®

833-02801
Fuel Air Ratio Controller
PRODUCT DATA

FEATURES
• Fast burner setup via PC or laptop.
• Fuel, air, FGR profile download capability.
• Two independent fuel profiles with or without FGR.
• 7 to 24 point profiles.
• Programmable behaviors of all actuators during
Purge and Standby.
• Programmable behavior of nonselected fuel actuator.
• Independent lightoff and minimum modulation
positions.
• Wide power voltage input range (50/60 Hz); two models
cover global applications.
• Auto/Manual input.
• Manual mode firing rate input.
• Pluggable controller to wiring subbase.
• Multipurpose communications port.
APPLICATION • Field-configurable device.
• Integrated boiler shock protection algorithms:
The 833-02801Fuel Air Ratio Controller uses the latest
— Water temperature low fire hold.
microprocessor-based technology to simultaneously control
— Stack temperature low fire hold.
up to four actuators. The device, when used with the Cleaver
— FGR and low fire hold.
Brooks Universal Parallel Positioning Actuators, represents
a value-added replacement of mechanical cam and linkage • Selectable FGR hold based on stack temperature.
assembly controlling the relationship between fuel, airflow
• Programmable behavior of FGR actuator during purge.
and flue gas recirculation (if used) on a power burner. The
Cleaver Brooks Fuel Air Ratio System consists of the • Maximum modulation limit capability.
833-02801 Fuel Air Ratio Controller, 833-02802 Universal
• Remote reset input.
Wiring Subbase and commissioning software.
• Automated actuator endpoint seeking process.
The 833-02801 Fuel Air Ratio Controller, with one
• UL/cUL Approved, CSD-1 and NFPA acceptable.
communications port, provides communications capabilities
similar to those found in the CB780/CB784 SERIES controls. • Infrared communications output.

CONTENTS
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Installation ........................................................................ 3
Wiring ............................................................................... 3
Operation .......................................................................... 6
Checkout and Troubleshooting ......................................... 8

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G.R. 7-01
833-02801 CONTROLINKS™ CONTROLLER

• Nonvolatile memory stores operating history and

current lockout and alarm status.
SPECIFICATIONS
• Six light-emitting diodes (LED) provide: Model:
— System status. 833-02801 Fuel Air Ratio Controller, consisting of a
— Fault information. four-channel actuator drive Input/Output (I/O) and
— Status of four actuator channels. hardware interface for a variety of burner controllers.

Electrical Ratings:
Safety Features Input Power:
• Class C operating software system. 100 to 120 Vac (+10/-15%), 50/60 Hz (±10%), 10VA maximum.
• Fail-safe feedback potentiometer circuitry. Outputs:
Limit/Control OUT (LCO):
• Curve verification algorithms. 120 Vac, 8.0A run, 42A inrush (UL).
• Step size enforcement during commissioning. 120 Vac, 6.0A run; 26A inrush (CE).
Alarm (ALR):
• Point plausibility algorithms. 120 Vac, 1A pilot duty (UL).
• Password protected. 120 Vac, 1.0A at PF = 0.4, 6A inrush (CE).
High Fire (HFP):
• Weld-resistant algorithm for LCI-LCO contact set. 120 Vac, 1A pilot duty (UL)
• Dual time base. 120 Vac, 1A at PF = 0.4, 6A inrush (CE).
Light-Off Position:
• Built-in self-test and safety relay circuits. 120 Vac, 1A pilot duty (UL)
• Component anti-swap protection. 120 Vac, 1A at PF = 0.4, 6 A inrush (CE).

• Off curve checking algorithm. A-1, F1-1, F2-1, FG-1:

Source: 4.25 to 5.25V minimum at 5 mA (counterclockwise
[CCW] drive command).
Sinking: 0 to 0.6V maximum at -5 mA (Clockwise [CW]
drive command).
A-2, F1-2, F2-2, FG-2:
Source: 4.25 to 5.25V minimum at 5 mA (Clockwise [CW]
drive command).
Sinking: 0 to 0.6V maximum at -5 mA (Counterclockwise
[CCW] drive command).
Inputs:
Limit/Control In (LCI)
120 Vac, 8A run, 42A inrush (UL).
120 Vac, 6A run, 26A inrush (CE).
Fuel 1 Select (FS1):
120 Vac at 2 mA (UL/CE).
Fuel 2 Select (FS2)
120 Vac at 2 mA (UL/CE).
Remote Reset (RR): 5V at 5 mA.
Feedback Potentiometer input (per channel):
CW: 5 Vdc at 1 mA.
S: 5 Vdc at 1 mA.
CCW: 5 Vdc at 1 mA.

Environmental Ratings:
Temperature Range:
Ambient: -40°F to +140°F (-40°C to +60°C).
Storage: -40°F to +150°F (-40°C to +65°C).
Humidity:
5 to 95 percent relative humidity, noncondensing.
Vibration:
0.0 to 0.5g continuous (V2 level).

Mounting: Mounts on Universal Subbase.

