modulate 120 Vac, 75VA pilot duty.
16 Unused —
17 Unused —
18 Low Fire Switch Input 120 Vac, 1 mA.
19 High Fire Switch Input 120 Vac, 1 mA.
20 Preignition Interlock Input 120 Vac, 1 mA.
21 Interrupted/Pilot Valve/First Stage Oil Valve 120 Vac, 2A pilot duty.
22 Shutter 120 Vac, 0.5A.
a
The CB780/CB784 must have an earth ground providing a connection between the subbase and the control panel or
the equipment. The earth ground wire must be capable of conducting the current to blow the 15A fuse (or breaker) in
event of an internal short circuit. The CB780/CB784 needs a low impedance ground connection to the equipment frame
which, in turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at RF fre-
quencies, the connection must be made by minimum length conductors having maximum surface areas. Wide straps or
brackets are preferred rather than leadwires. Be careful to ensure that mechanically tightened joints along the ground
path, such as pipe or conduit threads or surfaces held together with fasteners, are free of nonconductive coatings and
are protected against mating surface corrosion.
b
2000 VA maximum connected load to CB780/CB784 Assembly.
c
Can also be 120 Vac, 1A pilot duty, Terminals 8 & 10 sum of the “c“ loads must not exceed 8A.
d
Can also be 65 VA pilot duty with motorized valve, 1150 VA inrush, 460 VA open, 250 VA hold.
Environmental Ratings: Weight:
Ambient Temperature: CB780/CB784: 1 pound 10 ounces, unpacked.
Operating: -40°F to +140°F (-40°C to +40°C). Keyboard Display Module: 4 ounces, unpacked.
Storage: -40°F to +150°F (-40°C to +66°C).
Humidity: 85% RH continuous, noncondensing. IMPORTANT:
Vibration: 0.5G environment. Flame Detection System available for use with
CB780/CB784. To select your Plug-in Flame Sig-
Dimensions: nal Amplifier and matching Flame Detector, see
Refer to Fig. 1 and 2. Table 2.
3 32-00207—01
Table 2. Flame Detection Systems (Fig. 3, 4, 5).

Plug-In Flame Amplifiers Applicable Flame Detectors
Flame
Failure
Response
Type Color Self-Checking Part Number Time Fuel Type Part Number
Infrared Red No 833-2722 3 sec. Gas, oil, coal Infrared 817-1742
(Lead Sulfide)
Dynamic 833-2723a
AMPLI-CHECK™
Red/Whi No 833-3495 Infrared 817-4133
te
Dynamic 833-3496 a
AMPLI-CHECK™
Ultraviolet Purple No 833-2724 Gas, oil Ultraviolet 817-1743b
Ultraviolet Green Dynamic 833-2741c Gas, oil, coal Ultraviolet 817-1121
Self-Check Self-Check (Purple Peeper®)
a
Circuitry tests the flame signal amplifier 12 times a minute during burner operation and shuts down the burner if the
amplifier fails.
b
The 817-1743 Flame Detector should be used only on burners that cycle on-off at least once every twenty-four hours.
Appliances with burners that remain on for twenty-four hours continuously or longer should use the 817-1121 Flame
Detector with the 833-2741 Amplifier as the ultraviolet flame detection system.
c
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. Series 4 amplifiers check 60 to 120
times per minute.
Table 3. Sequence Timing For Normal Operation.a

Flame
Establishing Post Firing Energy
Period Purge Interlock Rate Saving Approval
Device Initiate Standby Purge Pilot Main Run Timing Circuits Circuit Prepurge Code Bodies
CB780/ 10 sec. * ** 4 or 10 10 or * 15 sec. Preignition 4-wire No FM/IRI
CB784 sec. 15 , Lockout, modulatin Modulating
sec.b High and g
Low Fire
*STANDBY and RUN can be an infinite time period.
**PURGE will be determined by which purge card is selected.
a The operating sequence of the CB780 and CB784 Relay Modules are identical. The only difference between the Relay
Modules is that the Keyboard Display Module is standard with the CB780 and optional with the CB784.
b The MFEP will be determined by which terminal is used, see Fig. 7 and 18.
SIL 3 Capable: 833-2730—30 sec.

833-2731—60 sec.
SIL 3 Capable in a properly designed Safety Instrumented 833-2732—90 sec.
System. See form number 65-0312 for Certificate Agree- 833-2733—-2-1/2 min.
ment.
Approvals: NOTE: The CB780 and CB784 are identical except for
Underwriters Laboratories Inc. listed, File No. MP268, the Keyboard Display Module which is standard
Guide No. MCCZ. with the CB780 and optional with the CB784.
Factory Mutual approved, Report No. 1V9A0. AF. Accessories:
IRI acceptable. Optional:
Federal Communications Commission, Part 15, DATA CONTROLBUS MODULE™—part no. 833-2729.
Class B—Emissions. Provides communication and remote reset capabili-
Mounting: ties on CB784; remote display capabilities on CB780
833-2725 for panel mount. and CB784.
CB783 Expanded Annunciator—part no. 833-2726.
Required Components: Keyboard Display Module—part no. 833-2727. (Stan-
CB780: 120 Vac, 50/60 Hz, 833-2718. dard on CB780; optional on CB784.)
CB784: 120 Vac, 50/60 Hz, 833-2720. Remote Mounting Kit for the Keyboard Display, NEMA
Plug-in Flame Signal Amplifier, see Table 2. 4—part no. 833-2740.
Plug-in Purge Timer Cards: selectable: Tester—part no. 626-5050.
32-00207—01 4
BURNER CONTROL
BACK 5
Edit: - + ENTER (127)
POWER
PILOT
FLAME
MAIN
ALARM 1
RESET
5-1/4 (133)
5 (127)
1 REMOVE ONLY FOR TERMINAL TEST ACCESS. M23943C
Fig. 1. Mounting dimensions of CB780/CB784 Relay Module and 833-2725 Subbase, in inches (mm).
MOUNTING FLANGE
3/4Ð14 NPT
7-7/32
BURNER CONTROL (183)
5-1/8 (130)
2-3/4 3-3/4
(69) (95)
3-7/16
BACK (87)
Edit: - + ENTER
1/2- 14 NPSM
4-27/32 (123) 5-1/4 (133)
5/32 29/32 LEADWIRES
(4) (23) FACEPLATE
4-3/32 (104)
5/16 817-1121 M20935A
19/32 1-1/4 1-1/32 (8)
(15) (32) (26)
Fig. 3. Ultraviolet Self-Check detector, mounting
dimensions in inches (mm).
7/16 (11) 1/2
1-5/16
(49) (13)
2-7/16 (62)
2-1/32 4 (102) 6 FOOT (1.83 METER)
(52) LEADWIRES (2)
29/32 3-1/2 (89)
(23)
1-1/16
(27)
5/32 (4) 5/16
13/ (8)
15/32 3-7/8 (99) 32
(12) (11) COLLAR WITH 1/2-14 NPSM
M23388C
INTERNAL THREADS
817-1743 M20937A
Fig. 2. Mounting dimensions of Keyboard
Display Module, in inches (mm).
Fig. 4. Ultraviolet detector, mounting
dimensions in inches (mm).
5 32-00207—01
e. Lockout Interlock does not close within 10 sec-

CELL MOUNT HEAT BLOCK onds.
1-5/8 (41) f. Lockout Interlock opens during PREPURGE.
2-3/4* g. Ignition/pilot valve/intermittent pilot valve ter-
1-1/16 (27)
(70) minal is energized.
h. Main valve terminal is energized.
1-1/4 1-1/4
i. Internal system fault.
(32) (32) j. Purge card is removed.
2 LEADS IN A k. Purge card is bad.
48 INCH (1.2 METER) 4. PILOT FLAME ESTABLISHING Period (PFEP)
APERTURE
FLEXIBLE CONDUIT
3/4-14 3/4-14 NPSM a. Low Fire Switch opens.
BUSHING WITH NPSM INTERNAL
MAGNIFYING LENS COLLAR, 3/4-14 NPSM THREADS b. Lockout Interlock opens.
INTERNAL THREADS c. Ignition/pilot valve/intermittent pilot valve ter-
817-1742 OR 817-4133 M27237A minal is not energized.
*817-4133 IS 2-1/4 (58) TOTAL LENGTH d. Early Spark Termination terminal is energized
after five seconds.
Fig. 5. Infrared detector, mounting dimensions e. No flame is present at end of PFEP.
in inches (mm). f. Internal system fault.
g. Purge card is removed.
h. Purge card is bad.
PRINCIPAL TECHNICAL 5. MAIN FLAME ESTABLISHING Period (MFEP)
a. Low Fire Switch opens.
FEATURES b. Lockout Interlock opens.
c. Ignition/pilot valve/intermittent pilot valve ter-
The CB780/CB784 provides all customary flame minal is not energized.
safeguard functions while providing significant d. Main valve terminal is not energized.
advancements in the areas of safety, annunciation and e. No flame is present at end of MFEP.
system diagnostics. f. Internal system fault.
g. Purge card is not installed or removed.
Safety Shutdown (Lockout) Occurs 6. RUN Period
If: a. No flame is present.
b. Lockout Interlock opens.
1. INITIATE Period c. Main valve terminal is not energized.
a. Purge card is not installed or removed. d. Internal system fault.
b. Purge card is bad. e. Purge card is not installed or removed.
c. Configuration jumpers were changed (after 200 f. Purge card is bad.
hours). 7. POSTPURGE Period
d. AC line power errors, see Operation. a. Preignition Interlock does not close within five
e. Four minute INITIATE period is exceeded. seconds or opens after five-second time period.
2. STANDBY Period b. Ignition/pilot valve/intermittent pilot valve ter-
a. Flame signal is present after 240 seconds. minal is energized.
b. Preignition Interlock is open an accumulative c. Main valve terminal is energized.
time of 30 seconds. d. Internal system fault.
c. Interlock check feature is enabled and the Inter- e. Purge card is removed.
lock String (including the airflow switch) is f. Purge card is bad.
closed for 120 seconds with controller closed.
d. Ignition/pilot valve/intermittent pilot valve ter-
minal is energized.
e. Main valve terminal is energized.
SAFETY PROVISIONS
f. Internal system fault.
g. Purge card is not installed or removed. Internal Hardware Status
3. PREPURGE Period Monitoring
a. Preignition Interlock opens anytime during PRE- The CB780/CB784 checks the purge card for correct
PURGE. parity to prevent purge timing shifts and circuitry failures.
b. Flame signal detected after first ten seconds It also analyzes the integrity of the configuration jumpers
during PREPURGE. and internal hardware. The POWER LED blinks every four
c. High Fire Switch fails to close within four min- seconds, signifying an internal hardware check.
utes, fifteen seconds after firing rate motor is
commanded to drive to high fire position at start
of PREPURGE. Closed Loop Logic Test
d. Low Fire Switch fails to close within four minutes, The test verifies the integrity of all safety critical loads,
fifteen seconds after firing rate motor is com- terminals 8, 9, 10 and 21. If the loads are not energized
manded to drive to low fire position at end of properly; i.e., the main valve terminal is powered during
PREPURGE. PREPURGE, the CB780/CB784 will lockout on safety
shutdown. The CB780/CB784 must react to input
32-00207—01 6
changes but avoid the occurrence of nuisance shutdown near the open position before starting the purge timing;
events. Signal conditioning is applied to line voltage otherwise, purge timing starts when the High Fire Switch
inputs to verify proper operation in the presence of normal is closed. This switch will also cause a hold (four minutes,
electrical line noise such as transient high voltage spikes fifteen seconds) condition when the switch is open before
or short periods of line dropout. Signal conditioning is purge or opens during purge. The
tolerant of synchronous noise (line noise events that occur CB780/CB784 will lockout and annunciate an alarm if the
at the same time during each line cycle). switch fails to close within the hold time period.
Low Fire Start Switch Test examines the Low Fire Start
Dynamic Ampli-Check™ Switch at the moment PREPURGE is completed. If the
Dynamic AMPLI-CHECK™ circuitry tests the flame signal switch is bypassed, welded or otherwise prematurely
amplifier during burner operation and shuts down the closed, the system automatically adds 30 seconds to allow
CB780/CB784 if the flame amplifier fails. the firing rate motor additional time to reach or near the
low fire start position before ignition trials; otherwise,
ignition trials start after the Low Fire Switch closes. The
Dynamic Flame Amplifier and test also is used to prove that the firing rate motor is at low
Shutter Check fire position throughout the ignition trial period. This
switch will also cause a hold (four minutes, fifteen
Self-checking circuitry tests all electronic components in seconds) condition if the switch opens after purging is
the flame detection system and amplifier 10 to 12 times complete. The CB780/CB784 will lockout and annunciate
per minute and shuts down the CB780/CB784 if the an alarm if the switch fails to close within the hold time
detection system fails. period.
Dynamic Input Check Mandatory Purge

