CleaverBrooks CB780E User manual

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:
—VPStesttime
— 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.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 2 750-234
The following assumptions apply when using the
CB780E/CB784E:
Fig. 1. The valve proving system.
MV1—Wired to terminal 9. It is located in the most
upstream position of the main gas valve train.
VPS—Valve Proving Switch: Setpoint at 1/2 of Main Valve
inlet pressure.
MV2—Wired to terminal 21. It is the main valve located
closest to the burner.
The PII—Pre-Ignition Interlock (or Proof of Closure Switch)
for terminal 20 can be installed on MV1, MV2, or as a
series connection through both valves.
FEATURES
• Safety features:
—Safetyinterlock.
— 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 capability.
• 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.
• First-out expanded annunciation with 26 Light
Emitting Diodes (LEDs) for limits and interlocks
(optional).
• Five function Run/Test Switch.
• Interchangeable plug-in flame amplifiers.
• Local or remote annunciation of operation and fault
information.
• Nonvolatile memory for retaining history files and
sequencing status after loss of power.
• Remote reset (optional).
• Report generation (optional).
• Five sequence information LEDs
• Burner controller data:
— Sequence status.
— Sequence time.
— Hold status.
— Lockout/alarm status.
— Flame signal strength.
— Expanded annunciation status.
— Total cycles of operation.
— Total hours of operation.
— Fault history of six most recent faults:
• Cycles of operation at time of fault.
• Expanded annunciator data at time of fault.
• Fault message and code.
• Hours of operation at time of fault.
• Sequence status at time of fault.
• Sequence time at time of fault.
— Diagnostic information:
• Device type.
• Flame amplifier type.
• Flame failure response time.
• Manufacturing code.
• On/Off status of all digital inputs and outputs.
• Selected prepurge time.
• Software revision and version of CB780E/CB784E and
Keyboard Display Module.
• Status of configuration jumpers.
• Status of Run/Test Switch.
SPECIFICATIONS
Electrical Ratings (see Table 1):
Voltage and Frequency: 120 Vac (+10/-15%), 50 or 60 Hz
(±10%).
Keyboard Display Module: 13 Vdc peak full wave rectified
(+20/-15%).
Power Dissipation:
CB780E/CB784E: 10W maximum.
Display Module: 3W maximum.
Maximum Total Connected Load: 2000 VA.
Fusing: 15A maximum, Type SC or equivalent—fast blow.
MV1 MV2
VP
SW.
M24788A
OUTLET
INLET
1CAUTION: VALVE ENERGIZING TIMING IS BASED ON VALVE
OPENING TIMES OF 13 SECONDS MAXIMUM.
− FOR VALVES WITH TIMINGS GREATER THAN 13
SECONDS OR THOSE THAT DO NOT OPEN THE ACTIVE
VALVE WITHIN THE ENERGIZED TIME, A SAFETY SHUTOFF
SOLENOID VALVE (1/4”, 120 VAC) IS REQUIRED TO
OBTAIN THE PROPER TEST PRESSURES.
− THE VALVE WILL BE WIRED IN PARALLEL TO THE
VALVE IT IS BYPASSING (TERMINAL 9 FOR MV1 OR
TERMINAL 21 FOR MV2).
1

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 332-00150—03
aThe relay module must have a good 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 relay module requires a low impedance ground connection to the equipment
frame, which, in turn, requires a low impedance connection to earth ground.
b2000 VA maximum connected load to relay module assembly.
cSee Table 2 and 3.
Table 1. Terminal Ratings.
Terminal No. Description Ratings (120 Vac)
GFlame Sensor Grounda—
Earth G Earth Ground —
L2(N) Line Voltage Common —
3 Alarm 1A pilot duty
120 Vac (+10%/-15%),
50 or 60 Hz (±10%).
4Line Voltage Supply (L1)b
5 Burner Motor 9.8AFL, 58.ALR (inrush)
6 Burner Controller and Limits Demand (Not Valve Proving) 1 mA.
7 Lockout/Running Interlock 8A run, 43A inrush 8A run, 43A inrush
8 Pilot Valve/Ignition c
9MainFuelValve c
10 Ignition c
F(11) Flame Sensor 60 to 220 Vac, current limited
12 Firing Rate High Fire 75VA pilot duty
13 Firing Rate Common 75VA pilot duty
14 Firing Rate Low Fire 75VA pilot duty
15 Firing Rate Modulate 75VA pilot duty
16 Valve Proving Switch 1 mA
17 Demand—Valve Proving 1 mA
18 Low Fire Switch Input 1 mA
19 High Fire Switch Input (7800/40L only) 1 mA
20 Pre-Ignition Interlock Input 1 mA
21 Interrupted First Stage Oil Valve or MV2 c
22 Shutter 0.5A
Table 2. Combinations for Terminals 8, 9, 10, and 21.
Combination No. Pilot Fuel # Main 9 Ignition 10 Valve 21
1 C F No load No load
2 B F No load No load
3 No load F No load B
4F F A Noload
5NoloadF A F
6D F A Noload
7NoloadD A D
8D D A Noload
9NoloadD A D

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 4 750-234
aJR2 intact - Direct Spark
bED - Pilot System
Environmental Ratings:
Ambient Temperature:
Operating: -40°F to +140°F (-40°C to +60°C).
Storage: -40°F to +150°F (-40°C to +66°C).
Humidity: 85% RH continuous, noncondensing.
Vibration: 0.5G environment.
Dimensions:
Refer to Fig. 2 and 3.
Weight:
CB780E/CB784E: 1 pound 10 ounces, unpacked.
Keyboard Display Module: 4 ounces, unpacked.
IMPORTANT:
Flame Detection System available for use with
CB780E/CB784E. To select your Plug-in Flame
Signal Amplifier and matching Flame Detector, see
Table 5.
aCircuitry tests the flame signal amplifier 12 times a minute during burner operation and shuts down the burner if the
amplifier fails.
bThe 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 833-2741 Amplifier as the ultraviolet flame detection system.
cCircuitry 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.
SIL 3 Capable:
SIL 3 Capable in a properly designed Safety Instrumented
System. See form 65-0312 for Certificate Agreement.
Table 3. Explanation of Each Combination
AB C D E
4.5A ignition 50 VA Pilot Dutyaplus
4.5A ignition.
180 VA ignition plus
motor valve with:
660 VA inrush, 360 VA,
open, 260 VA hold.
2A Pilot Duty.a64 VA Pilot Duty.aplus
motor valves with: 3850 VA
inrush, 700 VA open, 250
VA hold.
Table 4. Valve Proving Combinations.