Accessories:
Three-Pin Electrical Connector (RS-485).
985-126 RS-232/RS-485 Converter.

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 833-02801 CONTROLINKS™ CONTROLLER

Dimensions: See Fig. 1.

5-3/16 (131) 1-15/16 (48) WARNING
Electrical Shock Hazard.
Can cause serious injury or death.
Disconnect power supply before installation.More than
one disconnect can be required to remove line voltage
power completely.

7-3/16
(182) Location
Mount the 833-02801 Fuel Air Ratio Controller on the
833-02802 Universal Wiring Subbase. The subbase is
secured to a panel by four number 8 screws. Secure the
833-02801 Fuel Air Ratio Controller to the subbase by
tightening the two captive screws.

WIRING
All wiring for the 833-02801 Fuel Air Ratio Controller is
3
connected to the 833-02802 Universal Wiring Subbase. There
2-13/16 is no direct wiring to the controller. Tables 1 and 2 provide the
(76)
(71) CONTROLLER INSTALLED 833-02801 Fuel Air Ratio Controller input and output terminal
ON
SUBBASE descriptions, respectively. Table 3 provides the 833-02801
Fuel Air Ratio Controller maximum field wiring lengths. A
SUBBASE M17888 block hookup diagram for the Universal Parallel Positioning
Actuator Actuator is shown in Fig. 2 and a typical wiring
Fig. 1. Approximate dimensions of 833-02801 Fuel Air diagram is shown in Fig. 4.
Ratio Controller in in. (mm).
Earth Ground
Weight: 12oz (0.35 kg). Earth ground is required for proper operation of the Fuel Air
Ratio system. Earth ground provides a connection between
Approvals: the subbase and the control panel of the equipment. The
Underwriters Laboratories Inc. (UL)(cUL): earth ground must be capable of conducting enough current
Component Recognized; File Number MH17367. to blow the fuse or breaker in the event of an internal short.
Factory Mutual (FM): Pending.
CSD-1 and NFPA: Acceptable. 1. Use wide straps or brackets to provide minimum length,
maximum surface area ground conductors. If a leadwire
Required Components: must be used, use 14 AWG copper wire.
833-02802 Universal Wiring Subbase. 2. Make sure that mechanically tightened joints along the
Universal Parallel Positioning Actuators ground path are free of nonconductive coatings and
(number as required by application). protected against corrosion on mating surfaces.
Fuel Air Ratio Software Configuration Tool.
Shield Ground
INSTALLATION Connect the shield ground of the Universal Parallel
Positioning Actuator(s), Remote Reset, Manual
Potentiometer, Controller 4-to-20 mA and Auxiliary 4-to-20 mA
inputs to the earth ground strip provided in the 833-02802
When Installing This Product... Universal Wiring Subbase. Connect the shield at the controller
1. Read these instructions carefully. Failure to follow them end only. See Fig. 2.
could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out product
operation as provided in these instructions.

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833-02801 CONTROLINKS™ CONTROLLER

Table 1. 833-02801 Fuel Air Ratio Controller Input Terminal Description.