All system input circuits are examined to verify that the If lockout occurs after the initiation of ignition trials, (or at
CB780/CB784 is capable of recognizing the true status of anytime during a sequence when the fuel valves may have
external controls, limits and interlocks. If any input fails been energized), a mandatory POSTPURGE period is
this test, a safety shutdown occurs and the fault is imposed.
annunciated.
Off Cycle (STANDBY or PREPURGE)
Dynamic Safety Relay Test Flame Signal Check
Checks the ability of the dynamic safety relay contacts to
open and close. It also verifies that the safety critical loads, The flame detection subsystem (flame detector and
terminals 8, 9, 10 and 21, can be de-energized, as amplifier) is monitored during STANDBY. If a flame
required, by the Dynamic Self-Check logic. simulating condition or an actual flame exists, a system
hold occurs and start-up is prevented. If the flame signal
exists at any time after the first 40 seconds of STANDBY, a
Dynamic Self-Check Safety Circuit safety shutdown will occur and be annunciated. A shutter-
check amplifier and self-checking detector are energized
The microcomputer tests itself and related hardware while
for the first 40 seconds during STANDBY and the last two
at the same time the safety relay system tests the
seconds before exiting STANDBY. If a flame exists, a safety
microcomputer operation. If a microcomputer or safety
shutdown occurs. An
relay failure occurs and does not allow proper execution of
AMPLI-CHECK™ Amplifier is energized continually
the
through STANDBY and PREPURGE to detect any
self-check routine, safety shutdown will occur and all
possibility of a runaway detector or a flame. If either
safety critical loads will be de-energized.
situation happens, a safety shutdown occurs. A standard
amplifier is energized continually through STANDBY and
Expanded Safe-Start Check PREPURGE. If either situation happens, a safety shutdown
occurs.
The conventional safe-start check, which prevents burner
start-up if flame is indicated at start-up, is expanded to
include a flame signal check during STANDBY, a Preignition Output Circuit Check
preignition interlock check, an interlock check, and a
At the end of PREPURGE, the Dynamic Safety Relay
safety critical load check.
operation is checked. Also, all safety critical loads,
terminals 8, 9, 10 and 21 are checked to verify the
High Fire Purge and Low Fire Start terminals are not powered. If the Dynamic Safety Relay
operation is faulty, or if any of the safety critical loads are
Switch Tests powered, safety shutdown occurs and is annunciated.
High Fire Purge Switch Test examines the Purge Position
Interlock Switch at the moment the firing rate motor is
commanded to the high fire position. If the switch is
Tamper-Resistant Timing and Logic
bypassed, welded or otherwise closed prematurely, the Safety and logic timings are inaccessible and cannot be
system will automatically add 30 seconds to allow altered or defeated.
additional drive time for the firing rate motor to reach or
7 32-00207—01
Verified Spark Termination A typical Lockout Interlock string contains an airflow

switch (see Fig. 7). The Interlock Check is a site
The ignition terminal is monitored to verify early spark configurable option (see Table 7). If this feature is enabled,
termination (five seconds ignition and pilot and five the CB780/CB784 will lockout after 120 seconds
seconds pilot only). whenever control terminal 6 is energized, and the Lockout
Interlock string (including airflow switch) is closed during
First-Out Annunciation and Self- STANDBY.
Diagnostics Preignition Interlock

Sequence Status Lights (LEDs) provide positive visual The Preignition Interlock input is typically connected to
indication of the program sequence: POWER, PILOT, proof-of-closure switches for fuel valve(s). The Preignition
FLAME, MAIN and ALARM. The green POWER LED blinks Interlock must be energized throughout PREPURGE. If the
every four seconds to signify the CB780/CB784 hardware Preignition Interlock opens during STANDBY, it causes a
is running correctly. hold (30 seconds). The CB780/CB784 will lockout if the
interlock does not close within 30 seconds during
Multi-function Keyboard Display Module (standard with STANDBY. If the Preignition Interlock opens during
CB780, optional with CB784) shows elapsed time during PREPURGE, it will lockout. If the Preignition Interlock is
PREPURGE, PILOT IGN, MAIN IGN, and POSTPURGE. As open after five seconds into POSTPURGE, the
an additional troubleshooting aid, it provides sequence CB780/CB784 will lockout. The Preignition Interlock is
timing, diagnostic information, historical information and ignored during the ignition trials state and during RUN.
expanded annunciator information when a safety
shutdown or hold or normal operation occurs.
First-out Annunciation reports the cause of a safety

INSTALLATION
shutdown or identifies the cause of a failure to start or
continue the burner control sequence with an English text
and numbered code via the Keyboard Display Module. It
monitors all field input circuits, including the Flame
WARNING
Fire or Explosion Hazard.
Signal Amplifier and Firing Rate Position Switches. The Can cause severe injury, death or property
system distinguishes 118 modes of failure and detects damage.
and annunciates difficult-to-find intermittent failures. To prevent possible hazardous burner operation,
verification of safety requirements must be
Self-Diagnostics adds to the First-out Annunciation by performed each time a control is installed on a
allowing the CB780/CB784 to distinguish between field burner.
(external device) and internal (system related) problems.
Faults associated within the flame detection subsystem,
CB780/CB784 or plug-in Purge Card, are isolated and When Installing This Product…
reported by the Keyboard Display Module, see
1. Read these instructions carefully. Failure to follow
Troubleshooting section and CB780/CB784 System
them could damage the product or cause a hazard-
Annunciation Diagnostics and Troubleshooting, Bulletin
ous
Number CB-7803.
condition.
2. Check the ratings given in the instructions and
Interlock Requirements marked on the product to make sure the product is
suitable for the application.
The following interlock inputs are provided: 3. Installer must be a trained, experienced, flame safe-
guard technician.
Low Fire Interlock 4. After installation is complete, check out the product
This interlock verifies the firing rate motor is in the low fire operation as provided in these instructions.
position before and during ignition trials.
High Fire Interlock WARNING

This interlock verifies the firing rate motor is in the high Electrical Shock Hazard.
fire position prior to and during PREPURGE. Can cause severe injury, death or property
damage.
Disconnect the power supply before beginning
Lockout Interlock installation to prevent electrical shock, equipment
This interlock (ILK) input signifies a Lockout Interlock. If and control damage. More than one power supply
the Lockout Interlock is open for more than ten seconds disconnect may be involved.
into PREPURGE, the CB780/CB784 will lockout. After
entering PREPURGE, if the Lockout Interlock opens
during the first ten seconds, the purge timer will be reset.
Wiring Information
This provides a continuous PURGE to occur without 1. Wiring connections for the CB780/CB784 are
interruption before the Pilot Flame Establishing Period. If unique; therefore, refer to Figs. 6, 7, 8 or 9 or the cor-
a Lockout Interlock opens anytime after ten seconds into rect Specifications for proper subbase wiring.
PURGE, during the Ignition Trials or Run, it causes a 2. Wiring must comply with all applicable codes, ordi-
lockout. nances and regulations.
32-00207—01 8
3. Wiring, where required, must comply with NEC Class 1. Mount the subbase in any position except horizon-
1 (Line Voltage) wiring. tally with the bifurcated contacts pointing down. The
4. Loads connected to the CB780/CB784 must not standard vertical position is recommended. Any
exceed those listed on the CB780/CB784 label or other position decreases the maximum ambient
the Specifications, see Table 1. temperature rating.
5. Limits and interlocks must be rated to simultane- 2. The 833-2725 Wiring Subbase can be mounted
ously carry and break current to the ignition trans- directly in the control cabinet. Be sure to allow ade-
former, pilot valve, and main fuel valve(s). quate clearance for servicing, installation, access or
6. All external timers must be listed or component rec- removal of the CB780/CB784, Expanded Annuncia-
ognized by authorities who have jurisdiction for the tor, Keyboard Display Module, flame amplifier, flame
specific purpose for which they are used. amplifier signal voltage probes, Run/Test Switch,
electrical signal voltage probes and electrical field
IMPORTANT: connections.
1. For on-off gas-fired systems, some authorities 3. For surface mounting, use the back of the subbase
who have jurisdiction prohibit the wiring of any as a template to mark the four screw locations. Drill
limit or operating contacts in series between the the pilot holes.
flame 4. Securely mount the subbase using four no. 6 screws.
safeguard control and the main fuel valve(s).
2. Two Flame Detectors can be connected in parallel
with the exception of Infrared Flame Detector
(817-1742).
WIRING
3. This equipment generates, uses and can radiate 1. Proper Wiring:
radio frequency energy and, if not installed and a. For proper subbase wiring, refer to Fig. 7.
used in accordance with the instructions, may b. For proper remote wiring of the Keyboard Display
cause interference to radio communications. It Module, refer to Fig. 8, 9 or 10 or to the Specifica-
has been tested and found to comply with the lim- tions for the Keyboard Display Module, Modbus™
its for a Class A computing device of Part 15 of Module or DATA CONTROLBUS MODULE™.
FCC rules which are designed to provide reason- 2. Disconnect the power supply from the main discon-
able protection against such interference when nect before beginning installation to prevent electri-
operated in a commercial environment. Operation cal shock and equipment damage. More than one
of this equipment in a residential area may cause disconnect may be involved.
interference; in which case, the users at their own 3. All wiring must comply with all applicable electrical
expense may be required to take whatever mea- codes, ordinances and regulations. Wiring, where
sures are required to correct this interference. required, must comply with NEC, Class 1 (Line Volt-
4. This digital apparatus does not exceed the Class A age) wiring.
limits for radio noise for digital apparatus set out 4. Recommended wire size and type:
in the Radio Interference Regulations of the Cana- a. All Line Voltage terminals use no. 14 or 16 cop-
dian Department of Communications. per conductor (90°C or higher) 600 volt insula-
tion wire (wire size must be coordinated with fuse
Humidity protection). For high temperature installations,
use wire selected for a temperature rating above
Install the CB780/CB784 where the relative humidity the maximum operating temperature. All lead-
never reaches the saturation point. The CB780/CB784 is wires should be moisture resistant.
designed to operate in a maximum 85% RH continuous, b. Keyboard Display Module—For communications
noncondensing, moisture environment. Condensing purposes, use an unshielded 22 AWG 2-wire
moisture may cause a safety shutdown. twisted cable and one wire for ground if the lead-
wire run and noise conditions permit; however,
Vibration some installations may need up to five wires,
three for communications and two for remote
Do not install the CB780/CB784 where it could be reset (in either a single cable or separate cables
subjected to vibration in excess of 0.5G continuous for communications or remote reset) or use
maximum vibration. Belden 8771 shielded cable or equivalent. The
Keyboard Display Module, DATA CONTROLBUS
Weather MODULE™ (for remote mounting or communica-
tions) or Modbus Module must be wired in a
The CB780/CB784 is not designed to be weather tight. If daisy chain configuration, (1(a)-1(a), 2(b)-2(b),
installed outdoors, the CB780/CB784 must be protected 3(c)-3(c)). The order of interconnection of all the
by an approved weather-tight enclosure. devices listed above is not important. Be aware
that modules on the closest and farthest end of
Mounting Wiring Subbase the daisy chain configuration string require a
120 ohm (1/4 watt minimum) resistor termina-
tion across terminals 1 and 2 of the electrical
NOTE: For installation dimensions, see Fig. 1.
connectors, for connections over 100 feet, see
Fig. 8, 9 and 10.
c. DATA CONTROLBUS MODULE™—For communi-
cations purposes, use an unshielded 22 AWG 2-
wire twisted cable if the leadwire run and noise
9 32-00207—01
conditions permit; however, some installations 3(c)-3(c)). The order of interconnection of all the
may need up to five wires, three for communica- devices listed above is not important. Be aware
tions and two for remote reset (in either a single that modules on the closest and farthest end of
cable or separate cables) or use a Belden 8771 the daisy chain configuration string require a
shielded cable or equivalent. The Keyboard Dis- 120 ohm (1/4 watt minimum) resistor termina-
play Module, DATA CONTROLBUS MODULE™ tion across terminals 1 and 2 of electrical con-
(for remote mounting or communications) or nectors, for connections over 100 feet, see Fig. 8,
Modbus Module must be wired in a daisy chain 9 and 10.
configuration, (1(a)-1(a), 2(b)-2(b),
L1
(HOT) L2
1
4 L2
120 Vac
PLUG-IN PURGE
CONFIGURATION
TIMER CARD
JUMPERS
TEST
FLAME SIGNAL JACK
RUN/TEST F
SWITCH
PLUG-IN
MICROCOMPUTER FLAME G
TEST AMPLIFIER
RESET 22
PUSHBUTTON
2K
3K
4K
RELAY
DRIVE 5K
RELAY
CIRCUIT 6K
STATUS
7K FEEDBACK
8K AND LINE
VOLTAGE
9K INPUTS
SAFETY RELAY 1K
CIRCUIT
STATUS LEDs
CONTROL
POWER SUPPLY
POWER
20
PRE-IGNITION
INTERLOCK
LOCKOUT
LIMITS CONTROLLER INTERLOCK
1K1 2K1 5K1
6 7 10 IGNITION
4K1
LOW FIRE SWITCH
8 PILOT
18 7K1
21 PILOT/V2
HIGH FIRE SWITCH
2K2
19 9 MAIN VALVE
6K1
5 BLOWER
3K1
3 ALARM
HIGH FIRE
12
KEYBOARD
DDL DISPLAY MODULE 8K1
COMMON INDICATES FEEDBACK SENSING
13
RS485 TO RELAY STATUS FEEDBACK
8K2 MODULATE AND LINE VOLT INPUTS
1 15
9K1
DDL 2 2 9K2
3 REMOTE LOW FIRE FIELD WIRING
COMMUNICATIONS
RESET 14 INTERNAL WIRING
1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M7420A
2 DEDICATED DATA LINK.
Fig. 6. Internal block diagram of the CB780/CB784 (see Fig. 7, 8, 9, or 10 for detailed wiring instructions.
32-00207—01 10
d. Remote Reset—Use no. 22 AWG or greater b. DATA CONTROLBUS OR MODBUS MODULE™:

twisted pair wire, insulated for low voltage; see (1) Do not run high voltage ignition transformer
Fig. 8, 9 and 10. wires in the same conduit or close proximity
e. Use the recommended wire size for the 13 Vdc with the MODULE™ wiring.
full wave rectified transformer power input of no. (2) Do not route MODULE™ wires in conduit with
18 AWG wire insulated for voltages and tempera- line voltage circuits.
tures encountered in the application. Suggested c. Keyboard Display Module (VFD): Because the
wire types include TTW(60C), THW(75C) and VFD is powered from a low voltage, energy lim-
THHN(90C). ited source, it can be mounted outside of a con-
5. Recommended grounding practices: trol panel if it is protected from mechanical
a. The earth ground provides for a connection damage.
between the subbase and the control panel of d. Remote Reset:
the equipment. The earth ground wire must be (1) Do not run high voltage ignition transformer
capable of conducting the current to blow the wires in the same conduit with the Remote
20A fuse (or breaker) in event of an internal short Reset wiring.
circuit. The CB780/CB784 needs a low imped- (2) Do not route Remote Reset wires in conduit
ance ground connection to the equipment frame with line voltage circuits.
which, in turn, needs a low impedance connec-
tion to earth ground. For a ground path to be low NOTE: A 13 Vdc power supply must be used any time
impedance at RF frequencies, the connection more than one Keyboard Display Module is used.
must be made with minimum length conductors
that have a maximum surface area. Wide straps 7. Maximum wire lengths:
or a. CB780/CB784 leadwires—The maximum length
brackets are preferred rather than leadwires. Be of leadwire is 300 feet to terminal inputs (Con-
careful to ensure that mechanically tightened trol, Preignition Interlock, Running/Lockout
joints along the ground path, such as pipe or Interlock, High Fire Switch and Low Fire Switch).
conduit threads or surfaces held together with b. Flame Detector leadwires—The maximum flame
fasteners, are free of nonconductive coatings sensor leadwire length is limited by the flame
and are protected against corrosion on mating signal strength.
surfaces. c. Remote Reset leadwires—The maximum length
b. Keyboard Display Module, DATA CONTROL BUS of wire is 1000 feet to a Remote Reset pushbut-
MODULE™ or Modbus™ Module—The shield, if ton.
used, should be connected to the signal ground d. DATA CONTROLBUS or MODBUS MODULE™—
terminal 3(c) provided as part of the The maximum module cable length depends on
CB780/CB784 device ControlBus connection. the number of system modules connected, the
Connect the shield at both ends to earth ground. noise conditions and the cable used. The maxi-
c. CB780/CB784—Each CB780/CB784 will have mum length of all interconnecting wire is 1000
an earth ground terminal that must be grounded feet.
to the metal control panel with wire as short as 8. Make sure loads do not exceed the terminal ratings.
practical. Each ground wire must be capable of Refer to the label on the CB780/CB784 or to the rat-
carrying a fault current equal to the rating of the ings in Specifications; see Table 1.
protective fuse (20A). A number 14 copper con- 9. Check the power supply circuit. The voltage and fre-
ductor is adequate, but wide straps or brackets quency tolerance must match those of the
are preferred rather than leadwires. CB780/CB784. A separate power supply circuit may
6. Recommended wire routing: be required for the CB780/CB784. Add the required
a. Flame detector leadwires: disconnect means and overload protection.
(1) Do not run high voltage ignition transformer 10. Check all wiring circuits and complete the Static
wires in the same conduit with the flame Checkout, see Table 8, before installing the
detection wiring. CB780/CB784 on the subbase.
(2) Do not route scanner wires in conduit with 11. Install all electrical connectors.
line voltage circuits. 12. Restore power to the panel.
(3) Enclose scanner wires without armor cable in
metal cable or conduit.
(4) Follow directions in flame detector Instruc-
tions.
11 32-00207—01
SERIES 90
FIRING RATE SERIES 90
833-2725 MOTOR CONTROLLER
HIGH FIRE
G 12 B B
COMMON
L2 13 R R
LOW FIRE
120V ALARM 3 14 W W
MODULATE
4 (L1) 15
BURNER MOTOR 2
(BLOWER) 5 16
BURNER 6 17
CONTROLLER/LIMITS
LOCKOUT INTERLOCKS LOW FIRE

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

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

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

ULTRAVIOLET
FLAME DETECTOR
WHITE
9 FUEL VALVE
WHITE
L2
BLACK
L1
BLACK
L2
1 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
M7408A
2 DO NOT WIRE TO ANY UNUSED TERMINALS.
Fig. 7. Wiring the CB780/CB784 Relay Module.
32-00207—01 12
833-2727 KEYBOARD DISPLAY MODULE

(MOUNTED ON CB 780/CB 784 RELAY MODULE)
C (GND)
+13 VDC
MOMENTARY
RESET
2 PUSH BUTTON
SWITCH
B
1 2 3 4 5
832-1693
120 OHM
RESISTOR
1
832-1693
120 OHM 13 VDC
RESISTOR POWER SUPPLY
L2
1 L1
(HOT)
1 2 3 4 5
C (GND)
+13 VDC
RESET
A
833-2727 REMOTE KEYBOARD DISPLAY MODULE
1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

OHM TERMINATING RESISTORS ARE REQUIRED FOR
CONNECTIONS OVER 100 FEET. CABLE SHIELD MUST BE
TERMINATED TO EARTH GROUND AT BOTH ENDS. IF SHIELDED
CABLE IS NOT USED, TWISTED PAIR WIRE MUST BE USED.
2 TERMINALS OF 833-2760 5-WIRE CONNECTOR (PROVIDED
SEPARATELY). M27263A
Fig. 8. Wiring multiple Keyboard Display Modules.
13 32-00207—01
833-2729 DATA CONTROLBUS OR 833-2820 MODBUS MODULE™

(MOUNTED ON CB 780/CB 784)
C (GND)
+13 VDC
MOMENTARY
RESET
3
PUSH BUTTON
SWITCH
B
1 2 3 4 5
832-1693
120 OHM 2
RESISTOR
1
832-1693
120 OHM
RESISTOR
1 2 3
C (GND) 4 5
+13 VDC
RESET
A
833-2727 REMOTE KEYBOARD DISPLAY MODULE
1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO

832-1693 120 OHM TERMINATING RESISTORS ARE REQUIRED
FOR CONNECTIONS OVER 100 FEET. CABLE SHIELD MUST BE
TERMINATED TO EARTH GROUND AT BOTH ENDS. IF SHIELDED
CABLE IS NOT USED, TWISTED PAIR WIRE MUST BE USED.
2 WHEN CONNECTING THE KEYBOARD DISPLAY MODULE DATA

CONTROLBUS MODULE™, OR REMOTE RESET MODULE
EXTERNAL FROM THE CONTROL CABINET, APPROPRIATE
MEASURES MUST BE TAKEN TO MEET EN60730 SAFETY
LOW VOLTAGE REQURIEMENTS (SEE APPROVALS).
M27260A
Fig. 9. Wiring the Data ControlBus™ Module with Remote Keyboard Display Module.
ASSEMBLY 3. Make sure no subbase wiring is projecting beyond

the terminal blocks. Tuck wiring in against the back
of the sub-base so it does not interfere with the knife
Mounting CB780/CB784 Relay blade terminals or bifurcated contacts.
Modules IMPORTANT:
The CB780/CB784 must be installed with a plug-
NOTE: For installation dimensions, see Fig. 1. in motion rather than a hinge action.
4. Mount the CB780/CB784 by aligning the four L

Relay Module Mounting shaped corner guides and knife blade terminals with
the bifurcated contacts on the wiring subbase and
1. Mount the CB780/CB784 vertically, see Fig. 11, or
tightening the two screws securely without deform-
mount horizontally with the knife blade terminals
ing the plastic.
pointing downward. The CB780/CB784 must be in
an electrical enclosure.
2. Select the location in the electrical enclosure. Be Installing the Purge Card
sure to allow adequate clearance for servicing,
installation and removal of the CB780/CB784, Key- 1. Remove the Keyboard Display Module or DATA
board Display Module, flame amplifier, flame ampli- CONTROLBUS MODULE™, see Fig. 13 or 14.
fier signal voltage probes, electrical signal voltage 2. Remove the current Purge Card from the
probes, and electrical connections. CB780/CB784 by pulling the plastic support cover
a. Allow an additional two inches below the upward.
CB780/CB784 for the flame amplifier mounting. 3. Make sure that the Purge Card selected has the
b. Allow an optional three-inch minimum to both desired timing.
sides of the CB780/CB784 for electrical signal 4. Insert Purge Card into the opening of the
voltage probes. CB780/CB784 compartment, see Fig. 12.
32-00207—01 14
5. Reinstall the Keyboard Display Module or DATA 3. Be sure the DATA CONTROLBUS MODULE™ is firmly
CONTROLBUS MODULE™ onto the CB780/CB784 in place.
and restore power to the device.
6. Run the burner system through at least one com-
plete cycle to verify the system is operating as
desired.
Fig. 10. Electrical panel installation. Fig. 11. Purge card installation.
IMPORTANT:
The CB780 will not function properly without one
of the following mounted correctly: Keyboard Dis-
play Module, or DATA CONTROLBUS MODULE™.
Mounting Keyboard Display

Module
1. Align the two interlocking ears of the Keyboard Dis-
play Module with the two mating slots on the
CB780/CB784; see Fig. 13.
2. Insert the two interlocking ears into the two mating
slots and with a hinge action push on the lower cor-
ners of the Keyboard Display Module to secure it to
the
CB780/CB784.
3. Verify the Keyboard Display Module is firmly in
place.
Fig. 12. Keyboard Display Module installation.
Mounting Data ControlBus™
Module
1. Align the two interlocking ears with the two mating
slots on the CB780/CB784; see Fig. 14.
2. Insert the two interlocking ears into the two mating
slots and push on the lower corners of the DATA
CONTROLBUS MODULE™ to secure it to the
CB780/CB784.
15 32-00207—01
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 avail-
able for use with the CB780/CB784. Make sure
the correct combination of amplifier and flame
detector(s) is used.
Proper flame detector installation is the basis of a safe

and reliable flame safeguard installation. Refer to the
instructions packed with the flame detector and the
equipment manufacturer instructions; see Fig. 17.
Keep the flame signal leadwires as short as possible from

the flame detector to the wiring subbase. Capacitance
increases with leadwire length, reducing the signal
strength. The maximum permissible leadwire length
Fig. 13. Data ControlBus™ mounting. depends on the type of flame detector, leadwire and
conduit. The ultimate limiting factor in the flame detector
leadwire is the flame signal; see Table 9.
Remote Mounting of Keyboard
Display Module
1. The Keyboard Display Module can be mounted
either on the face of a panel door or on other remote
locations; see Fig. 15.
2. When mounting the Keyboard Display Module on
the face of a door panel, closely follow these instruc-
tions:
a. Select the location on the door panel for flush
mounting. Pay attention to the insertion dimen-
sion of the two Keyboard Display Module screws,
two interlocking ears and the two plug-in con-
nectors to allow for sufficient clearance, 1/4 inch
minimum inward from the surface of the door
panel.
b. Use the Keyboard Display Module as a template;
see Fig. 28. Mark the two screw locations, two
interlocking ear locations and two plug-in con-
nector locations. Drill the pilot holes for the
mounting screws. Provide for two holes on the
door panel for the interlocking ears and plug-in
Fig. 14. Remote mounting of Keyboard Display Module.
connector holes.
c. Mount the Keyboard Display Module securing
the two no. 4 screws.
3. A second Keyboard Display Module or a Data
ControlBus™ Module must be installed on the
CB780/CB784. Connections from the module to the
remote display are completed following wiring
shown in Fig.8, 9, 10.
Installing Plug-In Flame Signal