Pilot
Valve
Main
Valve 1 Ignition
Main
Valve 2
Combinatio
n
Terminal
8
Terminal
9
Terminal
10
Terminal
21
10a-- D A D
11 -- D A F
12 -- F A D
13 -- F A F
14bCD--D
15 C D -- F
16 C F -- D
17 C F -- F
18 B D -- D
19 B D -- F
20 B F -- D
21 B F -- F
22 DDA D
23 DDA F
24 D F A D
25 D F A F
Table 5. Flame Detection Systems (Fig. 4, 5, 6)
Plug-In Flame Amplifiers Applicable Flame Detectors
Type Color Self-Checking Part Number
Flame Failure
Response
Time Fuel Type Part Number
Infrared Red/Whi
te
No 833-3495 3 sec. Gas, oil, coal Infrared
(Lead Sulfide)
817-4133
Dynamic
AMPLI-CHECK™833-3496a
Ultraviolet Purple No 833-2724 Gas, oil Ultraviolet 817-1743b
Ultraviolet
Self-Check
Green Dynamic
Self-Check 833-2741cGas, oil, coal Ultraviolet
(Purple Peeper®)
817-1121

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 532-00150—03
Approvals:
Underwriters Laboratory, Inc., listed, File No. MP268,
Guide No. MCCZ.
Swiss Re (formerly IRI): acceptable.
Federal Communications Commission, Part 15,
Class B—Emissions
Factory Mutual Approved: Report No. 1V9A0.AF
To view certificates reference:
RM7800L1095 = CB780E = 833-03517
RM7840L1083 = CB784E = 833-03518
Required Components:
CB780E: 120 Vac, 50/60 Hz, 833-03517.
CB784E: 120 Vac, 50/60 Hz, 833-03518.
Wiring Subbase 833-2725
Plug-in Flame Signal Amplifier: see Table 5.
Plug-in Purge Timer Cards: selectable:
833-2730—30 sec.
833-2731—60 sec.
833-2732—90 sec.
833-2733—2 1/2 min.
NOTE: The CB780E and CB784E are identical, except for
the Keyboard Display Module, which is standard
with the CB780E and optional with the CB784E.
A 4-line LCD display option S78000A1092/U is
available to be purchased separately. Reference
document 32-00154 for more information.
Accessories:
Optional:
DATA CONTROLBUS MODULE—part no. 833-2729.Pro-
vides remote reset capabilities on CB780E; remote dis-
play capabilities on CB780E and CB784E.
CB783 Expanded Annunciator—part no. 833-2726.
Keyboard Display Module—part no. 833-2727.
Remote Mounting Kit for the Keyboard Display, NEMA 4—
part no. 833-2740.
Tester—part no. 626-5050.
833-2820 Modbus Module.
Fig. 2. Mounting dimensions of CB780E/CB784E Relay Module and 833-2725 Subbase, in inches (mm).
BURNER CONTROL
POWER
PILOT
FLAME
MAIN
ALARM
RESET
5
(127)
5 (127)
M28590B
REMOVE ONLY FOR TERMINAL TEST ACCESS.
1
1
5-1/4 (133)
BACK
ENTER
Edit: -+

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 6 750-234
Fig. 3. Mounting dimensions of Keyboard
Display Module, in inches (mm).
Fig. 4. Ultraviolet Self-Check detector, mounting
dimensions in inches (mm).
Fig. 5. Ultraviolet detector, mounting
dimensions in inches (mm).
Fig. 6. Infrared detector, mounting dimensions
in inches (mm).
PRINCIPAL TECHNICAL
FEATURES
The CB780E/CB784E provides all customary flame
safeguard functions while providing significant
advancements in the areas of safety, annunciation and
system diagnostics.
Safety Shutdown (Lockout) Occurs
If Any of the Following Occur
During the Indicated Period:
1. Anytime:
a. Purge card is not installed or removed.
b. Purge card is bad.
c. Configuration jumpers were changed (after 200
hours of main valve operation).
d. Internal system fault.
e. Demand present at terminals 6 and 17 at the
same time.
f. Failure of the Valve Proving test
g. Demand on terminal 17 and device at default
“Never”.
2. INITIATE Period
a. AC line power errors occurred. See Operation
section.
b. Four minute INITIATE period has been exceeded.
3. STANDBY Period
a. Flame signal is present after 240 seconds.
b. Pre-Ignition Interlock is open an accumulative
time of 30 seconds.
c. Interlock check feature is enabled (only with JR3
clipped) and the Interlock String (including the
airflow switch) is closed for 120 seconds with
controller closed.
d. Ignition/pilot valve terminal is energized.
e. Main valve terminal is energized.
f. Internal system fault occurred.
4. PREPURGE Period
a. Pre-Ignition Interlock opens anytime during
PREPURGE period (except during Valve Proving
test).
b. Flame signal is detected after first ten seconds
during PREPURGE.
M28591B
2-1/32
(5 2 )
BURNER CONTROL
29/32
(23)
19/32
(15)
1-1/4
(32)
1-1/32
(26)
5/32
(4)
5/16
(8)
1/2
(13)
7/16 (11)
1-5/16
(49) 2-7/16 (62)
29/32
(23)
5/32 (4)
15/32
(12) 3-7/8 (99)
5/16
(8)
13/
32
(11)
BACK
ENTER
Edit: -+
4-27/32 (123)
4-3/32 (104)
2-3/4
(69)
MOUNTING FLANGE
1/2- 14 NPSM
LEADWIRES FACEPLATE
3/4Ð14 NPT
M20935A
3-3/4
(95)
7-7/32
(183)
5-1/8 (130)
3-7/16
(87)
5-1/4 (133)
817-1121
COLLAR WITH 1/2-14 NPSM
INTERNAL THREADS
4 (102) 6 FOOT (1.83 METER)
LEADWIRES (2)
M20937A
3-1/2 (89)
1-1/16
(27)
817-1743
APERTURE
BUSHING WITH
MAGNIFYING LENS COLLAR, 3/4-14 NPSM
INTERNAL THREADS
3/4-14
NPSM
3/4-14 NPSM
INTERNAL
THREADS
HEAT BLOCKCELL MOUNT
M23944A
2 LEADS IN A
48 INCH (1.2 METER)
FLEXIBLE CONDUIT
2-3/4
(70)
1-1/4
(32)
1-5/8 (41)
1-1/16 (27)
1-1/4
(32)
817-1742
817-4133 IS 2-1/4 (58).
1
1

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 732-00150—03
c. High Fire Switch fails to close within four min-
utes, and fifteen seconds after firing rate motor
is commanded to drive to high fire position at
start of PREPURGE.
d. Low Fire Switch fails to close within four minutes,
and fifteen seconds after firing rate motor is
commanded to drive to low fire position at end of
PREPURGE.
e. Lockout Interlock does not close within 10 sec-
onds.
f. Lockout Interlock opens during PREPURGE.
g. Ignition/pilot valve terminal is energized.
h. Main valve terminal is energized (except during
Value Proving testing).
i. Internal system fault.