Name (Abbreviation) Terminal
Number Description
Ground (G) 2 Earth ground.
Line Power (L1) 1 Line Voltage Power: 100 to 120 Vac, 50/60 Hz (833-02801 Fuel Air Ratio Controller A),
10 VA maximum power consumption.
NOTE: The Fuel Air control must be on the same phase as the burner control.
Power Supply Neutral 3 Power Supply Neutral.
L2 (N)
High Fire (HF) 10 Purge Position is activated by line voltage ac signal. Upon activation of the input,
833-02801 Fuel Air Ratio Controller commands the air damper to the programmed
purge position. NOTE: 120 Vac, 2 mA maximum per device model type.
NOTE: LF and HF may not be energized at the same time. Operation will be halted if the
condition is introduced and will not start if the condition exists at power up.
Main Valve (MV) 11 Main Valve Input, activated by line voltage ac signal. Activation of this input releases the 833-
02801 Fuel Air Ratio Controller to position all actuators to the programmed position curve.
Maximum values same as High Fire. Improper insertion of the main valve input during the
sequence can cause lockouts, recycles or initiate holds.
Auto/Manual (AM) 4 Auto/Manual Input, activated by line voltage ac signal. Activation of this input during the Modulate
phase of the RUN state changes the input control variable from the CMA(+/-) to the MNC input.
Maximum values same as High Fire.
Low Fire (LF) 12 Low Fire is activated by line voltage ac signal. Upon activation, 833 02801 Fuel Air Ratio
Controller commands the air damper to the programmed Light-Off position in addition to causing
the selected fuel actuator to move to the light-off position. Maximum values same as High Fire.
NOTE: LF and HF may not be energized at the same time. Operation will be halted if the
condition is introduced and will not start if the condition exists at power up.
Limit/Ctrl In (LCI) 13 Line voltage input that signals limits are satisfied and that a demand exists to run the burner.
Provides power to energize Burner Control. Voltage present equates to function selected.
Controller Input (CmA+) 39 Firing Rate input: 4 to 20 mA positive input from temperature or pressure controller.
Controller Input (CmA-) 40 Firing Rate input: 4 to 20 mA negative input from temperature or pressure controller.
Manual Ctrl (MNC) 35/36 Use for manual control potentiometer. Resistance range: 0 to 5000 ohms, ±10%.
200 ohms or less equates to the 4.0 mA controller input.
4500 ohms or more equates to the 20 mA controller input.
Use linear interpolation for all other values.
Programmable also as the maximum modulation limit, if so configured.
Fuel 1 Select (FS1) 5 Line voltage input that selects fuel 1when activated. Voltage present equates to function selected.
Fuel 2 Select (FS2) 6 Line voltage input that selects fuel 2 when activated. Voltage present equates to function selected.
Feedback Air Damper Provides position feedback for the Air actuator:
(CW) 17 (CW) Clockwise rotational endpoint of the feedback potentiometer.
(S) 18 (S) Variable resistance signal from potentiometer.
(CCW) 19 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer.
Feedback Fuel 1 Provides position feedback for the Fuel 1 Actuator:
(CW) 22 (CW) Clockwise rotational endpoint of the feedback potentiometer.
(S) 23 (S) Variable resistance signal from potentiometer.
(CCW) 24 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer.
Feedback Fuel 2 Provides position feedback for the Fuel 2 Actuator:
(CW) 27 (CW) Clockwise rotational endpoint of the feedback potentiometer.
(S) 28 (S) Variable resistance signal from potentiometer.
(CCW) 29 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer.
Feedback FGR Provides position feedback for the FGR Actuator:
(CW) 32 (CW) Clockwise rotational endpoint of the feedback potentiometer.
(S) 33 (S) Variable resistance signal from potentiometer.
(CCW) 34 (CCW) Counterclockwise rotational endpoint of the feedback potentiometer.
Temperature Sensor 37 Configurable Sensor Input: 4 to 20 mA positive input from temperature sensor. For the
(XmA+) temperature input application the endpoints are programmable from -40°F to +1400°F. Minimum
span must exceed 100°F.
Temperature Sensor 38 Configurable Sensor Input: 4 to 20 mA negative input from temperature sensor.
(XmA-)
Remote Reset (RR) 35/38 Remote Reset Input. A cycled contact on this terminal indicates a reset condition. Retrieval of
fault codes is possible using this input.

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 833-02801 CONTROLINKS™ CONTROLLER

Table 2. 833-02801 Fuel Air Ratio Controller Output Terminal Description

Terminal
Name (Abbreviation) Number Description
Limit/Ctrl OUT (LCO) 14 Line voltage output that signals limits are satisfied and that a demand exists to run the burner
and Fuel Air Ratio Controller is operational. Provides power to energize Burner Control.
Alarm (ALR) 7 Alarm Output.
High Fire Proven (HFP) 8 High Fire Proved normally open contact is activated when the HF input terminal has been
energized and the Fuel Air Ratio Controller has successfully moved the air/fuel damper (and
FGR, if so configured) to the programmed Purge Position.
Low Fire Proven (LFP) 9 Low Fire Proved normally open contact is activated when the LF input terminal has been
energized and the Fuel Air Ratio Controller has successfully moved the Air, selected fuel, and
FGR damper to the programmed Light-Off Position.
A-1 15 A-1: Output when combined with A-2 is used to modulate the Air damper. The resultant push-
pull current flow of the two outputs causes the motor to advance, reverse, or hold.
A-2 16 A-2: Output when combined with A-1 is used to modulate the Air damper. The resultant push-
pull current flow of the two outputs causes the motor to advance, reverse, or hold.
F1-1 20 F1-1: Output when combined with F1-2 is used to modulate the Fuel 1 valve. The resultant
push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
F1-2 21 F1-2: Output when combined with F1-1 is used to modulate the Fuel 1 valve. The resultant
push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
F2-1 25 F2-1: Output when combined with F2-2 is used to modulate the Fuel 2 valve. The resultant
push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
F2-2 26 F2-2: Output when combined with F2-1 is used to modulate the Fuel 2 valve. The resultant
push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
FG-1 30 FG-1: Output when combined with FG-2 is used to modulate the FGR damper. The resultant
push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
FG-2 31 FG-2: Output when combined with FG-1 is used to modulate the FGR damper. The resultant
push-pull current flow of the two outputs causes the motor to advance, reverse, or hold.
.
Table 3. 833-02801 Fuel Air Ratio Controller Maximum Wiring Lengths .
Wiring Length Minimum/Maximum
Terminal Name (Maximum) Wire Type Wire Size
Ground (G) Short as possiblea b b

