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CleaverBrooks CB780E User Manual

CleaverBrooks CB780E
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INSTALLATION AND OPERATING INSTRUCTIONS
32-00150-03
CB Manual Part Number 750-234
CB780E/CB784E Relay Modules
with Valve Proving
APPLICATION
The Cleaver-Brooks CB780E/CB784E (833-03517/833-
03518) is a microprocessor based integrated burner
control for automatically fired gas, oil, or combination fuel
single burner applications. The CB780E consists of a
Relay Module and Keyboard Display Module. The CB784E
consists of the Relay Module only. A subbase, Amplifier,
and Purge Card are required to complete the system.
Options include: DATA CONTROLBUS MODULE™, Remote
Display Mounting, First-Out Expanded Annunciator and
Computer Interface using Modbus™ network.
The CB780E/CB784E is programmed to provide a level of
safety, functional capability, and features beyond the
capacity of conventional controls.
Functions provided by the CB780E/CB784E include
automatic burner sequencing, flame supervision, system
status indication, system or self-diagnostics, and
troubleshooting.
The CB780E/CB784E offer the Valve Proving test feature.
Using the 833-2727 Keyboard Display (standard on the
CB780E), the following features can be set-up:
Post Purge time—Up to 60 minutes—Device shipped
with 15 seconds Post purge
Valve Proving features include:
—VPS test time
When (Never, Before, After, Split or Both)
A new 4-line LCD display option S78000A1092/U is
available to be purchased separately. Reference document
32-00154 for more information.
See the 833-2727 Instructions (750-248) for its features.
Series 5 can be programmed for ModBus communication.
At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times:
Never—Device default as received—Valve proving
does not occur.
Before—Valve proving before run concurrent with
Pre-Purge.
After—Valve proving occurs after the Run state,
before the device goes to Standby (Concurrent with
Post-Purge, if selected.)
Both—Valve proving occurs at both times Before and
After, noted above.
Split—The main valve 2 (MV2) (high pressure) seat
test is performed at the Before time and the main
valve 1 (MV1) (low pressure) seat test is performed
during the After time.
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CleaverBrooks CB780E Specifications

General IconGeneral
ModelCB780E
Input Voltage120/240 VAC
Frequency50/60 Hz
DisplayLCD
ManufacturerCleaver-Brooks
Operating Temperature0 to 50°C (32 to 122°F)
Communication ProtocolModbus

Summary

INSTALLATION AND OPERATING INSTRUCTIONS

APPLICATION

Microprocessor-based integrated burner control for automatically fired gas, oil, or combination fuel...

Valve Proving Scheduling

Valve Proving System can be scheduled to occur at one of five different times: Never, Before, After, Both, Split.

FEATURES

Safety Features

Includes safety interlock, closed loop logic test, dynamic AMPLI-CHECK™, dynamic input check, etc.

Other Features

Covers voltage checks, communication, reliability, and diagnostics via VFD display.

SPECIFICATIONS

Electrical Ratings

Details voltage, frequency, power dissipation, and fusing requirements.

PRINCIPAL TECHNICAL FEATURES

Safety Shutdown (Lockout) Occurs

Details conditions under which safety shutdown occurs during various operational periods.

SAFETY PROVISIONS

Internal Hardware Status Monitoring

Checks purge card integrity, configuration jumpers, and internal hardware. POWER LED blinks for checks.

Closed Loop Logic Test

Verifies safety critical loads and terminal energization, preventing nuisance shutdowns.

Dynamic Checks

Includes Ampli-Check, flame amplifier, input, safety relay, self-check, safe-start, and switch tests.

First-Out Annunciation and Self-Diagnostics

Sequence Status Lights (LEDs)

LEDs provide visual indication of program sequence: POWER, PILOT, FLAME, MAIN, ALARM.

Keyboard Display Module Functionality

Shows sequence timing, diagnostics, historical info, and annunciator info for troubleshooting.

Annunciation and Diagnostics Features

Reports shutdown causes and distinguishes between field and internal system problems.

Interlock Requirements

Defines Low Fire, High Fire, and Lockout Interlock functions and requirements.

INSTALLATION

Preignition Interlock

Input typically connected to proof-of-closure switches; must be energized throughout PREPURGE.

Humidity and Vibration Precautions

Covers environmental limits for humidity (max 85% RH) and vibration (max 0.5G).

Weather Protection

Device is not weather tight; requires protection for outdoor installation.

Mounting Wiring Subbase

Instructions for mounting the wiring subbase, avoiding horizontal orientation with contacts down.

WIRING

Wiring Procedures and Compliance

Covers subbase/remote wiring, power disconnection, code compliance, and wire selection.

ASSEMBLY

Relay Module Mounting

Mount vertically or horizontally in an electrical enclosure, allowing clearance for components.

Mounting Modules

Mounting Keyboard Display Module

Align interlocking ears, insert, and push to secure module to the relay module.

Mounting Data ControlBus™ Module

Align interlocking ears, insert, and push to secure module to the relay module.