5. PILOT FLAME ESTABLISHING Period (PFEP)
a. Low Fire Switch opens.
b. Lockout Interlock opens.
c. Ignition/pilot valve terminal is not energized.
d. Early Spark Termination terminal is energized
after five seconds.
e. No flame is present at end of PFEP.
6. MAIN FLAME ESTABLISHING Period (MFEP)
a. Low Fire Switch opens.
b. Lockout Interlock opens.
c. Ignition/pilot valve terminal is not energized.
d. Main valve terminal is not energized.
e. No flame is present at end of MFEP.
7. RUN Period
a. No flame is present.
b. Lockout Interlock opens.
c. Interrupted pilot valve terminal is energized.
d. Main valve terminal is not energized.
8. POSTPURGE Period
a. Pre-Ignition Interlock does not close in five sec-
onds and opens after five-second time period
(except
during Value Proving testing).
b. Ignition/pilot valve terminal is energized.
c. Main valve terminal is energized (except during
Valve Proving testing)
SAFETY PROVISIONS
Internal Hardware Status
Monitoring
The CB780E/CB784E checks the purge card for correct
parity to prevent purge timing shifts and circuitry failures.
It also analyzes the integrity of the configuration jumpers
and internal hardware. The POWER LED blinks every four
seconds, signifying an internal hardware check.
Closed Loop Logic Test
The test verifies the integrity of all safety critical loads,
terminals 8, 9, 10 and 21. If the loads are not energized
properly; i.e., the main valve terminal is powered during
PREPURGE, the CB780E/CB784E will lockout on safety
shutdown. The CB780E/CB784E must react to input
changes but avoid the occurrence of nuisance shutdown
events. Signal conditioning is applied to line voltage
inputs to verify proper operation in the presence of normal
electrical line noise such as transient high voltage spikes
or short periods of line dropout. Signal conditioning is
tolerant of synchronous noise (line noise events that occur
at the same time during each line cycle).
Dynamic Ampli-Check™
Dynamic AMPLI-CHECK™ circuitry tests the flame signal
amplifier during burner operation and shuts down the
CB780E/CB784E if the flame amplifier fails.
Dynamic Flame Amplifier and
Shutter Check
Self-checking circuitry tests all electronic components in
the flame detection system and amplifier 10 to 12 times
per minute and shuts down the CB780E/CB784E if the
detection system fails.
Dynamic Input Check
All system input circuits are examined to verify that the
CB780E/CB784E is capable of recognizing the true status
of external controls, limits and interlocks. If any input fails
this test, a safety shutdown occurs and the fault is
annunciated.
Dynamic Safety Relay Test
Checks the ability of the dynamic safety relay contacts to
open and close. It also verifies that the safety critical loads,
terminals 8, 9, 10 and 21, can be de-energized, as
required, by the Dynamic Self-Check logic.
Dynamic Self-Check Safety Circuit
The microcomputer tests itself and related hardware while
at the same time the safety relay system tests the
microcomputer operation. If a microcomputer or safety
relay failure occurs and does not allow proper execution of
the self-check routine, safety shutdown will occur and all
safety critical loads will be de-energized.
Expanded Safe-Start Check
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 interlock check, an interlock check, and a
safety critical load check.
High Fire Purge and Low Fire Start
Switch Tests
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
bypassed, welded or otherwise closed prematurely, the
system will automatically add 30 seconds to allow
additional drive time for the firing rate motor to reach or
near the open position before starting the purge timing;
otherwise, purge timing starts when the High Fire Switch
is closed. This switch will also cause a hold (four minutes,
fifteen seconds) condition when the switch is open before

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 8 750-234
purge or opens during purge. The CB780E/CB784E will
lockout and annunciate an alarm if the switch fails to
close within the hold time period.
Low Fire Start Switch Test examines the Low Fire Start
Switch at the moment PREPURGE is completed. If the
switch is bypassed, welded or otherwise prematurely
closed, the system automatically adds 30 seconds to allow
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
test also is used to prove that the firing rate motor is at low
fire position throughout the ignition trial period. This
switch will also cause a hold (four minutes, fifteen
seconds) condition if the switch opens after purging is
complete. The CB780E/CB784E will lockout and
annunciate an alarm if the switch fails to close within the
hold time period.
Mandatory Purge
If lockout occurs after the initiation of ignition trials, (or at
anytime during a sequence when the fuel valves may have
been energized), a mandatory POSTPURGE period is
imposed.
Off Cycle (STANDBY or PREPURGE)
Flame Signal Check
The flame detection subsystem (flame detector and
amplifier) is monitored during STANDBY. If a flame
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
safety shutdown will occur and be annunciated. A shutter-
check amplifier and self-checking detector are energized
for the first 40 seconds during STANDBY and the last two
seconds before exiting STANDBY. If a flame exists, a safety
shutdown occurs. An AMPLI-CHECK™ Amplifier is
energized continually through STANDBY and PREPURGE
to detect any possibility of a runaway detector or a flame. If
either situation happens, a safety shutdown occurs. A
standard amplifier is energized continually through
STANDBY and PREPURGE. If either situation happens, a
safety shutdown occurs.
Preignition Output Circuit Check
At the end of PREPURGE, the Dynamic Safety Relay
operation is checked. Also, all safety critical loads,
terminals 8, 9, 10 and 21 are checked to verify the
terminals are not powered. If the Dynamic Safety Relay
operation is faulty, or if any of the safety critical loads are
powered, safety shutdown occurs and is annunciated.
Tamper-Resistant Timing and Logic
Safety and logic timings are inaccessible and cannot be
altered or defeated.
Verified Spark Termination
The ignition terminal is monitored to verify early spark
termination (five seconds ignition and pilot and five
seconds pilot only).
First-Out Annunciation and Self-
Diagnostics
Sequence Status Lights (LEDs) provide positive visual
indication of the program sequence: POWER, PILOT,
FLAME, MAIN and ALARM. The green POWER LED blinks
every four seconds to signify the CB780E/CB784E
hardware is running correctly.
Multi-function Keyboard Display Module (standard with
CB780E, optional with CB784E) shows elapsed time
during PREPURGE, PILOT IGN, MAIN IGN, and
POSTPURGE. As an additional troubleshooting aid, it
provides sequence timing, diagnostic information,
historical information and expanded annunciator
information when a safety shutdown or hold or normal
operation occurs.
First-out Annunciation reports the cause of a safety
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
Signal Amplifier and Firing Rate Position Switches. The
system distinguishes 118 modes of failure and detects
and annunciates difficult-to-find intermittent failures.
Self-Diagnostics adds to the First-out Annunciation by
allowing the CB780E/CB784E to distinguish between
field (external device) and internal (system related)
problems. Faults associated within the flame detection
subsystem, CB780E/CB784E or plug-in Purge Card, are
isolated and reported by the Keyboard Display Module,
see Troubleshooting section and CB780E/CB784E
System Annunciation Diagnostics and Troubleshooting,
Bulletin Number CB-7803.