Line Power (L1) c b b

No Restriction
Power Supply Neutral L2 (N) No Restriction b b

High Fire (HF) 100 Feet b b

Modulate (MOD) 100 Feet b b

Low Fire (LF) 100 Feet b b

Limit/Ctrl IN (LCI) No Restriction b b

Controller input (CmA+) d Belden 9502, 2-conductor, 100% shield coverage, 18 to 24 AWG
1000 Feet
Controller input (CmA-) 300V 80C (UL 2464, CSA PCC FT 4) or equivalent.
Manual Ctrl (MNC) 10 Feetd Belden 9502, 2-conductor, 100% shield coverage, 18 to 24 AWG
300V 80C (UL 2464, CSA PCC FT 4) or equivalent.
Fuel 1 Select (FS1) No Restriction b b

Fuel 2 Select (FS2) No Restriction b b

Actuator Interface 100 Feetd Belden 9535, 5-conductor, 100% shield coverage, 18 to 24 AWG
(A1, F1-1, F2-1, FG-1) 300V 80C (UL 2464, CSA PCC FT 4) or equivalent.
(A2, F1-2, F2-2, FG-2)
(CW)
(S)
(CCW)
Configurable Sensor (XmA+) 1000 Feetd Belden 9535, 2-conductor, 100% shield coverage, 18 to 24 AWG
Configurable Sensor (XmA-) 300V 80C (UL 2464, CSA PCC FT 4) or equivalent.
RS485 DDL Commissioning port 1000 Feete 18 to 24 AWG
a
Use wide straps or brackets to provide minimum length, maximum surface area ground conductors. If a leadwire must be used,
use 14 AWG copper wire. Make sure that all mechanically tightened joints along the ground path are free of nonconductive
coatings and protected against corrosion on mating surfaces.
b
Follow local and NEC 1 codes.
c
Implies no limitations beyond voltage (current times resistance) drop considerations versus wire size constraints.
d
Requires ground shield at controller end. See Fig. 2, 4.
e
Ground shield to digital ground terminal C at controller end and and PC or laptop end.

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833-02801 CONTROLINKS™ CONTROLLER

control mode during this state. Commands from the

configuration software increment or decrement motor

GND
945-00216

L2
L1
ACTUATOR positions. The 833-02801 Fuel Air Ratio Controller write
833-02801 the values for the valve and damper positions,
CONTROLLER
L2
as a function of firing rate, during this state.
L1
3. Initiate State. This state exists for a minimum of ten
G seconds after an internally- or externally-initiated reset.
DR1
DR2 The 833-02801 Fuel Air Ratio Controller performs
CW internal checks during this state.
S 4. Standby State. This state occurs whenever the LCI
CCW
input (terminal 13) is not active. All actuators move
1 2 to the Programmed Standby Stop Position (PSTP) or
1/2 IN. MAXIMUM
return to the light-off position, except for the FGR
1 TERMINATE WIRE SHIELD AT THE CONTROLLER (833-02801). actuator, which moves to the closed position.
2 SEE FIGURE 5 FOR ACTUATOR WIRING. M17887 5. Processing Demand State. The 833-02801 Fuel Air
Ratio Controller enters this state when the LCI has just
become active. The 833-02801 Fuel Air Ratio Controller
Fig. 2. 833-02801 Fuel Air Ratio Controller/Universal
makes sure the firing rate command inputs are valid
Parallel Positioning Actuator hookup block diagram.
before advancing to the next state.
6. Run State. The 833-02801 Fuel Air Ratio Controller
enters this state when the LCI input is active. The high
OPERATION fire or low fire command from the burner control causes
the air actuator and the FGR actuator (if configured) to
The 833-02801 Fuel Air Ratio Controller provides drive to the purge or light-off positions, respectively. The
communication capabilities similar to those found in the selected fuel, air and FGR actuators track the firing rate
CB780/CB784 SERIES equipment. Fault annunciation is input versus the programmed profile once the main
available through a connection to the communication data valve terminal is energized.
output (DDL). Operating history is kept in nonvolatile 7. Lockout State. The 833-02801 Fuel Air Ratio Controller
memory as is the current lockout status. enters this state when critical internal faults are
detected. The controller retains the lockout state
The Fuel Air Ratio Commissioning Software tool is necessary via nonvolatile memory. To exist this state, press the
for the field commissioning prior to operation. reset button.
Refer to the configuration software help screens for 8. Alarm Initiate State. Essentially an Initiate state, except
commissioning procedures. that the alarm terminal is energized. A controller will
remain in this state as long as the fault exists. The
The 833-02801 Fuel Air Ratio Controller tracks the firing 833-02801 Fuel Air Ratio Controller will automatically
rate input value and drives the Universal Parallel Positioning restart once the fault is removed. The user may restart
Actuators according to the commissioned profile and the system by pressing the Reset button.
maintains the relative programmed positions.
Normal operating sequence for the 833-02801 Fuel Air Ratio
Controller is: Initiate (ac power up or internal or external
WARNING reset), Standby, Processing Demand and Run. The
Non-Configured State may also occur.
Explosion Hazard.
Improper configuration can cause fuel buildup An LED status panel provides visual status of the operating
and explosion. condition of the 833-02801 Fuel Air Ratio Controller and
The Fuel Air Ratio Commissioning Software is associated components. See Fig. 3. Table 4 provides the LED
to be used only by experienced and/or licensed condition and meaning. Table 5 provides the Channel Status
burner-boiler operators and mechanics. LED condition and meaning.
Operators of this software may move fuel and/or air At power up, all LED will automatically turn on to verify
actuators to positions that can create hazardous operation.
burner conditions. Improper user operation can result
in property loss, physical injury or death. If all LED remain on, make sure one fuel select input is made,
not two or zero.
The 833-02801 Fuel Air Ratio Controller must go through an
Initiate state whenever the fuel select switch is changed.
MOTOR RESET
PWR ALRM
The 833-02801 Fuel Air Ratio Controller has the following
operating states: 1 2 3 4
1. Non-Configured State. The controller is shipped from
the factory in this condition and will not respond to any M16607