Amplifier
1. Disconnect power supply before beginning installa-
tion to prevent electrical shock and equipment dam-
age. More than one disconnect may be involved.
2. Align the amplifier circuit board edge connector with
the keyed receptacle on the CB780/CB784. Verify
the amplifier 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 Fig. 15. Flame signal amplifier mounting.
amplifier toward the CB780/CB784 retaining clasp.
32-00207—01 16
SOLID STATE SELF-CHECKING

INFRARED (817-1742, 817-4133) ULTRAVIOLET (817-1121)
F
3
G
ULTRAVIOLET (817-1743)
BLUE
F
1
WHITE
G
BLUE
F
2 YELLOW
G
WHITE
22
WHITE
L2
BLACK
L1
BLACK
L2
1 FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
2 FLAME DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW
MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN
MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE.
3 817-1742: 1 BROWN WIRE AND 1 WHITE WIRE FROM THE 817-1742, CONNECT TO THE CB 780/CB 784 WIRING SUBBASE,
COLOR NOT IMPORTANT. 817-4133 1 BLUE WIRE CONNECTED TO THE F TERMINAL AND 1 WHITE WIRE CONNECTED TO
THE GROUND TERMINAL OF THE CB780/784 WIRING SUBBASE. KEEP WIRES AS SHORT AS POSSIBLE AND TWIST THEM. M27238A
Fig. 16. Flame detector wiring.
OPERATION or control input.
STANDBY
Sequence of Operation The CB780/CB784 is
The CB780/CB784CB780/CB784 has the following ready
operating sequence, see Fig. 18 and Table 4. to start an operating STANDBY
sequence when the Total Cycles 132
operating control
INITIATE determines a call for heat M20278A
The CB780/CB784 enters the INITIATE sequence when is present. The burner
the Relay Module is powered. The CB780/CB784 can also switch, limits, operating control and all microcomputer
enter the INITIATE sequence if the Relay Module verifies monitored circuits must be in the correct state for the
voltage fluctuations of +10/-15% or frequency CB780/CB784 to continue into the PREPURGE sequence.
fluctuations of ±10% during any part of the operating
sequence. The INITIATE sequence lasts for ten seconds
unless the voltage or frequency tolerances are not met. NORMAL START-UP PREPURGE
When the tolerances are not met, a hold condition will be
initiated and will be displayed on the VFD for at least five The CB780/CB784 provides a PREPURGE timing
seconds. When the tolerances are met, the INITIATE selectable from 30 seconds to 2-1/2 minutes with power
sequence will restart. If the condition is not corrected and applied and the CB780/CB784 operating control
the hold condition exists for four minutes, the indicating a call for heat:
CB780/CB784 will lockout. Causes for hold conditions in
Running Interlocks, Preignition Interlocks, Burner Switch,
the INITIATE sequence:
Run/Test Switch, Lockout Interlocks and all
1. AC line dropout is detected. microcomputer
2. AC line noise that can prevent a sufficient reading of monitored circuits must be in the correct operating state.
the line voltage inputs. 1. The blower motor output, terminal 5, is powered to
3. Brownouts caused by a low line voltage. start the PREPURGE sequence. The firing rate motor
The INITIATE sequence is driven to the high fire position. The PREPURGE
also delays the burner timing does not begin until the Lockout Interlock
motor starter from being String and High Fire Switch are both closed.
INITIATE 00:10
energized and 2. The Preignition Interlock input must remain closed
Diagnostic Info
de-energized from an throughout PREPURGE; otherwise, safety shutdown
intermittent AC line input M20277A occurs.
17 32-00207—01
3. The Lockout Interlock or Running Interlock inputs 4. Main Flame Establishing Period (MFEP):
(interlock circuit including Airflow Switch) must a. The CB780/CB784 has a selectable ten second
close by ten seconds into PREPURGE; otherwise, a or fifteen second MFEP. After the Ignition Trials,
safety shutdown occurs. and with the presence of flame, the main fuel
4. After the firing rate motor reaches the PREPURGE valve, terminal 9, is powered. If a flameout
rate position and PREPURGE timing is completed, occurs, the CB780/CB784 will lockout within 3
the firing rate motor will drive to the low fire position. seconds.
5. When the firing rate motor reaches low fire position, RUN
the Low Fire Switch, terminal 18, input must be
energized before entering the Ignition Trial state. A ten second
stabilization RUN
period occurs Expanded Annun.
IGNITION TRIALS at the beginning M20285A
Pilot Flame of the RUN period.
Establishing PILOT IGN 00:10 1. The firing rate motor releases to modulation.
Period (PFEP): Fault History 2. The CB780/CB784 is now in RUN and will remain in
1. With the firing M20283A
RUN until the controller input, terminal 6, opens,
rate motor at the indicating that the demand is satisfied or a limit has
low fire position: opened.
a. The pilot valve and the ignition transformer, ter-
minals 8, 10 and 21, are energized. The POSTPURGE
CB780/CB784 has a fifteen second interrupted
pilot valve, terminal 21 and a ten second inter- The CB780/CB784 POST PURGE 00:12
rupted pilot valve/ignition, terminal 8. provides a fifteen Device RM7800L
b. During PFEP, the Low Fire Switch must remain second POST-PURGE
closed. If it opens, a safety shutdown occurs. following the completion M20286A
c. The Preignition Interlock input is ignored of the RUN period. The blower motor output is powered to
throughout the Ignition Trial state. drive all products of combustion and any unburned fuel
2. Flame must be proven by the end of the four or ten from the combustion chamber. It also supplies
second PFEP to allow the sequence to continue. If combustion air to burn fuel being purged from the fuel
flame is not proven by the end of PFEP, a safety line downstream of the fuel shutoff valve.
shutdown occurs. 1. The main fuel valve and intermittent pilot valve, ter-
3. With flame minals 9 and 21, are de-energized and the firing rate
proven, the motor is commanded to the low fire position to begin
MAIN IGN 00:15
ignition, the POSTPURGE period.
Flame Signal 2.7V 2. The Preignition Interlock closes within the first five
terminal 10,
is M20284A seconds of POSTPURGE.
de-energized for early spark termination. 3. After the fifteen second POSTPURGE period is com-
pleted, the CB780/CB784 reenters STANDBY.
32-00207—01 18
CB780/CB784
00 PREPURGE 00 00 PREPURGE 00 10 20 25 00 15
VFD DRIVE TO TIMED DRIVE TO PFEP
DISPLAY INITIATE STANDBY HIGH FIRE PURGE LOW FIRE 4 OR 10 SEC MFEP RUN POSTPURGE STANDBY
POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER
LED PILOT PILOT PILOT PILOT PILOT
DISPLAY
FLAME FLAME FLAME FLAME FLAME
MAIN MAIN MAIN MAIN MAIN
ALARM ALARM ALARM ALARM ALARM
BURNER BURNER/BLOWER MOTOR 5
10 IGN. 5 SEC.
10 SEC. IGN./PILOT 8
15 SEC. PILOT 21
MAIN VALVE 9
OPERATING L1 TO 6
CONTROLS LIMITS AND BURNER CONTROLLER CLOSED
AND
INTERLOCKS INTERLOCK CHECK LOCKOUT INTERLOCKS CLOSED 6 TO 7 IC
PREIGNITION INTERLOCK CLOSED 4 TO 20 PII
5 TO 19 HIGH FIRE SW. LOW FIRE SW. 5 TO 18
FLAME
SIGNAL SAFE START CHECK FLAME PROVING SSC
MOTOR OUTPUT SWITCHING 13 TO 15

13 TO 14 13 TO 14
13 TO 12
FIRING
RATE MOTOR ACTION
MOTOR
M7411B
Fig. 17. CB780/CB784 sequence.
KEYBOARD DISPLAY MODULE (KDM)

833-2760 FIVE WIRE CONNECTOR FOR
The first line of the Keyboard Display Module provides COMMUNICATIONS, REMOTE KEYBOARD
DI = DIAGNOSTICS
H1 = HISTORY
current status of the burner sequence (STANDBY, PURGE, DISPLAY AND REMOTE RESET
EA = EXPANDED
PILOT IGN, MAIN IGN, RUN and POST-PURGE), timing RUN/TEST SWITCH ANNUNCIATOR
information (PURGE, PILOT IGN, MAIN IGN and
CAPTIVE
POSTPURGE) in minutes and seconds, hold information SEQUENCE MOUNTING
(PURGE HOLD: T19) and lockout information (Lockout, STATUS SCREW
Fault Code, Message and Sequence); see Fig. 19. The SELECTABLE PLUG-IN
extreme right side of the first line will either be blank or it MESSAGE OR PURGE
PREEMPTIVE CARD
will show a small arrow pointing to the second line MESSAGE
followed by a two-letter code (DI-Diagnostic Information, KEYBOARD
Hn-Fault History Information, and EA-Expanded SEQUENCE
DISPLAY
MODULE
Annunciator). When the arrow and two-letter code are STATUS
displayed, it indicates the second line is showing a LEDs RELAY
selectable message submenu. The second line will display MODULE
selectable or preemptive messages. A selectable message RESET FLAME
supplies information for flame strength, system status PUSHBUTTON AMPLIFIER
indication, system or self-diagnostics and FLAME
FLAME CURRENT
troubleshooting. A preemptive message will have SIMULATOR INPUT
TEST JACKS M27264B
parentheses around the message and supply a detailed
message to support the sequence status information. A
Fig. 18. Keyboard Display Module and
preemptive message can also be a lockout message. A
sequence status LEDs (Table 4).
preemptive message will replace a selectable message to
support the sequence status information. It will also NOTE: Normal sequences (in Table 4) are in BOLD TYPE,
replace a selectable message after 60 seconds if it or a while abnormal sequences are not in bold type.
lockout message is available. The CB780/CB784 LEDs
provide positive visual indication of the program
sequence: POWER, PILOT, FLAME, MAIN and ALARM.
19 32-00207—01
Table 4. Sequence Status Display Information (see Fig. 19).

Burner Sequence LEDs Energized (BOLD type)
INITIATE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
selectable —message
INITATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(AC Freq/Noise)
INITIATE HOLD: AC POWER, PILOT, FLAME, MAIN AND ALARM
(AC Line Dropout)
(AC Frequency)
(Low Line Voltage)
STANDBY POWER, PILOT, FLAME, MAIN AND ALARM
selectable—message
STANDBY HOLD: REM POWER, PILOT, FLAME, MAIN AND ALARM
(Remote Control)
STANDBY HOLD: F/G POWER, PILOT, FLAME, MAIN AND ALARM
(Flame Detected)
STANDBY HOLD: POWER, PILOT, FLAME, MAIN AND ALARM
(Preignition ILK)
(Lockout ILK)
PURGE HOLD: POWER, PILOT, FLAME, MAIN AND ALARM
(High Fire Switch)
PURGE DELAY POWER, PILOT, FLAME, MAIN AND ALARM
(High Fire Jumprd)
PURGE HOLD: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
PURGE DELAY: POWER, PILOT, FLAME, MAIN AND ALARM
(Low Fire Jumprd)
PURGE HOLD: F/G POWER, PILOT, FLAME, MAIN AND ALARM
(Flame Detected)
PURGE HOLD: POWER, PILOT, FLAME, MAIN AND ALARM
(Low Fire Switch)
PILOT IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
PILOT HOLD: TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
MAIN IGN minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
RUN POWER, PILOT, FLAME, MAIN AND ALARM
RUN POWER, PILOT, FLAME, MAIN AND ALARM
RUN LOWFIRE:TEST POWER, PILOT, FLAME, MAIN AND ALARM
(Run/Test Switch)
POSTPURGE minutes:seconds POWER, PILOT, FLAME, MAIN AND ALARM
Waiting for connection… POWER, PILOT, FLAME, MAIN AND ALARM
RESET/ALARM TEST POWER, PILOT, FLAME, MAIN AND ALARM
Additional sequence status information when an Expanded Annunciator is connected to the relay module, also see
CB780/CB784 System Annunciation Diagnostics and Troubleshooting, Bulletin Number CB-7803.
BURNER OFF: POWER, PILOT, FLAME, MAIN AND ALARM
(Burner Switch)
(Expanded Annunciator hold
message)
(Circuit Fault)
32-00207—01 20
Keyboard Functions n represents a numbered value.
The keyboard contains four pushbuttons and each has T represents the terminal number.
separate functions (SCROLL-Down, SCROLL-Up, MODE
and Change-Level). The MODE and Change-Level push- x represents the suffix letter of the Relay Module.
buttons, when pressed together, provide a SAVE function.
1. SCROLL Down-Up pushbuttons (o), see Fig. 20.