Interlock Requirements
The following interlock inputs are provided:
Low Fire Interlock
This interlock verifies the firing rate motor is in the low fire
position before and during ignition trials.
High Fire Interlock
This interlock verifies the firing rate motor is in the high
fire position prior to and during PREPURGE.
Lockout Interlock
This interlock (ILK) input signifies a Lockout Interlock. If
the Lockout Interlock is open for more than ten seconds
into PREPURGE, the CB780E/CB784E will lockout. After
entering PREPURGE, if the Lockout Interlock opens
during the first ten seconds, the purge timer will be reset.
This provides a continuous PURGE to occur without
interruption before the Pilot Flame Establishing Period. If
a Lockout Interlock opens anytime after ten seconds into
PURGE, during the Ignition Trials or Run, it causes a
lockout.
A typical Lockout Interlock string contains an airflow
switch (see Fig. 8). The Interlock Check is a site
configurable option (see Table 7). If this feature is enabled,
the CB780E/CB784E will lockout after 120 seconds

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 932-00150—03
whenever control terminal 6 is energized, and the Lockout
Interlock string (including airflow switch) is closed during
STANDBY.
Preignition Interlock
The Preignition Interlock input is typically connected to
proof-of-closure switches for fuel valve(s). The Preignition
Interlock must be energized throughout PREPURGE. If the
Preignition Interlock opens during STANDBY, it causes a
hold (30 seconds). The CB780E/CB784E will lockout if the
interlock does not close within 30 seconds during
STANDBY. If the Preignition Interlock opens during
PREPURGE, it will lockout. If the Preignition Interlock is
open after five seconds into POSTPURGE, the
CB780E/CB784E will lockout. The Preignition Interlock is
ignored during the ignition trials state and during RUN.
INSTALLATION
WARNING
Fire or Explosion Hazard.
Can cause severe injury, death or property
damage.
To prevent possible hazardous burner operation,
verification of safety requirements must be
performed each time a control is installed on a
burner.
When Installing This Product…
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazard-
ous condition.
2. Check the ratings given in the instructions and
marked on the product to make sure the product is
suitable for the application.
3. Installer must be a trained, experienced, flame safe-
guard technician.
4. After installation is complete, check out the product
operation as provided in these instructions.
WARNING
Electrical Shock Hazard.
Can cause severe injury, death or property
damage.
Disconnect the power supply before beginning
installation to prevent electrical shock, equipment
and control damage. More than one power supply
disconnect may be involved.
Wiring Information
1. Wiring connections for the CB780E/CB784E are
unique; therefore, refer to Fig. 7–12 or the correct
Specifications for proper subbase wiring.
2. Wiring must comply with all applicable codes, ordi-
nances and regulations.
3. Wiring, where required, must comply with NEC Class
1 (Line Voltage) wiring.
4. Loads connected to the CB780E/CB784E must not
exceed those listed on the CB780E/CB784E label or
the Specifications, see Table 1.
5. Limits and interlocks must be rated to simultane-
ously carry and break current to the ignition trans-
former, pilot valve, and main fuel valve(s).
6. All external timers must be listed or component rec-
ognized by authorities who have jurisdiction for the
specific purpose for which they are used.
IMPORTANT:
1. For on-off gas-fired systems, some authorities
who have jurisdiction prohibit the wiring of any
limit or operating contacts in series between the
flame
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).
3. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and
used in accordance with the instructions, may
cause interference to radio communications. It
has been tested and found to comply with the lim-
its for a Class B computing device of Part 15 of
FCC rules which are designed to provide reason-
able protection against such interference when
operated in a commercial environment. Operation
of this equipment in a residential area may cause
interference; in which case, the users at their own
expense may be required to take whatever mea-
sures are required to correct this interference.
4. This digital apparatus does not exceed the Class B
limits for radio noise for digital apparatus set out
in the Radio Interference Regulations of the Cana-
dian Department of Communications.
Humidity
Install the CB780E/CB784E where the relative humidity
never reaches the saturation point. The CB780E/CB784E
is designed to operate in a maximum 85% RH continuous,
noncondensing, moisture environment. Condensing
moisture may cause a safety shutdown.
Vibration
Do not install the CB780E/CB784E where it could be
subjected to vibration in excess of 0.5G continuous
maximum vibration.
Weather
The CB780E/CB784E is not designed to be weather tight.
If installed outdoors, the CB780E/CB784E must be
protected by an approved weather-tight enclosure.
Mounting Wiring Subbase
NOTE: For installation dimensions, see Fig. 2.
1. Mount the subbase in any position except horizon-
tally with the bifurcated contacts pointing down. The
standard vertical position is recommended. Any
other position decreases the maximum ambient
temperature rating.
2. The 833-2725 Wiring Subbase can be mounted
directly in the control cabinet. Be sure to allow ade-
quate clearance for servicing, installation, access or

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 10 750-234
removal of the CB780E/CB784E, Expanded Annun-
ciator, Keyboard Display Module, flame amplifier,
flame amplifier signal voltage probes, Run/Test
Switch, electrical signal voltage probes and electri-
cal field connections.
3. For surface mounting, use the back of the subbase
as a template to mark the four screw locations. Drill
the pilot holes.
4. Securely mount the subbase using four no. 6 screws.
WIRING
1. Proper Wiring:
a. For proper subbase wiring, refer to Fig. 8.
b. For proper remote wiring of the Keyboard Display
Module, refer to Fig. 11 or Fig. 12 to the Specifi-
cations for the Keyboard Display Module, Com-
munication Interface Base Unit or DATA
CONTROLBUS MODULE™.
2. Disconnect the power supply from the main discon-
nect before beginning installation to prevent electri-
cal shock and equipment damage. More than one
disconnect may be involved.
3. All wiring must comply with all applicable electrical
codes, ordinances and regulations. Wiring, where
required, must comply with NEC, Class 1 (Line Volt-
age) wiring.
4. Recommended wire size and type:
a. All Line Voltage terminals use no. 14 or 16 cop-
per conductor (90°C or higher) 600 volt insula-
tion wire size must be coordinated with fuse
protection). For high temperature installations,
use wire selected for a temperature rating above
the maximum operating temperature. All lead-
wires should be moisture resistant.
WARNING
Keyboard Display Module and/or Data Controlbus
Module is powered from internally fused low
voltage source and shares the voltage supply with
Relay Module. The fuse is non-replaceable.
Excessive current draw or short at display
connection may cause fuse to blow out resulting in
dead, unpowered system.