input other than the DDL port (configuration tool port).

2. Commissioning State. The controller enters this state Fig. 3. 833-02801 Fuel Air Ratio Controller
once communications with a configuration tool is LED status panel.
established. Actuators are placed in pseudo-manual

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Table 4. 833-02801 Fuel Air Ratio Controller Status LED Blink Patterns.
Power (Green) LED State Meaning
Always Off Control has failed, or has no power.
Always On Control cannot run or communicate until a critical fault has been corrected. This state occurs at
each power up or reset. Control is in the Initiate State or Alarm Initiate State or Alarm Hold State.

Check that only one fuel has been selected, or that HF and LF are not active at the same time. If
HF and LF are active at the same time, the red LED will also be on.
1 short blink every interval Control is in Postpurge or Standby State.
2 short blinks every interval Control is in a low voltage condition.
3 short blinks every interval Control is in the non-configured state.
4 short blinks every interval Control is in the commissioning state.
Steady medium blink Control is in the Run State.
Steady fast blink Control is in manual mode.
A red LED, normally off, indicates a Lockout State when lit.

Table 5. 833-02801 Fuel Air Ratio Controller Channel Status LED Blink Patterns.
Motor (Amber) LED Statea Meaning
Always Off Actuator is not being commanded to move or is not configured.
On Actuator is in motion.
1 short blink every interval. Actuator Failure: Failed timing plausibility check.
2 short blinks every interval. Actuator Failure: Failed actuator ID process.
3 short blinks every interval. Actuator Failure: Analog/Digital reading of potentiometer out of range.
4 short blinks every interval Actuator Failure: Potentiometer failure—wiper resistance.
Medium speed blink. Actuator Warning: Wiper resistance high.
a The four amber motor LED provide status for the individual Universal Parallel Positioning Actuator Actuators; e.g., Motor 1 LED
is Air Actuator Status, Motor 2 LED is Fuel 1 Actuator Status, Motor 3 LED is Fuel 2 Status, and Motor 4 LED is FGR Actuator
Status.

Manual Operation
Place the 833-02801 Fuel Air Ratio Controller in a manually
commanded firing rate condition by applying a line voltage
signal to terminal 4. The 833-02801 Fuel Air Ratio Controller
will derive the desired firing rate control position by the value
of the resistance set at terminal 36. A 200-ohm value equals
minimum modulation; 4500 ohms equals maximum
modulation. Linear interpolation exists for all other values.

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833-02801 CONTROLINKS™ CONTROLLER

Commissioning Process Fig. 5 provides a standard block hookup diagram for

the 833 02801 Fuel Air Ratio Controller and associated
The primary tasks to be accomplished by the commissioning equipment.
process are as follows:
1. Establish the endpoints of each actuator within the
system.
2. Establish the purge position. CHECKOUT AND TROUBLESHOOTING
3. Establish the lightoff position.
4. Establish minimum and maximum modulation positions.
5. Establish a fuel, air, FGR mixture profile for up to 20 Fault Codes
points between the minimum and maximum modulation The 833-02801 Fuel Air Ratio Controller is designed so that
points for each fuel source within the system. only an unrecoverable internal related fault will cause lockout.
The 833-02801 Fuel Air Ratio Controller will recycle when
The commissioning process requires the use of the Fuel Air specific external problems are detected and then cleared.
Ratio Commissioning Software running on a laptop or PC with
an operating system of Windows 95, 98 or 2000. Additional When the 833-02801 Fuel Air Ratio Controller locks out,
minimum requirements include a Pentium® class processor, obtain the fault code (a repeating series of blinks from the
or equivalent, with 16 megabytes of RAM and a one gigabyte POWER LED) by pressing and holding the Reset button or
hard drive with 100 megabytes of free hard drive memory. The using a laptop in monitor or commissioning mode. To interpret
PC or laptop must have a RS232-to-RS485 converter to the LED flashes, for example, a Fault 11 would be one slow
communicate with the 833-02801 Fuel Air Ratio Controller. blink and one fast blink, while a Fault 67 would be six slow
Fig. 4. shows the 985-126 RS485 to RS232 Port Expander blinks followed by seven fast blinks.
and the hookup information.
See Table 8 for fault codes and descriptions.
The 833-02801 Fuel Air Ratio Controller requires the
presence of one of the Fuel Select inputs to start Abbreviation Definitions.
communications with the Fuel Air Ratio Commissioning
Software. Additional wiring interface requirements include
that HF and LF command inputs cannot be activated at the
same time. Abbreviation Description

