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CB780/CB784
Relay Modules
APPLICATION
The Cleaver-Brooks CB780/CB784 (833-2718/833-
2720) is a microprocessor based integrated burner control
for automatically fired gas, oil, or combination fuel single
burner applications. The CB780 consists of a Relay
Module and Keyboard Display Module. The CB784
consists of the Relay Module only. The Keyboard Display
Module is optional with the CB784. Subbase, Amplifier,
and Purge Card are required to complete the system.
Options include DATA CONTROLBUS MODULE™*, Remote
Display Mounting, First-Out Expanded Annunciator or
Modbus™ Module.
The CB780/CB784 is programmed to provide a level of
safety, functional capability and features beyond the
capacity of conventional controls.
Functions provided by the CB780/CB784 include
automatic burner sequencing, flame supervision, system
status indication, system or self-diagnostics and
troubleshooting
INSTALLATION INSTRUCTIONS
FEATURES
• Safety features:
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Interlock check.
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Closed loop logic test.
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Dynamic AMPLI-CHECK™.
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Dynamic input check.
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Dynamic safety relay test.
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Dynamic self-check logic.
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Expanded safe-start check.
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High Fire Purge Switch test.
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Internal hardware status monitoring.
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Low Fire Start Switch test.
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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
microcomputer technology.
• First-out annunciation and system diagnostics
provided by a 2 row by 20 column Vacuum
Fluorescent Display (VFD) located on the Keyboard
Display Module (Optional on CB784).
Application .....................................................................................
Features ..........................................................................................
Specifications ...............................................................................
Principal Technical Features ..................................................
Safety Provisions .........................................................................
Installation .....................................................................................
Wiring ............................................................................................... 10
Assembly ......................................................................................... 13
Operation ........................................................................................ 17
Static Checkout ............................................................................ 26
Troubleshooting ........................................................................... 26
SIL
3
Capable
Contents
1
2
2
6
6
7
32-00207-01
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Summary of Contents for CleaverBrooks CB780
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Page 1: Table Of Contents
Display Mounting, First-Out Expanded Annunciator or Principal Technical Features ..........Modbus™ Module. Safety Provisions ................. Installation ..................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. - Page 2 • On/Off status of all digital inputs and outputs. • Nonvolatile memory for retaining history files and • Selected prepurge time. sequencing status after loss of power. • Software revision and version of CB780/CB784 • Remote reset (optional). and Keyboard Display Module. • Report generation (optional).
- Page 3 120 Vac, 0.5A. 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.
- Page 4 **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.
- Page 5 FLAME MAIN ALARM RESET 5-1/4 (133) 5 (127) 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) 3-3/4...
- Page 6 Purge card is bad. Monitoring 3. PREPURGE Period 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.
- Page 7 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.
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Page 8: Installation
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. -
Page 9: Wiring
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. - Page 10 FIELD WIRING REMOTE LOW FIRE COMMUNICATIONS INTERNAL WIRING RESET PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M7420A 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...
- Page 11 8. Make sure loads do not exceed the terminal ratings. to the metal control panel with wire as short as Refer to the label on the CB780/CB784 or to the rat- practical. Each ground wire must be capable of ings in Specifications; see Table 1.
- Page 12 YELLOW BLUE ULTRAVIOLET FLAME DETECTOR WHITE FUEL VALVE WHITE BLACK BLACK 120V, 50/60 Hz POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M7408A DO NOT WIRE TO ANY UNUSED TERMINALS. Fig. 7. Wiring the CB780/CB784 Relay Module. 32-00207—01...
- Page 13 CB780/CB784 RELAY MODULES 833-2727 KEYBOARD DISPLAY MODULE (MOUNTED ON CB 780/CB 784 RELAY MODULE) MOMENTARY PUSH BUTTON SWITCH 832-1693 120 OHM RESISTOR 832-1693 13 VDC 120 OHM RESISTOR POWER SUPPLY (HOT) 833-2727 REMOTE KEYBOARD DISPLAY MODULE THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 120 OHM TERMINATING RESISTORS ARE REQUIRED FOR CONNECTIONS OVER 100 FEET.