2. Change Level pushbutton («), see Fig.21.
The Change-Level pushbutton is used to change
between the first hierarchy of selectable messages
to a subset of selectable messages. The Change- BURNER CONTROL
Level pushbutton can also be used to change from a
subset message to a first level selectable message.
The symbol (>) located on the second line in the
lower right corner of the KDM represents a first level RUN
hierarchy of selectable messages. The symbol (<) Total Cycles 333
located on the second line in the lower right corner
of the KDM represents a subset of selectable mes- SCROLL
MODE
sages.
SAVE
3. MODE pushbutton, see Fig. 22.
The MODE pushbutton instantaneously switches
the display from a second-line-selectable message
to second-line-preempted message. The sixty sec-
ond timeout function also can be used for this task.
The MODE pushbutton will work only if there is a
second-line-preempted message or lockout mes-
sage.
4. SAVE function; see Fig. 23.
The SAVE function enables users to identify the
selectable message they want to view upon power
restoration. The second line selectable message will BURNER CONTROL
be restored to the most recently saved selection
when power returns. The SAVE function is performed
by pressing and holding the MODE key and then
pressing the Change-Level pushbutton («). The sec- RUN
ond line of the display will briefly note “…SAVING…” to Total Hours 1332
confirm the key press.
SCROLL
MODE
Selectable Messages SAVE
KDM Second Line Display, Two-Level Hierarchy, see Table M7401D

5.
The display values are as follows: Fig. 19. SCROLL pushbutton function.
21 32-00207—01
BURNER CONTROL
BURNER CONTROL
LOCKOUT #17 MFEP

Main Valve 0
PILOT IGN 00:05
Fault History SCROLL
MODE
SCROLL SAVE
MODE
SAVE
BURNER CONTROL
BURNER CONTROL
LOCKOUT #17 MFEP

*Main Flame Fail*
PILOT IGN 00:10 H1
Fault Cycle 174 SCROLL
MODE
SCROLL SAVE
MODE
SAVE
M7403D
M7402C
Fig. 21. MODE pushbutton function.

Fig. 20. Change Level pushbutton function.
BURNER CONTROL
PURGE 00:30
... SAVING ...
SCROLL
MODE
SAVE
M7404C
Fig. 22. SAVE function.
32-00207—01 22
Table 5. Selectable Messages.

Selectable Message Display Value First Line
(Second Line) (Second Line) Message
n.nV
Flame Signal
Total Cycles nnnnn
Total hours nnnnn
Fault History
Fault Cycle nnnnn < H1
Fault Hours nnnnn < H1
Fault Code nnn < H1
*fault—message* H1
sequence—message< H1
(second-line-msg)< H1
Fault Cycle nnnnn <H2
Fault Hours nnnnn <H2
Fault Code nnn < H2
*fault—message*< H2
H2
sequence—message<
Fault Code nnn < H3
sequence—message< H3
Fault Code nnn < H4
sequence—message H4
(second-line-msg) H4
Fault Code nnn < H5
Fault Code nnn < H6
23 32-00207—01
Table 5. Selectable Messages. (Continued)

Diagnostic Info
Device RM78nnx < DI

Device Suffix nnnn < DI
Run/Test Sw. RUN or TEST < DI
Operating Control (OperControl) 1 or 0 < DI
Interlock 1 or 0 < DI
Pilot Valve 1 or 0 < DI
Main Valve 1 or 0 < DI
Ignition 1 or 0 < DI
Low Fire Sw 1 or 0 < DI
High Fire Sw 1 or 0 < DI
Preignition Interlock (PreIgn ILK) 1 or 0 < DI
Pilot Valve/First State Oil 1 or 0 < DI
Valve(Valv/Start, V25)
Jumper 1 INTACT or CLIPPED < DI
Amplifier Type (Amp Type) NORMAL or AMP-CHECK or SHUTTER DI
Flame Response 0.8s or 3s < DI
Purge Time mm:ss < DI
Manufacturing Code (Mfg Code) nnnn < DI
Software Revision (SW Rev.) nnnn/nnnn < DI
Expanded Annun. (see Table 6)
Remote Command NONE/HOLD/HF/LF
Expanded Annunciator Messages shown, see Table 6 and CB780/CB784 System

Annunciation Diagnostics and Troubleshooting, Bulletin
(See Table 6) Number CB-7803, Tables 6 and 7 for fault codes. When
accessing Expanded Annunciator Messages, follow the
The Expanded Annunciator (EA) may or may not be
same operations as used with the Selectable Messages.
connected because it is an optional device. If the EA is not
connected, a display message of “(EA not connected)” will
be shown. If the EA is connected, display messages will be
32-00207—01 24
Table 6. Expanded Annunciator Messages.

Expanded Annun.
Expanded Annunciator (EA not connected)<

Current status (CS:)a EA Message<
Valve Closure (Valve Close) T4 1 or 0< EA
Burner Switch (Burner Sw.) T5 1 or 0< EA
Operating Control (OperControl) T6 1 or 0< EA
Auxiliary Limit (Aux Limit 1) T7 1 or 0< EA
Low Water Cutoff (LWCO) T9 1 or 0< EA
High Limit (High Limit) T10 1 or 0< EA
Oil Selection Switch (Oil Select) T12 1 or 0< EA
High Oil Pressure Switch (HiOilPres) T13 1 or 0< EA
Low Oil Pressure Switch (LowOilPres) T14 1 or 0< EA
High Oil Temperature Switch (HiOilTemp) T15 1 or 0< EA
Low Oil Temperature Switch (LowOilTemp) T16 1 or 0< EA
Atomizing Switch (Atomize Sw) T19 1 or 0< EA
Gas Selection Switch (Gas Select) T17 1 or 0< EA
High Gas Pressure Switch (Hi GasPres) T18 1 or 0< EA
Low Gas Pressure Switch (LowGasPres) T19 1 or 0< EA
Airflow Switch (Airflow Sw) T20 1 or 0< EA
Auxiliary Interlock (Aux ILK 4) T21 1 or 0< EA
Auxiliary Interlock (Aux ILK 5) T22 1 or 0< EA
EA Fault Code nnn< EA
Software Revision (SW Rev.) nnnn< EA
a
Expanded Annunciator Diagnostic Current Status Messages can be reviewed in CB780/CB784 System Annunciation
Diagnostics and Troubleshooting, Bulletin Number CB-7803.
Run/Test Switch Functions during the first three seconds when a four second
PFEP is selected, allowing pilot-turn-down test and
The Run/Test Switch is located on the top side of the other burner adjustments to be made. This activates
CB780/CB784; see Fig. 19. The Run/Test Switch allows a fifteen second flameout timer that permits pilot
the burner sequence to be altered as follows: flame adjustment without nuisance safety shut-
downs. The Run/Test Switch will be ignored during
1. In Prepurge Drive To High Fire Position, the PFEP for the
Run/Test Switch, when placed in the TEST position, CB780/CB784 if terminals 8 and 9 or 9 and 21 are
will hold in PREPURGE with the firing rate motor in jumpered.
the High Fire position. 5. During RUN, the Run/Test Switch, when placed in
2. In the measured PREPURGE sequence, the the TEST position, will drive the firing rate motor to
Run/Test Switch, when placed in the TEST position, the Low Fire position.
will cause the PREPURGE timing to stop. The firing
rate motor will be in the High Fire position. NOTE: When CB780/CB784 is switched to the TEST
3. In Prepurge Drive to Low Fire position, the Run/Test mode, it will stop and hold at the next Run/Test
Switch, when placed in the TEST position, will hold Switch point in the operating sequence. Make
the burner sequence in PREPURGE with the firing sure that the
rate motor in the Low Fire position. Run/Test Switch is in the RUN position before
4. In PFEP, the Run/Test Switch, when placed in the leaving the installation.
TEST position, will stop the timer during the first
eight seconds when a ten second PFEP is selected or
25 32-00207—01
Selectable Site-Configurable 2. Open the master switch before installing or

removing a jumper on the subbase.
Jumpers 3. Before continuing to the next test, be sure to
remove test jumper(s) used in the previous test.
The CB780/CB784 has two site-configurable jumper
4. Replace all limits and interlocks that are not
options; see Fig. 24 and Table 7. The site-configurable
operating properly. Do not bypass limits and
jumpers should be clipped with side cutters and the
interlocks.
resistors removed from the Relay Module.
5. Close all manual fuel shutoff valve(s) before
Table 7. Site Configurable Jumper Options. starting these tests.
Jumper After checking all wiring, perform this checkout before

Number Description Intact Clipped installing the CB780/CB784 on the subbase. These tests
JR1 Pilot Flame 10 seconds 4 seconds verify the Wiring Subbase is wired correctly, and the
Establishing external controllers, limits, interlocks, actuators, valves,
Period (PFEP) transformers, motors and other devices are operating
properly.
JR3 Start-up Disabled Enabled
Interlock Check NOTE: Do not perform a dielectric test with
theCB780/CB784 installed. Internal surge pro-
NOTE: For all standard installations, these jumpers tectors will break down and conduct a current.
should be left intact, unless otherwise indicated This could cause the CB780/CB784 to fail the
on wiring diagram. Removal after 200 hours of dielectric test or possibly destroy the internal
operation will result in a hard lockout, Code 110. lightning and high current protection.
SELECTABLE CONFIGURATION JUMPERS Equipment Recommended

RUN/TEST SWITCH
1. Voltmeter (1 megohm/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 listed in Static Checkout,
Table 8, in the order listed.
2. Make sure all manual fuel shutoff valve(s) are closed.
3. Raise the setpoint of the operating controller to sim-
ulate a call for heat.
4. For each test, open the master switch and install the
jumper wire(s) between the subbase wiring termi-
nals listed in the Test Jumpers column.
5. Close the master switch before observing operation.
6. Read the voltage between the subbase wiring termi-
M7397A
nals listed in the Voltmeter column.
7. If there is no voltage or the operation is abnormal,
check the circuits and external devices as described
Fig. 23. Selectable site-configurable jumpers.
in the last column.
8. Check all wiring for correct connections, tight termi-
nal screws, correct wire, and proper wiring tech-
STATIC CHECKOUT niques. Replace all damaged or incorrectly sized
wires.
9. Replace faulty controllers, limits, interlocks, actua-
WARNING tors, valves, transformers, motors and other devices
as required.
Electrical Shock Hazard and Explosion Hazard.
Can cause severe injury, death or property 10. Ensure normal operation is obtained for each
damage. required test before continuing the checkout.
1. Use extreme care while testing the system. Line 11. After completing each test, be sure to remove the
voltage is present on most terminal connections test jumper(s).
when power is on.
32-00207—01 26
Table 8. Static Checkout.

Test Test Volt- If Operation is Abnormal, Check the
No. Jumpers meter Normal Operation Items Listed Below
WARNING
Explosion Hazard.
Can cause severe injury, death or property damage.
Make sure all manual fuel shutoff valves are closed.
IMPORTANT:
Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if
required).
1 None 4-L2 Line voltage at terminal 4. 1. Master switch.
2. Power connected to the master
switch.
3. Overload protection (fuse, cir-
cuit breaker, etc.) has not
opened the power line.
2 None 6-L2 Line voltage at terminal 6. 1. Limits.
2. Burner controller.
3 None 20-L2 Line voltage at terminal 20. 1. Preignition interlocks.
4 4-5 7-L2 1. Burner motor (fan or blower) starts. 1. Burner motor circuit.
2. Line voltage at terminal 7 within 10 seconds. a. Manual switch of burner
motor.
b. Burner motor power supply,
overload protection, and
starter.
c. Burner motor.
2. Running or Lockout Interlocks
(including Airflow Switch).
5 4-10 — Ignition spark (if ignition transformer is connected 1. Watch for spark or listen for
to terminal 10). buzz.
a. Ignition electrodes are clean.
b. Ignition transformer is okay.
6 4-8 — 1. Ignition spark (if ignition transformer is con- 1. Watch for spark or listen for
nected to terminal 8). buzz.
2. Automatic pilot valve opens (if connected to a. Ignition electrodes are clean.
terminal 8). b. Ignition transformer is okay.
2. Listen for click or feel head of
NOTE: Refer to wiring diagram of system being valve for activation.
tested. a. Actuator, if used.
b. Pilot valve.
7 4-21 — Same as test no. 6 for connections to terminal 8. If Same as test no. 6. If using direct
using direct spark ignition, check the first stage spark ignition, check the first stage
fuel valve(s) instead of pilot valve. fuel valve(s) instead of the pilot valve.
8 4-9 — Automatic main fuel valve(s) open. If using direct 1. Listen for and observe operation
spark ignition with intermittent pilot on terminal of the main fuel valve(s) and
21, check the optional second stage fuel valve, if actuator(s).
used. 2. Valve(s) and actuator(s).
9 4-3 — Alarm (if used) turns on. 1. Alarm.
10 4-5 and 18-L2 Firing rate motor drives open; zero volts at terminal 1. Low Fire Start Switch.
12-13 18 after motor starts driving open. 2. Firing rate motor and trans-
former.
11 4-5 and 18-L2 Firing rate motor drives closed; line voltage at 1. Low Fire Start Switch.
14-13 terminal 18 after motor is in Low Fire position. 2. Firing rate motor and trans-
former.
12 4-5 and 19-L2 Firing rate motor drives open; line voltage at 1. High Fire Purge Switch.
12-13 terminal 19 after motor is in High Fire position. 2. Firing rate motor and trans-
former.
27 32-00207—01
Table 8. Static Checkout. (Continued)