NOTE: A stack gas analyzer is required to commission the LCI Limit Control Input
Fuel Air Ratio Control System. HF High Fire Input
LF Low Fire Input
MV Main Valve Input
RS-485 RS-485
CONNECTOR
3 1
CONNECTOR LCO Limit Control Output
833-02801 abc
2
HFP High Fire Proved
FUEL AIR RATIO
PORT EXPANDER LFP Low Fire Proved
CONTROLLER

FS1 Fuel Select Channel 1

RS-232 RS-232
(Ext) (DB9) (PC) FS2 Fuel Select Channel 2
3
ALM Alarm
ILK Interlock
DMD Demand
1 WIRE TYPE: BELDEN 8760 SHIELDED WIRE OR EQUIVALENT,
3-CONDUCTOR, 100% SHIELD COVERAGE, 300V, 80°C COM Common
(UL2464, CSA PCCFT4, 18 TO 24 AWG).
MNC Manual Control
2 RS-232 (DB9) PC CONNECTION CAN BE EITHER DIRECT OR
RS-232 (DB9) CABLE.

3 MAXIMUM WIRE/CABLE LENGTHS: RS-232 — 50FT

RS-485 — 1000 FT. M17951

Fig. 4. 985-126 Port Expander to 833-02801

Fuel Air Ratio Controller hookup.

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 833-02801 CONTROLINKS™ CONTROLLER

AUTO MANUAL A-1 41 1

2 833-02802 15 DR
L1 L1
A-2 1 AIR
(HOT) 1 DR

945-00216
16 2
L2 CW
G CW
GND 2 17
S S
FUEL SELECT SWITCH L2 18
W
3 CCW CC
FUEL 1 mV 19
F1-1 42
A/M 1
4 20 DR
FUEL 2 mV F1-2 1 FUEL 1
DR

945-00216
FS1 21 2
5 CW
22 CW
FS2 S S
6 23
W
CCW CC
ALR 24
ALARM 7 F2-1 43
1
25 DR
MV 1 FUEL 2
HFP F2-2
HFS 26 DR
19 8 2

945-00216
L1 L2 G 9 CW
CW
LFP 27
LFS S S
18 9
28 W
BURNER HF CCW CC
CONTROL HF 29
12 10
(CB78XX) COM FG-1 44 1
13 30
MV DR
1 FGR
15 11 FG-2
LF 31 DR
2

945-00216
14 CW
7 6 LF CW
12 32
CTRL S S
2 LCI 33 W
ILK DMD
13 CCW CC
34
LIMITS IN LCO MNC RESET
14 35
(REMOTE) MIN
36
1 MAX
MANUAL
XmA+45 FIRING RATE
37 STACK OR
WATER TEMP. POTENTIOMETER
XmA– 5K OHM
38 4-20mA

1
CmA+ 46
39
RS232/RS485 CmA– SSLC
CONVERTER 40 4-20mA
RS485 DDL
3

1 EARTH GROUND TERMINAL (SUBBASE ONLY).

2 FUSE LINE VOLTAGE TO CONTROL SYSTEM WITH TYPE SC15 FUSE OR FUSE LIMIT INPUT WITH TYPE SC5 FUSE.

3 RS-485 DDL CONNECTOR IS ON 833-02801 CONTROLLER. M17886

Fig. 5. Hookup block diagram—833-02801 Fuel Air Ratio Controller and associated equipment.

NOTE: Shields on MNC (terminal 36, 38) and RESET (35,

38) also go to earth ground terminal on the subbase.

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Table 6. Fault Listings and Descriptions.