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Page 14: Assembly
NOTE: For installation dimensions, see Fig. 1. 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. - Page 15 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.
- Page 16 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.
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Page 17: Operation
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. - Page 18 Establishing 1. The firing rate motor releases to modulation. Fault History Period (PFEP): 2. The CB780/CB784 is now in RUN and will remain in 1. With the firing RUN until the controller input, terminal 6, opens, M20283A rate motor at the...
- Page 19 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.
- Page 20 POWER, PILOT, FLAME, MAIN AND ALARM selectable—message 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...
- Page 21 CB780/CB784 RELAY MODULES 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.
- Page 22 CB780/CB784 RELAY MODULES SAVE SAVE SAVE SAVE M7403D M7402C Fig. 21. MODE pushbutton function. Fig. 20. Change Level pushbutton function. SAVE M7404C Fig. 22. SAVE function. 32-00207—01...
- Page 23 CB780/CB784 RELAY MODULES Table 5. Selectable Messages. Selectable Message Display Value First Line (Second Line) (Second Line) Message n.nV Flame Signal nnnnn Total Cycles nnnnn Total hours Fault History Fault Cycle nnnnn < H1 Fault Hours nnnnn < H1 nnn <...
- Page 24 Expanded Annun. (see Table 6) NONE/HOLD/HF/LF Remote Command 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.
- Page 25 EA Fault Code nnnn< Software Revision (SW Rev.) 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...
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Page 26: Static Checkout
After checking all wiring, perform this checkout before Number Description Intact Clipped installing the CB780/CB784 on the subbase. These tests verify the Wiring Subbase is wired correctly, and the Pilot Flame 10 seconds 4 seconds external controllers, limits, interlocks, actuators, valves,... - Page 27 CB780/CB784 RELAY MODULES Table 8. Static Checkout. Test Test Volt- If Operation is Abnormal, Check the 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.
- Page 28 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.
- Page 29 CB780/CB784 RELAY MODULES 4. Initial lightoff check for direct spark ignition of oil— Flame Signal Measurement (Table all burners using DSI. 9 and Fig. 25) 5. Pilot turndown test—all installations using a pilot. 6. Hot refractory saturation test—all installations using Measure the flame signal at the appropriate times as Infrared (lead sulfide) Flame Detectors.
- Page 30 CB780/CB784 RELAY MODULES 5. If the pilot flame is not established in ten seconds, safety shutdown occurs. Let the sequence complete its cycle. Consult the equipment operating manual POSITIVE (+) METER LEAD for further information. 6. Push the reset pushbutton, and let the system recy-...
- Page 31 CB780/CB784 RELAY MODULES 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.
- Page 32 (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 Hot Refractory Saturation Test (All point. The pilot is at the minimum turndown posi- tion.
- Page 33 Perform these tests at the end of Checkout, after all other Detectors) tests have been completed. If used, the external alarm should turn on. Press the CB780/CB784 reset pushbutton Test to make certain that the ignition spark is not to restart the system.
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Page 34: Troubleshooting
IMPORTANT: a. *Lockout ILK* fault will be displayed on the VFD. 1. If the CB780/CB784 fails to shut down on any of Fault code 11 or 12 or 21 or 29 will be displayed these tests, take corrective action; refer to to denote the fault. - Page 35 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.
- Page 36 CB780/CB784 RELAY MODULES Table 10. Hold and Fault Message Summary. (Continued) Fault Number Annunciation Message Fault 52-70 *Call Service* Fault 71-75 *Device Specific* Fault 76-93 *Accessory Fault* Fault 94-127 *Call Service* 1/8 in. DIA. (2) (3.175 mm) M5082C Fig. 26. Flush mounting of a Keyboard Display Module template.
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