WARNING
b. Keyboard Display Module—For communications
purposes, use an unshielded 22 AWG 2-wire
twisted cable and one wire for ground if the lead-
wire run and noise conditions permit; however,
some installations may need up to five wires,
three for communications and two for remote
reset (in either a single cable or separate cables
for communications or remote reset) or use
Belden 8771 shielded cable or equivalent. The
Keyboard Display Module, DATA CONTROLBUS
MODULE™ (for remote mounting or communica-
tions) or Communication Interface ControlBus
Module must be wired in a daisy chain configu-
ration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order
of interconnection of all the devices listed above
is not important. Be aware that modules on the
closest and farthest end of the daisy chain con-
figuration string require a 120 ohm (1/4 watt
minimum) resistor termination across terminals
1 and 2 of the electrical connectors, for connec-
tions over 100 feet, see Fig. 11–13.
c. DATA CONTROLBUS MODULE™—For communi-
cations purposes, use an unshielded 22 AWG 2-
wire twisted cable if the leadwire run and noise
conditions permit; however, some installations
may need up to five wires, three for communica-
tions and two for remote reset (in either a single
cable or separate cables) or use a Belden 8771
shielded cable or equivalent. The Keyboard Dis-
play Module, DATA CONTROLBUS MODULE™
(for remote mounting or communications) or
Communication Interface ControlBus Module
must be wired in a daisy chain configuration,
(1(a)-1(a), 2(b)-2(b),
3(c)-3(c)). The order of interconnection of all the
devices listed above is not important. Be aware
that modules on the closest and farthest end of
the daisy chain configuration string require a
120 ohm (1/4 watt minimum) resistor termina-
tion across terminals 1 and 2 of electrical con-
nectors, for connections over 100 feet, see Fig.
11–13.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 11 32-00150—03
Fig. 7. Internal block diagram of the CB780E/CB784E (see Fig. 8–13 for detailed wiring instructions).
d. Remote Reset—Use no. 22 AWG or greater
twisted pair wire, insulated for low voltage; see
Fig. 11–13.
e. Communication Interface ControlBus Module—
For communications purposes, use an
unshielded 22 AWG 2-wire twisted cable if the
leadwire run and noise conditions permit or use a
Belden 8771 shielded cable or equivalent. The
Keyboard Display Module, DATA CONTROLBUS
MODULE™ (for remote mounting or communica-
tions) or Communication Interface ControlBus
Module must be wired in a daisy chain configu-
ration, (1(a)-1(a), 2(b)-2(b), 3(c)-3(c)). The order
of interconnection of all the devices listed above
is not important. Be aware that modules on the
closest and farthest end of the daisy chain con-
figuration string require a 120 ohm (1/4 watt
M28586A
CONFIGURATION
JUMPERS
MICROCOMPUTER
RESET
PUSHBUTTON
RUN/TEST
SWITCH
STATUS LEDs
PLUG-IN PURGE
TIMER CARD
SAFETY RELAY
CIRCUIT
POWER SUPPLY
KEYBOARD
DISPLAY MODULE
HIGH FIRE
COMMON
MODULATE
LOW FIRE
HIGH FIRE SWITCH
PLUG-IN
FLAME
AMPLIFIER
RELAY
DRIVE
CIRCUIT
CONTROL
POWER
TEST
JACK
REMOTE
RESET
DDL
DDL
COMMUNICATIONS
INDICATES FEEDBACK SENSING
TO RELAY STATUS FEEDBACK
AND LINE VOLT INPUTS
FIELD WIRING
INTERNAL WIRING
IGNITION
PILOT
PILOT/V2
MAIN VALVE
1K
9K
RELAY
STATUS
FEEDBACK
AND LINE
VOLTAGE
INPUTS
LIMITS CONTROLLER
LOCKOUT
INTERLOCK
PRE-IGNITION
INTERLOCK
1K1 2K1 5K1
8K1
8K2
9K1
9K2
120 Vac
FLAME SIGNAL
TEST
LOW FIRE SWITCH
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
DEDICATED DATA LINK.
RS485
1
2
3
L1
(HOT) L2
4
6
20
7
4K1
7K1
2K2
10
8
21
9
18
19
8K
7K
6K
5K
4K
3K
2K
F
G
22
1
BLOWER
6K1
5
ALARM
3K1
3
L2
12
13
15
14
2
2
1

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 12 750-234
minimum) resistor termination across terminals
1 and 2 of the electrical connectors, for connec-
tions over 100 feet, see Fig. 11–13.
f. Use the recommended wire size for the 13 Vdc
full wave rectified transformer power input of no.
18 AWG wire insulated for voltages and tempera-
tures encountered in the application. Suggested
wire types include TTW(60C), THW(75C) and
THHN(90C).
5. Recommended grounding practices:
a. The earth ground provides for a connection
between the subbase and the control panel of
the equipment. The earth ground wire must be
capable of conducting the current to blow the
20A fuse (or breaker) in event of an internal short
circuit. The CB780E/CB784E needs a low
impedance ground connection to the equipment
frame which, in turn, needs a low impedance
connection to earth ground. For a ground path to
be low impedance at RF frequencies, the connec-
tion must be made with minimum length con-
ductors that have a maximum surface area. Wide
straps or brackets are preferred rather than lead-
wires. 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 coat-
ings and are protected against corrosion on mat-
ing surfaces.
b. Keyboard Display Module, DATA CONTROL-BUS
MODULE™ or Communication Interface Control-
Bus Module—The shield, if used, should be con-
nected to the signal ground terminal 3(c)
provided as part of the CB780E/CB784E device
ControlBus connection. Connect the shield at
both ends to earth ground.
c. CB780E/CB784E—Each CB780E/CB784E will
have an earth ground terminal that must be
grounded to the metal control panel with wire as
short as practical. Each ground wire must be
capable of carrying a fault current equal to the
rating of the protective fuse (15A maximum, Type
SC or equivalent). A number 14 copper conduc-
tor is adequate, but wide straps or brackets are
preferred rather than leadwires.
6. Recommended wire routing:
a. Flame detector leadwires:
(1) Do not run high voltage ignition transformer
wires in the same conduit with the flame
detection wiring.
(2) Do not route scanner wires in conduit with
line voltage circuits.
(3) Enclose scanner wires without armor cable in
metal cable or conduit.
(4) Follow directions in flame detector Instruc-
tions.
b. DATA CONTROLBUS MODULE™:
(1) Do not run high voltage ignition transformer
wires in the same conduit or close proximity
with the DATA CONTROLBUS MODULE™ wir-
ing.
(2) Do not route DATA CONTROLBUS MODULE™
wires in conduit with line voltage circuits.
c. Keyboard Display Module (VFD): Because the
VFD is powered from a low voltage, energy lim-
ited source, it can be mounted outside of a con-
trol panel if it is protected from mechanical
damage.
d. Remote Reset:
(1) Do not run high voltage ignition transformer
wires in the same conduit with the Remote
Reset wiring.