Fault/
BlinK
Code Description Corrective Action
11 Device is operating properly.
13 MV input energized at an improper time. Reset control. Check Burner Control Interface wiring and correct
error. This error causes the device to remain in initiate state at
power up.
14 HF and LF are energized at the same time. Reset control. Check Burner Control Interface wiring and correct
error. This error causes the device to remain in initiate state at
power up.
15 Transition to the requested Burner Control input state is Reset control. Check wiring to burner control and/or burner control
not allowed from the current state. E.g. Standby to operation.
Modulate is not allowed.
NOTE: Moving a CB780/CB784 Run/Test switch to Test will
induce this fault during commissioning mode.
21 Internal error—Time Base. Reset controla
22 Internal error—Safety relay. Reset controla
23 Internal error—Safety relay. Reset controla
24 Internal error—Time storage. Reset control.a
25 Internal error—Limited move. Reset control.a,c
26 Internal error—Targeted move. Reset control.a,c
27 Internal error—LVD. Reset control.a
28 Internal error—ISR check. Reset control.a
31 Internal fault—A2D Range. Reset control.a
Check actuator wiring; see Channel LED for actuator at fault.
32 Internal fault—A2D cross-matching error. Reset control.a
33 Internal fault—LCO Drive. Reset control.a
34 Internal fault—LCO/I Feedback. 1. Reset controlb.
2. Terminal 14 has voltage present from external source; correct
wiring error.
3. Make sure that short does not exist at terminal 14. Control will
need replacement if a sustain fault code 34 exists after steps 1, 2
and 3 are performed.
35 Internal fault— Reset control.a
36 Fuel selection error. 1.Check wiring through fuel select switch. Only one fuel can be
selected at any one time. This error causes the device to remain in
initiate state.
2. No fuel selected. Correct by selecting fuel.
37 Fault—HFP or LFP output. Verify correct wiring to burner control; specifically check wiring at
LFP and HFP.
38 Internal Fault—Memory curve. Reset control.a
39 Internal Fault—AC sampling. Reset control.a
41 Feedback potentiometer Interface circuit fault—Air. Verify correct wiring of potentiometer.a
42 Feedback potentiometer Interface circuit fault—Fuel 1. Verify correct wiring of potentiometer.a
43 Feedback potentiometer Interface circuit fault—Fuel 2. Verify correct wiring of potentiometer.a
44 Feedback potentiometer Interface circuit fault—FGR. Verify correct wiring of potentiometer.a
45 Feedback potentiometer wiper resistance problem—Air. Check for loose potentiometer wiring.a,c
46 Feedback potentiometer wiper resistance problem—Fuel Check for loose potentiometer wiring.a,c
1.
47 Feedback potentiometer wiper resistance problem—Fuel Check for loose potentiometer wiring.a,c
2.

65-0253-1 10
 833-02801 CONTROLINKS™ CONTROLLER

Table 6. Fault Listings and Descriptions. (Continued)

Fault/
BlinK
Code Description Corrective Action
48 Feedback potentiometer wiper resistance problem— Check for loose potentiometer wiring.a,c
FGR.
49 Feedback potentiometer total resistance problem—Air. Check for loose potentiometer wiring.a,c
51 Feedback potentiometer total resistance problem—Fuel Check for loose potentiometer wiring.a,c
1.
52 Feedback potentiometer total resistance problem—Fuel Check for loose potentiometer wiring.a,c
2.
53 Feedback potentiometer total resistance problem—FGR. Check for loose potentiometer wiring.a,c
54 Internal memory function problem—Air. Repeat actuator ID on-line process.
55 Internal memory function problem—Fuel 1. Repeat actuator ID on-line process.
56 Internal memory function problem—Fuel 2. Repeat actuator ID on-line process.
57 Internal memory function problem—FGR. Repeat actuator ID on-line process.
58 Stuck Reset button. Turn off remote reset switch; check operation of controller reset
button.
61 Actuator(s) not reaching lightoff point. Check for actuator wiring problems or stuck valves or dampers.
Place controller in standby and use actuator manual keys to verify
actuator travel.
65 Internal memory fault. Reset control.a
66 Internal Initialization Error. Reset control.a
67 Fuel actuator off curve (selected fuel type). Check for stuck fuel actuator and/or proper shielding on actuator
interface.
68 FGR actuator off curve. Check for stuck FGR actuator and/or proper shielding on actuator
interface.
69 Air actuator off curve. Check for stuck air actuator and/or proper shielding on actuator
interface.
71 Verifies that the Air actuator accepted the offline, online, Check wiring of actuator, verify correct ID is being used. Watch
move counter-clock-wise and move clock-wise actuator LED to verify that the actuator is being brought online. A
commands. Furthermore, all potentiometer tests must be fast flash in the actuator equals offline status, while a
successfully passed to bring an actuator online. one-second flash equals online status.
72 Verifies that the Fuel 1 actuator accepted the offline, Check wiring of actuator, verify correct ID is being used. Watch
online, move counter-clock-wise and move clock-wise actuator LED to verify that the actuator is being brought online. A
commands. Furthermore, all potentiometer tests must be fast flash in the actuator equals offline status, while a
successfully passed to bring an actuator online. one-second flash equals online status.
73 Verifies that the Fuel 2 actuator accepted the offline, Check wiring of actuator, verify correct ID is being used. Watch
online, move counter-clock-wise and move clock-wise actuator LED to verify that the actuator is being brought online. A
commands. Furthermore, all potentiometer tests must be fast flash in the actuator equals offline status, while a
successfully passed to bring an actuator online. one-second flash equals online status.
74 Verifies that the FGR actuator accepted the offline, Check wiring of actuator, verify correct ID is being used. Watch
online, move counter-clock-wise and move clock-wise actuator LED to verify that the actuator is being brought online. A
commands. Furthermore, all potentiometer tests must be fast flash in the actuator equals offline status, while a
successfully passed to bring an actuator online. one-second flash equals online status.
75 Internal memory fault. Reset control.a
76 Internal checksum error. Reset control.a
82 Actuator secondary fault. Check actuator wiring. See Channel LED for actuator.
83 Air actuator nonresponsive. Check actuator wiring and stuck damper/valve.c
84 Fuel 1 actuator nonresponsive. Check actuator wiring and stuck damper/valve.c
85 Fuel 2 actuator nonresponsive. Check actuator wiring and stuck damper/valve.c
86 FGR actuator nonresponsive. Check actuator wiring and stuck damper/valve.c
87 Internal math error. Reset control.a