Remote Mounting of Keyboard Display Module

Mount on panel door or remote locations, following instructions for clearance and drilling.

Installing Plug-In Flame Signal Amplifier

Installing the Flame Detector

VALVE PROVING SYSTEM

Valve Proving System Function

Tests valve seat integrity to detect leaks >0.1% of burner capacity.

Valve Proving Scheduling Options

System can be scheduled for Never, Before, After, Both, and Split at commissioning.

Valve Proving Test Setup Items

Specify when to perform, and the time duration for the Valve Proving test.

Typical Valve Proving System Function

Valve Proving Sequence Description

Monitors pressure between shutoff valves (MV1, MV2) to detect leaks, operating via sequence A-F.

Pressure Switches for Valve Proving System

Pressure Switch Selection

Guides selection of Honeywell pressure switches based on operating range and pressure.

Pressure Switch Installation and Adjustment

Refer to instructions for installation and adjustment of C6097A Pressure Switch.

Setup (Programming) of Valve Proving Function

SETUP: Valve Prove screen

Sets up when Valve Proving test occurs: Never, Before, After, Both, or Split.

SETUP: Valve Prove time screen

Sets up the duration for the Valve Proving Test.

Setting Postpurge time

Confirmation Acknowledgement screen

Confirm screen

Confirm Correct screen

Setup Done screen

SETTINGS AND ADJUSTMENTS

Selectable Site-Configurable Jumpers

Details three jumper options (JR1, JR2, JR3) for configuring pilot flame, DSI, and interlock checks.

Equipment Recommended

Lists recommended equipment for static checkout, including voltmeter and jumper wires.

General Instructions

Provides general guidelines for performing static checkout tests.

OPERATION

Sequence of Operation

Describes the burner sequence: Initiate, Standby, Pre-Purge, Ignition Trials, Run, Postpurge.

Initiate Sequence

Sequence starts upon power-up; lasts ten seconds unless voltage/frequency tolerances are not met.

Standby State

Control is ready to start sequence when operating control determines a call for heat.

Pre-Purge Sequence

Purge timers provide selectable timings; blower motor starts, firing rate motor drives to high fire.

Ignition Trials

Covers pilot flame and main flame establishment, including VP and DSI systems.

Run Period

Postpurge Period

KEYBOARD DISPLAY MODULE (KDM)

Keyboard Functions

Arrow Push-buttons

Used to scroll through selectable messages; wraps around when end is reached.

tu push-button Function

Changes selectable message levels, from main to subset or vice-versa.

BACK push-button Function

Switches display from second-line selectable to preempted/lockout message.

SAVE push-button Function

Save Display/Exit screen

Run/Test Switch Functions

CHECKOUT

Equipment Recommended

Lists recommended equipment for static checkout, including voltmeter and jumper wires.

Checkout Summary

Lists various tests to perform, including preliminary inspection, flame signal, lightoff, and safety shutdown.

Preliminary Inspection

Flame Signal Measurement

Initial Lightoff Check for Proved Pilot

Initial Lightoff Check for Direct Spark Ignition

Pilot Turndown Test (All Installations Using a Pilot)

Infrared Detector Tests

Hot Refractory Hold-in Test

Tests if hot refractory masks flame signal; corrects issue by adjusting detector sighting or orifice.

Ultraviolet Sensor and Spark Ignition Test

Ensures ignition spark does not actuate FLAME LED; checks signal is <0.5 Vdc.

Response to Other Sources

Checks detector response to artificial light and tests Flame Failure Response Time (FFRT).

Flame Signal with Hot Chamber

Measures flame signal at max temperature; checks signal stability and response.

Safety Shutdown Tests

Performs tests after checkout to ensure safety shutdown functions correctly.

Safety Shutdown Procedures

Preignition Interlock Opening

Checks fault code and shutdown on Preignition Interlock opening during STANDBY or PREPURGE.

Lockout Interlock Opening

Checks fault code and shutdown on Lockout Interlock opening during PREPURGE, PILOT IGN, MAIN IGN or RUN.

Flame Detection Issues

Covers issues like premature flame detection, pilot/main ignition failure, and loss of flame during RUN.

Failure to Ignite Pilot

Checks fault code and safety shutdown if pilot fails to ignite.

Failure to Ignite Main

Checks fault code and safety shutdown if main burner fails to ignite.

Post-Purge Interlock Opening

Checks fault code and shutdown on Preignition Interlock opening after POSTPURGE starts.

TROUBLESHOOTING

Blinking Fault Codes

Identifies faults via Power LED blink codes and provides troubleshooting steps.

SAFETY AND SECURITY

Physical Device Protection

Recommends securing the device in an enclosed cabinet and protecting wiring.

CB780/ECB784E System Diagnostics

Diagnostic Information Index

Index of diagnostic information available on KDM, including terminal status, device type, and software revision.

Historical Information Index

Nonvolatile memory retains historical data for six most recent lockouts, including fault details.

APPENDIX A

Valve Proving Test

Provides a systematic way to test valve seat integrity to ensure valves are closed when system is offline.

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