Test Test Volt- If Operation is Abnormal, Check the
No. Jumpers meter Normal Operation Items Listed Below
13 4-5 and 19-L2 Firing rate motor drives closed; zero volts at 1. Low Fire Start Switch.
14-13 terminal 19 after motor starts driving closed. 2. Firing rate motor and trans-
former.
WARNING
Explosion Hazard.
Can cause severe injury, death or property damage.
Make sure all manual fuel shutoff valves are closed.
IMPORTANT:
Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if
required).
14 15-13 — 1. Raise set point of Series 90 controller—firing 1. Series 90 Controller.
rate motor should drive toward open. 2. Firing rate motor and trans-
2. Lower set point of Series 90 controller—firing former.
rate motor should drive toward closed.
Final
CAUTION
Equipment Damage Hazard.
Failure to remove test and bypass jumpers can damage equipment or affect operation.
On completing these tests, open the master switch and remove all test jumpers from the subbase
terminals. Also, remove bypass jumpers from the low fuel pressure limits (if used).
CHECKOUT 2. Open the master switch before removing or

installing the CB780/CB784 or Keyboard
Display Module connector.
WARNING 3. Make sure all manual fuel shutoff valve(s) are
closed before starting the initial lightoff check
Explosion Hazard.
Can cause severe injury, death or property and the Pilot Turndown tests.
damage. 4. Do not put the system in service until you have
Do not allow fuel to accumulate in the combustion satisfactorily completed all applicable tests in
chamber. If fuel is allowed to enter the chamber for this section and any others required by the
longer than a few seconds without igniting, an equipment manufacturer.
explosive mixture could result. It is recommended
that you limit the trial for pilot to ten seconds, and IMPORTANT:
limit the attempt to light the main burner to two 1. If the system fails to perform properly, note the
seconds from the time the fuel has reached the fault code, fault message, equipment status, and
burner nozzle. In any case, do not exceed the sequence time on the display. Refer to the Trouble-
nominal lightoff time specified by the equipment shooting section and CB780/CB784 System
manufacturer; close the manual fuel shutoff Annunciation Diagnostics and Troubleshooting,
valve(s) if the flame is not burning at the end of the Bulletin Number CB-7803.
specified time. 2. Repeat ALL required Checkout tests after all
adjustments are made. ALL tests must be satisfied
with the flame detector(s) in its FINAL position.
WARNING Equipment Recommended:

Electrical Shock Hazard and Explosion Hazard.
Can cause severe injury, death or property 1. Volt-ohmmeter (one megohm/volt minimum sensi-
damage. tivity) with:
1. Use extreme care while testing the system. Line a. 0-300 Vac capability.
voltage is present on most terminal connections b. 0-6000 ohm capability.
when power is on. c. 0-10 Vdc capability.
Checkout Summary
1. Preliminary inspection—all installations.
2. Flame signal measurement—all installations.
3. Initial lightoff check for proved pilot—all installations
using a pilot.
32-00207—01 28
4.Initial lightoff check for direct spark ignition of oil—

all burners using DSI.
Flame Signal Measurement (Table
5. Pilot turndown test—all installations using a pilot. 9 and Fig. 25)
6. Hot refractory saturation test—all installations using
Measure the flame signal at the appropriate times as
Infrared (lead sulfide) Flame Detectors.
defined in the following Checkout tests. Read the flame
7. Hot refractory hold-in test—all installations.
signal in volts dc at the flame amplifier test jacks + and
8. Ignition interference test—all installations using
(Com) or at the Keyboard Display Module.
flame rods.
9. Ignition spark pickup—all installations using Ultravi- 1. Use one megohm/volt meter with a 0 to 10 Vdc
olet Flame Detectors. capability.
10. Response to other ultraviolet sources—all installa- 2. Set the one megohm/volt meter to the 0 to 10 Vdc
tions using Ultraviolet Flame Detectors. range.
11. Flame signal with hot combustion chamber—all 3. Insert the positive (red) probe into the + jack of the
installations. flame amplifier. Insert the negative (black) probe
12. Safety shutdown tests—all installations. into the (Com) jack of the flame amplifier; see Fig.
See Figs. 1 and 2 for location of component parts and Fig. 25.
7 or wiring subbase specifications for terminal locations. 4. Allow a few seconds for the meter reading to stabi-
lize.
Preliminary Inspection 5. If using AMPLI-CHECK™ or shutter check amplifiers,
read the average stable voltage, disregarding the
Perform the following inspections to avoid common peaks and valleys caused by the self-checking oper-
problems. Make certain that: ation.
6. The meter reading must be as specified in Table 8
1. Wiring connections are correct and all terminal after all tests are completed and all adjustments
screws are tight. made.
2. Flame detector(s) is clean, and installed and posi-
tioned properly. Consult the applicable instructions. As an option, the flame signal can be checked by using the
3. Correct combination of amplifier and flame detec- Keyboard Display Module.
tor(s) is used. See Table 2 in the Specifications sec-
tion. If the signal is unstable or less than the minimum
4. Plug-in amplifier and purge card are securely in acceptable voltage, check flame detector installation and
place. circuitry.
5. Burner is completely installed and ready to fire; con-
sult equipment manufacturer instructions. Fuel 1. Check the supply voltages at terminals 4 (L1) and L2
lines are purged of air. (N). Make sure the master switch is closed, connec-
6. Combustion chamber and flues are clear of fuel and tions are correct, and the power supply is of the cor-
fuel vapor. rect voltage, frequency and is sinusoidal.
7. Power is connected to the system disconnect switch, 2. Check the detector wiring for defects including:
(master switch). a. Incorrect connections.
8. Lockout is reset (push in reset button) only if the b. Wrong type of wire.
Relay Module is powered; see Figs. 1 and 2. c. Open circuits.•Deteriorated wire.
9. Run/Test Switch is in RUN position. d. Short circuits.
10. System is in the STANDBY condition. STANDBY mes- e. Leakage paths caused by moisture, soot or accu-
sage is viewable in the VFD. mulated dirt.
11. All limits and interlocks are reset.
Table 9. Flame Signal.
Minimum Acceptable Maximum Expected dc
Flame Detector Flame Signal Amplifier Steady dc Voltagea Voltage
817-1121 833-2741b 1.25 Vdc 5.0 Vdc at Keyboard Display
Module
817-1742 833-2722 or or
833-2723c 5.0 Vdc at one megohm/volt
817-1743 833-2724 meter.
817-4133 833-3495 or
833-3496c
a
This minimum or stronger signal should easily be obtained if the detector is correctly installed and positioned to prop-
erly sense the flame. This voltaged must be obtained before completing checkout.
b
The flame detector shutter and amplifier are tested one-half second every five seconds. Series 4 (or greater) amplifiers
pulse the shutter when the flame signal reaches 1.5 Vdc. Expected flame signal on Series 4 (or greater) amplifiers will
vary between 0.8 Vdc and 2.4 Vdc.
c
This flame amplifier is AMPLI-CHECK™ type. The flame signal amplifier circuitry is tested 1/2 second every five seconds
during burner operation and shuts down the burner if the amplifier fails.
29 32-00207—01
5. If the pilot flame is not established in ten seconds,