11 65-0253-1
 Table 6. Fault Listings and Descriptions. (Continued)
Fault/
BlinK
Code Description Corrective Action
91 The 4 to 20 mA firing rate input is below 3 mA, Out of Check CmA+-input (Terminals 39 and 40) for proper operation
Range—Low. (Actuators return to or remain at the polarity and range. The input must be within 3.0 mA to 21.0 mA. The
minimum modulation point with the alarm on; the control voltage at this terminal must be within 0.7 to 5.0 Vdc, respectively.
remains operational only to the extent that Minimum Conditional Alarm—Alarm output is energized; controller continues
Modulation firing operation is allowed.) to run.
92 The manual potentiometer rate input is higher than an The Manual potentiometer is out of range high. Make sure a 5000
allowable range, i.e., Out of Range—High. (The ohm (±10%) potentiometer is being used and wiring to it is correct.
actuators move to the maximum modulation point with Shielded cable is recommended.
alarm ON, control will remain operable, yet when Conditional Alarm—Alarm output is energized; controller continues
MANUAL MODE is selected, maximum modulation and to run.e
alarm output shall occur.) Auto mode operation is not
affected.
93 The auxiliary 4-20 mA input must be below 3.0 mA when Check XmA+- input (Terminals 37 and 38) for proper operation
configured for use. (The actuators return or remain at the polarity and range. The input must be within 3.0 mA to 21.0 mA. The
minimum modulation point with alarm ON, the control will voltage at this terminal must be within 0.7 to 5.0 Vdc respectively.
remain operable only to the extent that Minimum Conditional Alarm—Alarm output is energized; controller continues
Modulation firing operation is allowed.) to run.e
94 After LCO is set by the 833 02801 Fuel Air Ratio Check burner control interface wiring and burner control operation
Controller, the Burner Control must provide a Lightoff or (Terminals 10, 11, 12). The 833 02801 Fuel Air Ratio Controller is
Purge request within 20 seconds. (Controller remains in a waiting for a command via these terminals.
processing demand condition indefinitely waiting for valid Conditional Alarm—Alarm output is energized; controller continues
inputs on the LF, MV and HF inputs; the alarm is sounded to run.e
after the 20-second period expires.)

a
It is possible that a random external electrical noise has caused a fault checking algorithm to be detected. Resetting the control will
allow recalculation of the fault and, if it is not a hard failure, the device will continue to operate. If the condition will not clear, the device
must be replaced.
b
Check ac waveform; severe noise on ac lines can corrupt sampling of ac signals.
c
Verify actuator total resistance and wiper measurements; check the ability of the actuator to travel full stroke using the manual override
buttons in the actuator. Verify input power to the actuator. if actuator is not functioning, replace the actuator.
d
Verify a short does not exist at terminal 14. The control will need replacement if a sustained fault code 34 exists after the noted items 1
and 2 have been performed. Fuse line voltage power to control system with type SC15 fuse or fuse Limit Input (terminal 13) with type
SC5 fuse.
e
Conditional Alarm. Causes the alarm output to be energized, the system may still be operating but requires attention in order to
modulate or to proceed with the light off sequence. The actuators would be positioned at lightoff point, minimum modulation point or
maximum modulation point, dependent on what the particular fault is and when the fault is introduced, relative to the 833-02801
operating state.

Wiring Checkout and Error Faults wiring problems occurring between the actuators and
controller, after commissioning, may be annunciated by fault
The commissioning and monitoring tools provides an effective codes 41 through 53 or 61,67,68,69 or 82 through 86.
means of an indirect status reading of all line voltage inputs
and outputs. Use these tools to confirm wiring. The Burner control wiring interface problems are annunciated by
commissioning tool and monitoring tool environments require fault codes 13, 14, 15, 34, 37.
that a single fuel select input to be active before proceeding
with communications between the tool and controller. Further, The 833-02802 Universal Wiring Subbase is partitioned into a
simultaneous HF and LF commands from the burner are not line voltage section and a low voltage section. Utilize shielded
allowed and will preclude communications with the tools. cabling on all low voltage wiring. Keep the earth ground cable
shield short as possible for all interface wiring as illustrated by
The act of bringing actuators successfully “on-line” verifies the Figure 2.
initial wiring between the controller and actuators. See error
codes 71 through 74 and/or 54 through 57 for details. Other

65-0253-1 7-01 Printed in U.S.A.