(2) Do not route Remote Reset wires in conduit
with line voltage circuits.
NOTE: A 13 Vdc power supply must be used any time
more than one Keyboard Display Module is used.
7. Maximum wire lengths:
a. CB780E/CB784E leadwires—The maximum
length of leadwire is 300 feet to terminal inputs
(Control, Preignition Interlock, Running/Lock-
out Interlock, High Fire Switch and Low Fire
Switch).
b. Flame Detector leadwires—The maximum flame
sensor leadwire length is limited by the flame
signal strength.
c. Remote Reset leadwires—The maximum length
of wire is 1000 feet to a Remote Reset pushbut-
ton.
d. DATA CONTROLBUS MODULE™—The maximum
DATA CONTROLBUS MODULE™ cable length
depends on the number of system modules con-
nected, the noise conditions and the cable used.
The maximum length of all interconnecting wire
is 1000 feet.
8. Make sure loads do not exceed the terminal ratings.
Refer to the label on the CB780E/CB784E or to the
ratings in Specifications; see Table 1.
9. Check the power supply circuit. The voltage and fre-
quency tolerance must match those of the
CB780E/CB784E. A separate power supply circuit
may be required for the CB780E/CB784E. Add the
required disconnect means and overload protection.
10. Check all wiring circuits and complete the Static
Checkout, see Table 8, before installing the
CB780E/CB784E on the subbase.
11. Install all electrical connectors.
12. Restore power to the panel.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 13 32-00150—03
Fig. 8. Typical wiring subbase and sequence for the CB780E/CB784E, without Valve Proving.
M23945A
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)
MASTER
SWITCH
LOW FIRE
START SWITCH
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
MAIN FUEL VALVE(S)
BURNER
CONTROLLER/LIMITS
BURNER MOTOR
(BLOWER)
HIGH FIRE
COMMON
LOW FIRE
MODULATE
120V ALARM
10 SEC. INTERRUPTED
PILOT/IGNITION
PREIGNITION
INTERLOCK
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
FLAME DETECTOR
120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
IGNITION
TRANSFORMER
2ND STAGE
FUEL VALVE
(OPTIONAL)
R
W
B
R
W
B
L1
(HOT)
L2 1
8
9
10
L2
833-2725
15 SEC.
INTERRUPTED
PILOT VALVE
2
1
3
3
HIGH FIRE
PURGE SWITCH
2
POWER
00
OPERATING
CONTROLS
AND
INTERLOCKS
BURNER
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
POWER
PREPURGE
HOLD
DRIVE TO
HIGH FIRE
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
PILOT
FLAME
MAIN
POWER
MFEP
PILOT
FLAME
MAIN
RUN
POWER
POSTPURGE
POWER
STANDBY
00 00 10 25 00 1520
SWITCHING
MOTOR ACTION
BURNER/BLOWER MOTOR
IGN.
15 SEC. PILOT
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
SAFE START CHECK FLAME PROVING
10 SEC. IGN./PILOT 8
10
5
5 SEC.
21
6
TO
7TO
20TO
518
TO
13 15
TO
13 12
TO
M23946A
INTERLOCK. CHECK
HIGH FIRE SW. 19TO
13 14
TO 13 14
TO
5
4
6
L1
MAIN VALVE 9
NOTE: SEE APPENDIX FOR APPLICATION OPTIONS.
TIMED
PREPURGE
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARMALARMALARMALARM
00
IC
PII
SSC
LED
DISPLAY

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 14 750-234
Fig. 9. Typical wiring subbase and sequence for the CB780E/CB784E, with Valve Proving enabled.
POWER
00
OPERATING
CONTROLS
AND
INTERLOCKS
BURNER
FLAME
SIGNAL
FIRING
RATE
MOTOR
INITIATE
(INITIAL
POWERUP
ONLY)
POWER
STANDBY
POWER
PREPURGE
HOLD
DRIVE TO
HIGH FIRE
PREPURGE
HOLD
DRIVE TO
LOW FIRE
POWER
PILOT
FLAME
MAIN
POWER
PFEP
10 SEC.
(4 SEC. IF
JR1
CLIPPED
PILOT
FLAME
MAIN
POWER
MFEP
PILOT
FLAME
MAIN
RUN
POWER
POSTPURGE
POWER
STANDBY
00 00 10 25 00 1520
SWITCHING
MOTOR ACTION
BURNER/BLOWER MOTOR
IGN.
LIMITS AND BURNER CONTROLLER CLOSED
LOCKOUT INTERLOCKS CLOSED
PREIGNITION INTERLOCK CLOSED
LOW FIRE SW.
SAFE START CHECK FLAME PROVING
10 SEC. IGN./PILOT 8
10
5
5 SEC.
17
TO
7
20TO
518
TO
13 15
TO
13 12
TO
M24790A
INTERLOCK. CHECK
HIGH FIRE SW. 19TO
13 14
TO 13 14
TO
5
4
L1
MAIN VALVE 9
MV2 IS MAIN VALVE CLOSEST TO THE BURNER. JR2 REMOVED FOR PILOT SEQUENCE.
1
TIMED
PREPURGE
POWER
FLAME
MAIN
PILOT
ALARM
POWER
FLAME
MAIN
PILOT
ALARMALARMALARMALARM
00
IC
SSC
LED
DISPLAY
PII
MV2 21 1
2
2
M28583A
G
L2
3
4
5
6
7
8
9
10
F
(L1)
13
14
15
16
17
18
19
20
21
22
12
LOCKOUT INTERLOCKS
(INC. AIR FLOW SWITCH)
MASTER
SWITCH
LOW FIRE
START SWITCH
5 SECOND IGNITION
(EARLY SPARK
TERMINATION)
MAIN FUEL VALVE 1
BURNER MOTOR
(BLOWER)
HIGH FIRE
COMMON
LOW FIRE
MODULATE
120V ALARM
10 SEC. INTERRUPTED
PILOT/IGNITION
PREIGNITION
INTERLOCK
SERIES 90
FIRING RATE
MOTOR
SERIES 90
CONTROLLER
FLAME DETECTOR
120V, 50/60 Hz (EC7840L 220-240 VAC) POWER SUPPLY.
PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
DO NOT WIRE TO ANY UNUSED TERMINALS.
SEE FLAME DETECTOR INSTALLATION INSTRUCTIONS
FOR CORRECT WIRING.
JR2 INTACT ON RM7800L/40L/EC7840L FOR DSI
FUNCTION.
FOR DIRECT SPARK IGNITION (OIL
OR GAS)
JR2 - INTACT
IGNITION
TRANSFORMER
MAIN VALVE 2
BURNER CONTROL
R
W
B
R
W
B
L1
(HOT)
L2 1
9
21
10
L2
833-2725
MV2 VALVE
MAIN VALVE 1
2
1
3
4
3
HIGH FIRE
PURGE SWITCH
2
VALVE PROVING
SWITCH
LIMITS

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 15 32-00150—03
Fig. 10. CB780E/CB784E Relay Module operation, Valve Proving test options.