safety shutdown occurs. Let the sequence complete
POSITIVE (+) its cycle. Consult the equipment operating manual
METER LEAD for further information.
ONE 6. Push the reset pushbutton, and let the system recy-
NEGATIVE (-) MEGOHM/VOLT
METER LEAD METER cle once. If the pilot still does not ignite, make the
following ignition/pilot adjustments:
a. Open master switch and remove the CB 780/CB
784 from the subbase.
b. On the subbase, temporarily jumper terminal 4
to ignition terminals 8, 10 or 21; refer to the
appropriate wiring diagram to determine the
proper terminal. Disconnect the leadwire to the
pilot valve if it is connected to the same terminal.
c. Close the master switch to energize only the igni-
tion transformer.
d. If the ignition spark is not strong and continuous,
open the master switch and adjust the ignition
electrode spark gap setting to the manufacturer
M7383C
recommendations.
e. Make sure the ignition electrodes are clean.
Fig. 24. Flame signal measurement. f. Close the master switch and observe the spark.
g. After a continuous spark is obtained, open the
3. For all optical detectors, clean the detector viewing master switch and add a jumper on the subbase
window and inside of the sight pipe as applicable. from terminal 4 (L1) to the pilot terminal 8 or 21.
4. With the burner running, check temperature at the Reconnect the leadwire from the pilot valve if it
detector. If it exceeds the detector maximum rated was disconnected in step b.
temperature: h. Close the master switch to energize both the
a. Add a heat block to stop conducted heat travel- ignition transformer and the pilot valve.
ing up the sight pipe. i. If the pilot does not ignite and if the ignition
b. Add a shield or screen to reflect radiated heat. spark is still continuous, adjust the pressure reg-
c. Add cooling (refer to sight pipe ventilation in the ulator until a pilot is established.
detector Instructions). j. When the pilot ignites properly and stays ignited,
5. Make sure the flame adjustment is not too lean. open the master switch and remove the
6. Make sure the detector is properly sighting the jumper(s) from terminals 4-8, 4-10 and 4-21 of
flame. the subbase.
7. If necessary, resight or reposition the detector. k. Check for adequate bleeding of the fuel line.
l. Reinstall the CB 780/CB 784 on the subbase,
Initial Lightoff Check for Proved close the master switch, and then return to step
4.
Pilot 7. When pilot ignites, measure the flame signal. If the
pilot flame signal is unsteady or approaching the
Perform this check on all installations that use a pilot. It
1.25 Vdc minimum value, adjust the pilot flame size
should immediately follow the preliminary inspection.
or detector sighting to provide a maximum and
NOTE: Low fuel pressure limits, if used, could be open. If steady flame signal.
so, bypass them with jumpers during this check. 8. Recycle the system to recheck lightoff and pilot
flame signal.
1. Open the master switch. 9. When the MAIN IGN period is displayed on the VFD,
2. Make sure that the manual main fuel shutoff valve(s) make sure the automatic main fuel valve is open;
is closed. Open the manual pilot shutoff valve. If the then smoothly open the manual main fuel shutoff
pilot takeoff is downstream from the manual main valve(s) and watch for main burner flame ignition.
fuel shutoff valve(s), very slightly open the manual When the main burner flame is established, proceed
main valve to supply pilot gas flow. Make sure the to step 15.
main fuel is shut off just up-stream from the burner 10. If the main burner flame is not established within ten
inlet, or disconnect power from the automatic main seconds, close the manual main fuel shutoff
fuel valve(s). valve(s).
3. Close the master switch and start the system with a 11. Recycle the system to recheck the lightoff and pilot
call for heat by raising the set point of the operating flame signal.
controller; see Fig. 19 or CB 780/CB 784 sequence. 12. Smoothly open the manual fuel shutoff valve(s) and
The program should start the ten second INITIATE try lightoff again. (The first reattempt may have been
sequence. required to purge the lines and bring sufficient fuel
4. Let the sequence advance through PREPURGE. to the burner.)
When the PILOT IGN status is displayed on the Key- 13. If the main burner flame is not established within
board Display Module, ignition spark should occur five seconds or the normal lightoff time specified by
and the pilot should light. If the pilot ignites, the the equipment manufacturer, close the manual main
FLAME LED will be energized. Proceed to step 7. fuel shutoff valve(s). Check all burner adjustments.
32-00207—01 30
14. If the main burner flame is not established after two 5. Let the sequence advance through PREPURGE.
attempts: Ignition spark should occur after PREPURGE period.
a. Check for improper pilot size. Listen for the click of the first stage fuel solenoid
b. Check for excess combustion air at low fire. valve(s).
c. Check for adequate low fire fuel flow. 6. Let the program sequence complete its cycle.
d. Check for proper gas supply pressure. 7. Open the manual fuel shutoff valve(s).
e. Check for proper valve operation. 8. Push the reset button and recycle the program
f. Check for proper pilot flame positioning. sequence through PREPURGE.
15. Repeat steps 10 through 14 to establish the main 9. When PILOT IGN status is displayed, watch that the
burner flame; then proceed to step 16. first stage burner flame is established. If it is estab-
16. With the sequence in RUN, make burner adjust- lished, proceed to step 15.
ments for flame stability and Btu input rating. 10. If the first stage burner flame is not established
17. Shut down the system by opening the burner switch within ten seconds, close the manual fuel shutoff
or by lowering the set point of the operating control- valve(s), and open the master switch after POST-
ler. Make sure the main flame goes out. There may PURGE is completed.
be a delay due to gas trapped between the valve(s) 11. Check all burner adjustments.
and burner. Make sure all automatic fuel valve(s) 12. Wait about three minutes. Close the master switch,
close. open the manual fuel shutoff valve(s), and try to
18. Restart the system by closing the burner switch lightoff the burner again. The first attempt may have
and/or raising the set point of the operating control- been required to purge the lines and bring sufficient
ler. Observe that the pilot is established during fuel to the burner.
PILOT IGN and the main burner flame is established 13. If the first stage burner flame is not established
during MAIN IGN within the normal lightoff time. within ten seconds, close the manual fuel shutoff
19. Measure the flame signal. Continue to check for the valve(s), and open the master switch.
proper signal, see Table 9, through the RUN period. 14. If necessary, repeat steps 11 through 13 to establish
Check the signal at both High and Low Firing Rate the first stage burner flame. Then proceed to step
positions and while modulating. 15.
20. Run the burner through another sequence, observ- 15. When the first stage burner flame is established, the
ing the flame signal for: sequence will advance to RUN. Make burner adjust-
a. Pilot flame alone (DSI). ments for flame stability and input rating. If a sec-
b. Pilot and main flame together. ond stage is used, proceed to step 18.
c. Main flame alone (unless monitoring an inter- 16. Shut down the system by opening the burner switch
mittent pilot). Also observe the time it takes to or by lowering the set point of the operating control-
light the main flame. Ignition of main flame ler. Make sure the burner flame goes out and all
should be smooth. automatic fuel valve(s) close.
21. Make sure all readings are in the required ranges 17. If used, remove the bypass jumpers from the low fuel
before proceeding. pressure limit and subbase.
22. Return the system to normal operation. 18. If a second stage is used, make sure the automatic
second stage fuel valve(s) has opened. Check the
NOTE: After completing these tests, open the master lightoff as follows (otherwise proceed to step 19):
switch and remove all test jumpers from the sub- a. Open the manual second stage fuel valve(s).
base terminals, limits/controls or switches. b. Restart the system by raising the set point of the
operating controller.
Initial Lightoff Check for Direct c. When the first stage burner flame is established,
watch for the automatic second stage fuel
Spark Ignition valve(s) to open. Observe that the second stage
lights off properly.
This check applies to gas and oil burners not using a pilot.
d. Make burner adjustments for flame stability and
It should immediately follow the preliminary inspection.
input rating.
Refer to the appropriate sample block diagram of field
e. Shut down the system by lowering the set point
wiring for the ignition transformer and fuel valve(s)
of the operating controller. Make sure the burner
hookup.
flame goes out and all automatic fuel valve(s)
NOTE: Low fuel pressure limits, if used, could be open. If close.
so, bypass them with jumpers during this check. f. Proceed to step 19.
19. Restart the system by closing the burner switch
1. Open the master switch. and/or raising the set point of the operating control-
2. Complete the normal ready-to-fire checkout of the ler. Observe that the burner flame is established
fuel supply and equipment as recommended by the during PILOT IGN, within the normal lightoff time
equipment manufacturer. specified by the equipment manufacturer.
3. Close all manual main fuel shutoff valve(s). Check 20. Measure the flame signal. Continue to check for the
that the automatic fuel valve(s) are closed. Make proper signal, see Table 9, through the RUN period.
sure fuel is not entering the combustion chamber. Check the signal at both high and low firing rate
4. Close the master switch and start the system with a positions and while modulating. Any pulsating or
call for heat by raising the setpoint of the operating unsteady readings will require further attention.
controller, see Fig.18 for CB 780/CB 784 sequenc- 21. Make sure all readings are in the required ranges
ing. The program sequence should start the ten sec- before proceeding.
ond INITIATE sequence.
31 32-00207—01
NOTE: Upon completing these tests, open the master 10. Set the Run/Test Switch in the RUN position and let
switch and remove all test jumpers from the sub- the sequence proceed. At ten seconds into the Igni-
base terminals, limits/controls or switches. tion Trial period, make sure the automatic main fuel
valve(s) open; then smoothly open the manual main
22. Return the system to normal operation. fuel shutoff valve(s) (or any other manually opened
safety shutoff valve(s), if used) and watch for main
Pilot Turndown Test (All burner ignition. If the main burner flame is estab-
lished, proceed to step 18.
Installations Using a Pilot)
NOTE: This step requires two people, one to open the
Perform this check on all installations that use a pilot. The manual valve(s) and one to watch for ignition.
purpose of this test is to verify that the main burner can be
lit by the smallest pilot flame that will hold in the flame 11. If the main burner flame is not established within ten
amplifier and energize the FLAME LED. Clean the flame seconds, close the manual main fuel shutoff valve(s)
detector(s) to make sure that it will detect the smallest and open the master switch. If the lightoff was
acceptable pilot flame. If using AMPLI-CHECK™ or Self- rough, the pilot flame size is too small.
Checking Amplifier and 1M ohm/volt meter, the flame 12. Recycle the burner and stop the sequence in the
signal will fluctuate every time the amplifier does a self- PILOT IGN period by using the Run/Test Switch.
check or a shutter check. 13. Increase the pilot flame size by increasing its fuel
flow until a smooth main flame is accomplished.
NOTE: Low fuel pressure limits, if used, could be open. If 14. Reposition the flame scanner sight tube or use ori-
so, bypass them with jumpers during this test. fices until the pilot flame signal voltage is in the
range of 1.25 to 1.50 Vdc.
1. Open the master switch.
15. When the main burner lights reliably with the pilot at
2. Close the manual main fuel shutoff valve(s).
turndown, disconnect the manometer (or pressure
3. Connect a manometer (or pressure gauge) to mea-
gauge) and turn the pilot gas flow up to that recom-
sure pilot gas pressure during the turndown test.
mended by the equipment manufacturer.
4. Open the manual pilot shutoff valve(s).
16. If used, remove the bypass jumpers from the sub-
5. Close the master switch and start the system with a
base terminals, limits/controls, or switches.
call for heat. Raise the set point of the operating con-
17. Run the system through another cycle to check for
troller. The program sequence should start, and
normal operation.
PREPURGE should begin.
18. Return the system to normal operation.
6. When the PILOT IGN begins, set the Run/Test
Switch to TEST position to stop the sequence. The
FLAME LED will come on when the pilot ignites.
LOCKOUT #16 PFEP
NOTE: If the sequence does not stop, reset the system * Flame-out Timer*
and make sure you set the Run/Test Switch to
TEST within the first eight seconds of the PILOT
IGN sequence. Condition at the
time of lockout . . .
IMPORTANT:
You have eight seconds or three seconds, depend-
ing on PFEP selected, to position the
Run/Test Switch to the TEST position to stop the PILOT HOLD:
sequence after the start of the PILOT IGN period. (Run/Test Sw)
M5001A
7. Turn the pilot pressure down very slowly, reading the
manometer (or pressure gauge) as it drops. Stop Fig. 25. Flame-out timer lockout.
instantly when the FLAME LED goes out. Note the
pressure at the CB780/CB784 flame relay dropout
point. The pilot is at the minimum turndown posi- Hot Refractory Saturation Test (All
tion. Immediately turn up the pilot pressure until the
FLAME LED comes on again or the flame signal
Infrared Detectors)
increases to 1.25 Vdc. Test to make certain that radiation from hot refractory
does not mask the flickering radiation of the flame itself.
NOTE: If there is no flame for fifteen seconds with the
sequence stopped at this point, the Start the burner and monitor the flame signal during the
CB780/CB784 will lockout and flash a lockout warm-up period. A decrease in signal strength as the
message; see Fig. 26. refractory heats up indicates hot refractory saturation. If
saturation is extreme, the flame signal will drop below
8. Repeat step 7 to verify the pilot gas pressure reading 1.25 Vdc and the system will shut down as though a flame
at the exact point the FLAME LED light goes out. failure occurred.
9. Increase the pilot pressure immediately until the
FLAME LED comes on, and then turn it down slowly If hot refractory saturation occurs, the condition must be
to obtain a pressure reading just above the dropout corrected. Add an orifice plate in front of the cell to restrict
point or until the flame signal increases to 1.25 Vdc. the viewing area, lengthen the sight pipe or decrease the
pipe size (diameter). Continue adjustments until hot
refractory saturation is eliminated.
32-00207—01 32
Hot Refractory Hold-in Test (All 1. Close the pilot and main burner manual fuel shut-off
valve(s).
Infrared Detectors) 2. Start the burner and use the Run/Test Switch to stop
the sequence in the PILOT IGN period. Ignition spark
Test to make certain hot refractory will not delay the flame
should occur, but the flame signal should not be
detection system response to a flameout. This condition
more than 0.5 Vdc.
can delay response to flame failure and also can prevent a
3. If the flame signal is higher than 0.5 Vdc and the
system restart as long as hot refractory is detected.
FLAME LED does come on, consult the equipment
Infrared (lead sulfide) detectors can respond to infrared operating manual and resight the detector farther
rays emitted by a hot refractory, even when the refractory out from the spark, or away from possible reflection.
has visibly ceased to glow. Infrared radiation from a hot It may be necessary to construct a barrier to block
refractory is steady, but radiation from a flame has a the ignition spark from the detector view. Continue
flickering characteristic. The infrared detection system adjustments until the flame signal due to ignition
responds only to flickering infrared radiation; it can reject spark is less than 0.5 Vdc.
a steady signal from hot refractory. The refractory steady
signal can be made to fluctuate if it is reflected, bent or Response to Other Ultraviolet
blocked by smoke or fuel mist within the combustion
chamber. Be careful when applying an infrared system to Sources
verify its response to flame only. Some sources of artificial light, such as incandescent or
To check infrared (lead sulfide) detectors for hot refractory fluorescent bulbs, mercury sodium vapor lamps and
hold-in, operate the burner until the refractory reaches its daylight, produce small amounts of ultraviolet radiation.
maximum temperature. If the installation has a multi-fuel Under certain conditions, an ultraviolet detector will
burner, burn the heavier fuel that is most likely to reflect, respond to these sources as if it is sensing a flame. To
bend or obscure the hot refractory steady infrared check for proper detector operation, check the Flame
radiation. When the maximum refractory temperature is Failure Response Time (FFRT) and conduct Safety
reached, close all manual fuel shutoff valve(s), or open the Shutdown Tests under all operating conditions.
electrical circuits of all automatic fuel valve(s). Visually
observe when the burner flame or FLAME LED goes out. If Flame Signal With Hot Combustion
this takes more than three seconds, the infrared detector
is sensing hot refractory. Immediately terminate the firing Chamber (All Installations)
cycle. (Lower the set point to the operating controller, or With all initial start-up tests and burner adjustments
set the Burner Switch to OFF. Do not open the master completed, operate the burner until the combustion
switch.) chamber is at the maximum expected temperature.
Observe the equipment manufacturer warm-up
NOTE: Some burners continue to purge oil lines between
instructions. Recycle the burner under these hot
the valve(s) and nozzle(s) even though the fuel
conditions and measure the flame signal. Check the pilot
valve(s) are closed. Terminating the firing cycle
alone, the main burner flame alone, and both together
(instead of opening the master switch) will allow
(unless monitoring only the main burner flame when
purging the combustion chamber. This will
using DSI). Check the signal at both High and Low Firing
reduce a buildup of fuel vapors in the combustion
Rate positions and while modulating, if applicable.
chamber caused by oil line purging.
If the flame signal is too low or unsteady, check the flame
If the detector is sensing hot refractory, the condition
detector temperature. Relocate the detector if the
must be corrected. Add an orifice plate in front of the cell
temperature is too high. If necessary, realign the sighting
to restrict the viewing area of the detector. If this does not
to obtain the proper signal and response time. If the
correct the problem, resight the detector at a cooler, more
response time is still too slow, replace the Plug-in Flame
distant part of the combustion chamber. While resighting
Signal Amplifier. If the detector is relocated or resighted, or
the detector, be aware that it must also properly sight the
the amplifier is replaced, repeat all required Checkout
flame. For an infrared detector, try lengthening the sight
tests.Check the FFRT of the Flame Amplifier. Lower the set
pipe or decreasing the pipe size (diameter). For details,
point of the operating controller and observe the time it
refer to the detector Instructions and the equipment
takes for the burner flame to go out. This should be within
Operating Manual. Continue adjustments until hot
3 seconds maximum.
refractory hold-in is eliminated.
Ultraviolet Sensor, Ignition Spark Safety Shutdown Tests (All

Response Test (All Ultraviolet Installations)
Perform these tests at the end of Checkout, after all other
Detectors) tests have been completed. If used, the external alarm
Test to make certain that the ignition spark is not should turn on. Press the CB780/CB784 reset pushbutton
actuating the FLAME LED. to restart the system.
33 32-00207—01
1. Opening a Preignition Interlock during STANDBY or g. Safety shutdown will occur.

PREPURGE period. 7. Opening a Preignition Interlock after the first five
a. *Preignition ILK* fault will be displayed on the seconds of POSTPURGE.
VFD. Fault code 10 or 33 will be displayed to a. *Preignition ILK* fault will be displayed on the
denote the fault. KDM. Fault code 33 will be displayed to denote
b. Safety shutdown will occur. the fault.
2. Opening a Lockout Interlock during PREPURGE, b. Safety shutdown will occur.
PILOT IGN, MAIN IGN or RUN period.
a. *Lockout ILK* fault will be displayed on the VFD. IMPORTANT:
Fault code 11 or 12 or 21 or 29 will be displayed 1. If the CB780/CB784 fails to shut down on any of
to denote the fault. these tests, take corrective action; refer to
b. Safety shutdown will occur. CB780/CB784 Troubleshooting and diagnostics
3. Detection of flame 40 seconds after entry to STAND- manual and return to the beginning of all Check-
BY, fault code 9. Detection of flame ten seconds into out tests.
Drive to Purge Rate or during measured PREPURGE 2. When all Checkout tests have been completed,
time. reset all switches to original status.
a. Simulate a flame to cause the flame signal volt-
age level to be at least 1.25 Vdc for 40 seconds
after entry to STANDBY and also simulate a TROUBLESHOOTING
flame signal for 10 seconds during PREPURGE.
b. *Flame Detected* fault will be displayed on the
VFD. Fault code 9 or 15 or 18 will be displayed to CB780/CB784 System Diagnostics
denote the fault. Troubleshooting control system equipment failures is
c. Safety shutdown will occur. made easier with the CB780/CB784 self-diagnostics and
4. Failure to ignite pilot. first-out annunciation. In addition to an isolated spst
a. Close pilot and main fuel manual shutoff alarm relay (audible annunciation), the CB780/CB784
valve(s). provides visual annunciation by displaying a fault code
b. Depress the reset button. and fault or hold message at the Keyboard Display
c. Start the system. Module. The CB780/CB784 provides118 diagnostic
d. The automatic pilot valve(s) should be energized messages for troubleshooting the system (see the
but the pilot cannot ignite. CB780/CB784 System Annunciation Diagnostics and
e. *Pilot Flame Fail* fault will be displayed on the Troubleshooting, Bulletin Number CB-7803.
VFD. Fault code 28 will be displayed four or ten
seconds (depending on the jumper configuration Self-diagnostics of the CB780/CB784 enables it to detect
selection for PFEP) after the pilot valve(s) is and annunciate both external and internal system
energized to denote the fault. problems. Internal faults and external faults such as
f. Safety shutdown will occur. interlock failures, flame failures and false flame signals
5. Failure to ignite main. are annunciated by the CB780/CB784, which energizes
a. Open the manual pilot valve(s); leave the main the ALARM LED or visually displayed at the Keyboard
fuel manual shutoff valve(s) closed. Display Module.
b. Depress the reset button.
c. Start the system. The KDM displays a sequence status message indicating:
d. The pilot should ignite and the flame signal STANDBY, PREPURGE, PILOT IGN, MAIN IGN, RUN and
should be at least 1.25 Vdc but the main burner POSTPURGE. The selectable messages also provide visual
cannot light. indication of current status and historical status of the
e. The flame signal should drop below 1.25 Vdc equipment such as: Flame Signal, Total Cycles, Total
within 3 seconds after the interrupted pilot goes Hours, Fault History, Diagnostic Information and
out. Expanded Annunciator terminal status (if used). With this
f. *Main Flame Ign.* fault will be displayed on the information, most problems can be diagnosed without
VFD. Fault code 19 will be displayed to denote extensive trial and error testing.
the fault.
g. Safety shutdown will occur. Table 4 provides the sequence and status hold messages.
6. Loss of flame during RUN. Table 10 provides a summary of all CB780/CB784 fault
a. Open the main fuel manual shutoff valve(s) and messages and fault codes. In addition, Diagnostic
open manual pilot shutoff valve(s). Information and History Data are available to assist in
b. Depress the reset button. troubleshooting the CB780/CB784, see Table 6.
c. Start the system. Start-up should be normal and
The CB780/CB784 provides diagnostic information to aid
the main burner should light normally.
the service mechanic in obtaining information when
d. After the sequence is in the normal RUN period
troubleshooting the system, see Tables 4, 5, 6 and 10.
for at least ten seconds with the main burner fir-
Information available in the Diagnostic Information
ing, close the manual main fuel shutoff valve(s)
includes Device Type, Device Suffix, Software Revision,
to extinguish the main burner flame.
Manufacturing Code, Flame Amplifier Type, Flame Failure
e. The flame signal should drop below 1.25 Vdc
Response Time, Selectable Jumper Configuration Status,
within 3 seconds after the main flame goes out.
Run/Test Switch Status and Terminal Status.
f. *Main Flame Fail* fault will be displayed on the
KDM. Fault code 17 will be displayed to denote
the fault.
32-00207—01 34
Diagnostic Information Index 2760, ordered separately) on the Keyboard Display

Module or DATA CONTROLBUS MODULE™. A power-up
The CB780/CB784 monitors input/output terminals and reset will cause an electrical reset of the CB780/CB784
can display the status of the terminal at the KDM but will not reset a lockout condition.
(example: Pilot Valve T8 ON<). See Table 5 for a complete
terminal description and number. The display will show SERVICE NOTE:
the actual status of the terminal. If voltage is detected at If the Keyboard Display Module is scrambled, remove
the terminal, ON is displayed, but if no voltage is detected and reinstall the Keyboard Display Module, and reset
at the terminal, OFF is displayed; see Table 5. the CB780/CB784 Relay Module.
Historical Information Index SERVICE NOTE:

The CB780/CB784 has nonvolitile memory that allows the Use the access slots on the sides of the Wiring Subbase
Relay Module to retain Historical Information for the six to check the terminal voltage of the CB780/CB784.
most recent lockouts. Each of the six lockout files retains
the cycle when the fault occurred, the hour of operation SERVICE NOTE:
when the fault occurred, a fault code, a fault message and Maximum ambient operating temperature of an 817-
burner status when the fault occurred; see Table 4. 1121 flame sensor, Series 1 through 6 will be reduced
to 125°F because of the duty cycle operation of the
SERVICE NOTE: CB780/CB784 Relay Module.
Reset CB780/CB784 by pressing the reset pushbutton
on the CB780/CB784, or pressing a remote reset push-
button wired through the the 5-wire connector (833-
Table 10. Hold and Fault Message Summary.

Fault Number Annunciation Message
Fault 1 *No Purge Card*
Fault 2 *AC Frequen/Noise*
Fault 3 *AC Line Dropout*
Fault 4 *AC Frequency*
Fault 5 *Low Line Voltage*
Fault 6 *Purge Card Error*
Fault 7 *Flame Amplifier*
Fault 8 *Flame Amp/Shutr*
Fault 9 *Flame Detected*
Fault 10 *Preignition ILK*
Fault 11 *Running ILK On*
Fault 12 *Lockout ILK On*
Fault 14 *High Fire Sw.*
Fault 16 *Flame-Out TImer*
Fault 17 *Main Flame Fail*
Fault 19 *Main Flame Ign.*
Fault 20 *Low FIre Sw. Off*
Fault 21 *Running ILK*
Fault 24 *Call Service*
Fault 25 *Call Service*
Fault 28 *Pilot Flame Fail*
Fault 29 *Lockout ILK*
Fault 33 *Preignition ILK*
Fault 35-40 *Call Service*
Fault 41 *Main Valve On*
Fault 42 *Pilot Valve On*
Fault 43 *Ignition On*
Fault 44 *PIlot Valve 2 On*
Falt 45 *Low Fire Sw. Off*
Falut 46 *Flame Amp. Type*
Fault 47 *Jumpers Changed*
Fault 50 *Jumpers Wrong*
Fault 51 *Flame Too Strong*
35 32-00207—01
Table 10. Hold and Fault Message Summary. (Continued)

Fault Number Annunciation Message
Fault 71-75 *Device Specific*
Fault 76-93 *Accessory Fault*
1/8 in. DIA. (2)

(3.175 mm)
M5082C
Fig. 26. Flush mounting of a Keyboard Display Module template.
SAFETY AND SECURITY Modbus & DDL Interface security

Any conducts critical to device functionality (DDL,
Physical device protection Modbus lines etc.) shall be physically protected (installed
outside public access) since they could be damaged or
Device shall be accessible to authorized personnel only – tampered-with by unauthorized people, either
Installation on publicly accessible places is not accidentally or for purpose.
recommended as this could lead to unwanted and
potentially unsafe changes to device (wiring, Modbus RS-485 & DDL protocols do not support security
configuration, etc). features. For DDL interface - only DDL devices shall be
connected to the Burner Controller DDL line.
It is recommended to lock the device in an enclosed
cabinet with access allowed only to approved and trained
personnel. Also, it is strongly advised to keep all the wiring
License agreement
of device physically secure. Copying and reverse engineering is prohibited by the law.
Physical protection of the device is applied via Run/Test
switch label/seal. It is intended to prevent and detect
unauthorized access.
® U.S. Registered Trademark

Brands and Product Names shown are the
trademarks of their respective owners.
32-00207—01 M.S. 01-19
65-0180
Printed in United States

CB780/CB784 Relay Modules: Features

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CB780/CB784

• Access for external electrical voltage checks.

• Hours of operation at time of fault.

Table 1. Terminal Ratings.

Table 2. Flame Detection Systems (Fig. 3, 4, 5).

Table 3. Sequence Timing For Normal Operation.a

SIL 3 Capable: 833-2730—30 sec.

1 REMOVE ONLY FOR TERMINAL TEST ACCESS. M23943C

e. Lockout Interlock does not close within 10 sec-

Dynamic Input Check Mandatory Purge

Verified Spark Termination A typical Lockout Interlock string contains an airflow

Diagnostics Preignition Interlock

First-out Annunciation reports the cause of a safety

High Fire Interlock WARNING

1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M7420A

2 DEDICATED DATA LINK.

d. Remote Reset—Use no. 22 AWG or greater b. DATA CONTROLBUS OR MODBUS MODULE™:

LOCKOUT INTERLOCKS LOW FIRE

10 SEC. INTERRUPTED 8 19 HIGH FIRE

WHITE 817-1743 BLUE FOR DIRECT SPARK IGNITION (OIL

YELLOW 817-1121 BLUE 8 L2

Fig. 7. Wiring the CB780/CB784 Relay Module.

833-2727 KEYBOARD DISPLAY MODULE

833-2727 REMOTE KEYBOARD DISPLAY MODULE

1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120

Fig. 8. Wiring multiple Keyboard Display Modules.

833-2729 DATA CONTROLBUS OR 833-2820 MODBUS MODULE™

833-2727 REMOTE KEYBOARD DISPLAY MODULE

1 THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO

2 WHEN CONNECTING THE KEYBOARD DISPLAY MODULE DATA

ASSEMBLY 3. Make sure no subbase wiring is projecting beyond

4. Mount the CB780/CB784 by aligning the four L

Mounting Keyboard Display

4. Verify the amplifier is firmly in place.

Installing the Flame Detector

Proper flame detector installation is the basis of a safe

Keep the flame signal leadwires as short as possible from

Installing Plug-In Flame Signal

SOLID STATE SELF-CHECKING

Fig. 16. Flame detector wiring.

OPERATION or control input.

BURNER BURNER/BLOWER MOTOR 5

PREIGNITION INTERLOCK CLOSED 4 TO 20 PII

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

MOTOR OUTPUT SWITCHING 13 TO 15

Fig. 17. CB780/CB784 sequence.

KEYBOARD DISPLAY MODULE (KDM)

Table 4. Sequence Status Display Information (see Fig. 19).

Keyboard Functions n represents a numbered value.

1. SCROLL Down-Up pushbuttons (o), see Fig. 20.

Selectable Messages SAVE

KDM Second Line Display, Two-Level Hierarchy, see Table M7401D

LOCKOUT #17 MFEP

LOCKOUT #17 MFEP

Fig. 21. MODE pushbutton function.

Fig. 22. SAVE function.

Table 5. Selectable Messages.

Table 5. Selectable Messages. (Continued)

Device RM78nnx < DI