Fig. 11. Wiring the Keyboard Display Module with
Communications Interface ControlBus Module.
Fig. 12. Wiring multiple Keyboard Display Modules.
M24791A
1
SPLIT
3 SEC. TEST TIME 3 SEC. STANDBY
TEST TIME
L1-17
L1-7
MV1 (9) MV2 (21)
VPS (16) VPS (16)
PII (20) PII (20)
21
BURNER RUN TIME
LOCKOUT IF ON, MV1 LEAKING (LOW PRESSURE TEST).
LOCKOUT IF OFF, MV2 LEAKING (HIGH PRESSURE TEST).
2
4 SEC. 4 SEC.
34
CONTROLLER
LOCKOUT INTERLOCKS
TEST IS RUN CONCURRENT WITH PRE PURGE TIME.
TEST IS RUN CONCURRENT WITH POSTPURGE, IF POSTPURGE TIME IS ENABLED.
3
4
BEFORE
3 SEC. TEST TIME 3 SEC. IGNITION TRIALS
L1-17
17-7
MV2 (21)
MV1 (9)
VPS (16) VPS (16)
PII (20) PII (20)
AFTER
3 SEC. TEST TIME 3 SEC. STANDBY
RUN TEST TIME
TEST TIME
L1-17
L1-7
MV2 (21) MV1 (9)
VPS (16) VPS (16)
PII (20) PII (20)
12
12
CONTROLLER
4 SEC.
4 SEC.
4 SEC.
4 SEC.
PII (20)
4
HF T19
CLOSED 3
FINISH
PURGE
AIRFLOW
POST
PURGE FINISH POST
PURGE
CONTROLLER
POST PURGE
FINISH POST
PURGE
HF T19
CLOSED
1
1
832-1693
120 OHM
RESISTOR
832-1693
120 OHM
RESISTOR
1
A
B
A
B CC (GND)
+13 VDC
RESET
123 45
123
MOMENTARY
PUSH BUTTON
SWITCH
833-2727 KEYBOARD DISPLAY MODULE
(MOUNTED ON CB 780/CB 784 RELAY MODULE)
833-2734
COMMUNICATIONS
INTERFACE
CONTROLBUS
MODULE
THREE WIRE SHIELDED CABLE MAY BE REQUIRED. TWO 832-1693
120 OHM TERMINATING RESISTORS ARE REQUIRED FOR
CONNECTIONS OVER 100 FEET (30 METERS). CABLE SHIELD
MUST BE TERMINATED TO EARTH GROUND AT BOTH ENDS.
IF SHIELDED CABLE IS NOT USED, TWISTED PAIR
WIRE MUST BE USED.
M28584A
2TERMINALS OF 203541 5-WIRE CONNECTOR.
2
L1
(HOT)
L2
1
1
1
A
B
A
B
C (GND)
+13 VDC
RESET
C (GND)
+13 VDC
RESET
123 45
123 45
MOMENTARY
PUSH BUTTON
SWITCH
833-2727 KEYBOARD DISPLAY MODULE
(MOUNTED ON CB 780/CB 784 RELAY MODULE)
13 VDC
POWER SUPPLY
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. CABLE SHIELD MUST BE
TERMINATED TO EARTH GROUND AT BOTH ENDS. IF SHIELDED
CABLE IS NOT USED, TWISTED PAIR WIRE MUST BE USED.
M28585A
832-1693
120 OHM
RESISTOR
832-1693
120 OHM
RESISTOR
2
2TERMINALS OF 203541 5-WIRE CONNECTOR.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 16 750-234
Fig. 13. Wiring the Data ControlBus™ Module with
Remote Keyboard Display Module.
ASSEMBLY
Mounting CB780E/CB784E Relay
Modules
NOTE: For installation dimensions, see Fig. 2.
Relay Module Mounting
1. Mount the CB780E/CB784E vertically. See Fig. 14 or
mount horizontally with the knife blade terminals
pointing downward. The CB780E/CB784E must be
in an electrical enclosure.
2. Select the location in the electrical enclosure. Be
sure to allow adequate clearance for servicing,
installation and removal of the CB780E/CB784E,
Keyboard Display Module, flame amplifier, flame
amplifier signal voltage probes, electrical signal
voltage probes, and electrical connections.
a. Allow an additional two inches below the
CB780E/CB784E for the flame amplifier mount-
ing.
b. Allow an optional three-inch minimum to both
sides of the CB780E/CB784E for electrical sig-
nal voltage probes.
3. Make sure no subbase wiring is projecting beyond
the terminal blocks. Tuck wiring in against the back
of the subbase so it does not interfere with the knife
blade terminals or bifurcated contacts.
IMPORTANT:
The CB780E/CB784E must be installed with a
plug-in motion rather than a hinge action.
4. Mount the CB780E/CB784E by aligning the four
L-shaped corner guides and knife blade terminals
with the bifurcated contacts on the wiring subbase
and tightening the two screws securely without
deforming the plastic.
Installing the Purge Card
1. Remove the Keyboard Display Module or DATA
CONTROLBUS MODULE™, see Fig. 16 or 17.
2. Remove the current Purge Card from the
CB780E/CB784E by pulling the plastic support
cover upward.
3. Make sure that the Purge Card selected has the
desired timing.
4. Insert Purge Card into the opening of the
CB780E/CB784E compartment, see Fig. 15
5. Reinstall the Keyboard Display Module or DATA
CONTROLBUS MODULE™ onto the
CB780E/CB784E 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. 14. Electrical panel installation.
IMPORTANT:
The CB780E will not function properly without one
of the following mounted correctly: Keyboard Dis-
play Module, or DATA CONTROLBUS MODULE™.
1
1
2
2
832-1693
120 OHM
RESISTOR
832-1693
120 OHM
RESISTOR
1
A B
A B
C (GND)
+13 VDC
RESET
C (GND)
+13 VDC
RESET
123 45
123 45
MOMENTARY
PUSH BUTTON
SWITCH
833-2729 DATA CONTROLBUS MODULE™
(MOUNTED ON CB 780/CB 784)
833-2727 REMOTE KEYBOARD DISPLAY MODULE
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.
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).
M28587A
3
3
3
TERMINALS ARE ON 5-WIRE CONNECTOR 203541.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 17 32-00150—03
Mounting Keyboard Display
Module
1. Align the two interlocking ears of the Keyboard Dis-
play Module with the two mating slots on the
CB780E/CB784E; see Fig. 16.
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 CB780E/CB784E.
3. Verify the Keyboard Display Module is firmly in
place.
Mounting Data ControlBus™
Module
1. Align the two interlocking ears with the two mating
slots on the CB780E/CB784E; see Fig. 17.
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
CB780E/CB784E.
3. Be sure the DATA CONTROLBUS MODULE™ is firmly
in place.
Fig. 15. Purge card installation.
Fig. 16. Keyboard Display Module installation.
Fig. 17. Data ControlBus™ mounting.
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. 18.
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. 50. 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
connector holes.
c. Mount the Keyboard Display Module securing
the two no. 4 screws.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 18 750-234
3. A second Keyboard Display Module or a Data
ControlBus™ Module must be installed on the
CB780E/CB784E. Connections from the module to
the remote display are completed following wiring
shown in Fig. 11–13.
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 CB780E/CB784E. Verify
the amplifier nameplate faces away from the Relay
Module, see Fig. 19.
3. Push in the amplifier until the circuit board is fully
inserted into the receptacle and then push the
amplifier toward the CB780E/CB784E retaining
clasp.
4. Verify the amplifier is firmly in place.
5. Perform all required checkout tests.
Installing the Flame Detector
NOTE: Table 5 lists the flame detection systems avail-
able for use with the CB780E/CB784E. 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. 20.
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
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 .
Fig. 18. Remote mounting of Keyboard Display Module.
Fig. 19. Flame signal amplifier mounting.

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
750-234 19 32-00150—03
Fig. 20. Flame detector wiring.
VALVE PROVING SYSTEM
The Valve Proving System feature provides a systematic
way of testing the valve seat integrity to assure the valves
are in the closed state whenever the sequence of
operation requires them to be closed. It is designed to
detect a leak greater than 0.1% of the burner input
capacity. For example, a 10 million Btu/hr natural gas-
fueled burner would have a fuel input capacity of
approximately 1,000 ft3/hr. A leak rate greater than 0.1%
of 1,000 ft3/hr or 1 ft3/hr in either valve will be detected
with the Valve Proving System. Smaller leaks will not be
detected.
At commissioning time, the Valve Proving System may be
scheduled to occur at one of five different times: Never,
Before, After, Both, and Split.
Never—Device default as received: in this case Valve
Proving does not occur.
Before—Valve Proving occurs concurrently with Pre-
Purge.
After—Valve Proving occurs after the Run state before
the internal Safety Relay dropout state and concurrent
with Post Purge (if configured).
Both—Valve proving occurs at both times Before and
After noted above.
Split—The downstream seat (high pressure) test is per-
formed at the Before time and the upstream seat (low
pressure) test is performed during the After time.
The Valve Proving items programmed are:
1. Specify when to perform Valve Proving. Demand
input to terminal 17 actually enables the function of
Valve
Proving.
2. Specify the time duration of the test (calculated from
Appendix A).
BLUE
YELLOW
WHITE
WHITE
BLACK
BLACK
F
G
22
L2
L1
L2
M28588A
BLUE
WHITE
BLUE
WHITE
F
G
F
G
INFRARED (817-4133)
ULTRAVIOLET (817-1743)
SOLID STATE SELF-CHECKING
ULTRAVIOLET (817-1121)
1
2
1FLAME 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.
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.
2

CB780E/CB784E RELAY MODULES WITH VALVE PROVING
32-00150—03 20 750-234
Typical Valve Proving System
Function
Valve proving consists of monitoring the pressure in the
space between two shutoff valves, MV1 (upstream) and
MV2 (downstream). The valve proving function, identified
by letters A through F, operates as follows:
The tolerance on all valve proving timing values is ±10%.
The following are steps performed during valve proving
tests. This section is for background information and does
not define the exact behavioral requirements.
A. MV2 is commanded to be open while MV1 remains
closed; to depressurize the space. After 4 seconds, MV2
is commanded closed again.
B. This is followed by a three second delay during which
the valve proving pressure switch (VPS) is ignored.
C. Thereafter, the VPS is monitored for the duration of
the valve proving test time and, if it turns on, then a
lockout occurs. (Because the gas pressure has
increased due to a leaky upstream valve.) (Low pressure
test.)
D. MV1 is commanded to be open while MV2 remains
closed, to pressurize the space. After 4 seconds, MV1 is
commanded closed again.
E. This is followed by a three second delay, during
which the valve proving pressure switch (VPS) is
ignored.
F. Thereafter, the VPS is monitored for the duration of
the valve proving test time and, if it turns off, then a
lockout occurs. (Because the gas pressure has
decreased due to a leaky downstream valve.) (High
pressure test.)
Pressure Switches for Valve Proving
System
The Valve Proving System requires a pressure switch to be
installed to monitor the pressure in the internal space
between the two shutoff valves. Recommended pressure
switches are the following Honeywell non-manual reset
models:
Pressure Switch Selection
1. Determine the maximum operating inlet pressure for
the upstream valve; for example, 5.0 psi (140 in. wc).
2. Divide the inlet pressure by two (2.5 psi [70 in. wc],
for example).
3. From column 2 in Table 6 find the operating range
upper limit that is closest to but greater than the
inlet pressure divided by two. In the example given,
the possible selections from column 1 are the
C6097A1129 and C6097A1137 with an operating
range upper limit of
7 psi. (The C6097A1079 and C6097A1087 with an
upper limit of 60 in. wc are close, but 60 in. wc is less
than the 70 in. wc minimum, so the next higher
range must be selected.)
4. From column 6, select the preferred mounting type,
1/4 in. NPT or Flange. For example, if a flange mount
is required, the pressure switch choice from column
1 would be the C6097A1137.
Pressure Switch Installation and
Adjustment
1. Refer to the instructions for the C6097A Pressure
Switch, form number 65-0237.
2. Install the C6097A Pressure Switch according to the
instructions.
3. Adjust the setpoint to 50% of the maximum operat-
ing inlet pressure for the upstream valve.
4. Complete the operation and checkout procedures in
the instructions.
Setup (Programming) of Valve
Proving Function
Prior to setup of the Valve Proving Function, follow the
procedures in the appendix to complete the worksheet
and obtain the Valve Proving Test Time.
Table 6. Honeywell Pressure Switch Selection for Valve Proving System
12345 6
Model Number
Operating
Pressure Range
Maximum
Differential
(Additive)
Maximum
Continuous
Rated Pressure
(psi)
Switch Action at
Setpoint Mounting Type
C6097A1004 0.4 to 5 in. wc 0.24 in. wc 2.9 Breaks N.O. to C
connection on
pressure fall.
1/4-in. NPT
C6097A1053 3 to 21 in. wc 0.48 in. wc 5.0
C6097A1061 Flange
C6097A1079 12 to 60 in. wc 2.4 in. wc 1/4 in. NPT
C6097A1087 Flange
C6097A1129 1.5 to 7 psi 0.3 psi 9.3 1/4 in. NPT
C6097A1137 Flange
C6097A1210 0.4 to 4 in. wc 0.24 in. wc 2.9