FRS100 Multiburner Control User`s Manual
Contents
1. 11er enne nnne nnne nnn nnne nnn 5 2 SPECIFICATIONS B Specifications oer aaa aeaaea SES iine E ai AEAEE EASE 6 1 B External dimensions eeeeeeee eene ener nnn nnn nnna 6 2 vi Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION m Overview The FRS100 Multiburner Control features built in safe start circuitry To ensure safety this circuitry prevents ignition if a failure is detected at startup and shuts off the fuel line if the flame is interrupted during operation Combined use with an ultraviolet flame detector or flame rod enables batch operation of burners B Features The start check function inspects the flame detector and flame relay body at startup to ensure safe operation If an abnormality is found ignition is prevented The controller is designed to be compact and can be plugged into the wiring sub base The sub base can be mounted by screws or onto a DIN rail The power supply state and ignition detection can be read easily from the LEDs on the front display Completion of the start check is indicated by the LED on the center of the body behind the front cover Flame voltage output 0 to 5Vdc can be checked at the dedicated terminal by a general purpose tester or continuously monitored by a panel meter or recorder The controller has a dedicated connector so that the optional FRS60A Flame Meter can be attached B Model listing wes Done vasorum e TERRE nemore2. 5 Press the controller into the subbase with the display facing upwards 6 Tighten the mounting screw on the center of the body to fix onto the subbase with a maximum torque of 0 3N m 7 If necessary wire the flame voltage meter terminal 8 Mount the cover on the control body Handling Precautions Do not tighten the subbase mounting screws using a torque exceeding the maximum torque 2 3 Chapter 2 MOUNTING AND WIRING 2 2 Wiring NWARNING Wire external leads between the power supply terminals 100V or 200V and OV of this control so that power is supplied at all times from the moment the power switch is turned ON This wiring is necessary to ensure operation of the self test circuits at startup NCAUTION When mounting or wiring be sure to follow the instructions in this user s manual and manuals provided by the equipment manufacturer or other device manufacturers Follow all applicable regulations when wiring Before wiring be sure to turn the power supply OFF Touching terminals by mistake with the power ON might cause an electric shock or malfunction Make sure that the loads connected to the terminals do not exceed the ratings indicated in the specifications Make sure that power of the same voltage and frequency as indicated on the Model No label is supplied to the controller When configuring control circuits select reliable timers and auxiliary relays as necessary for use as additional
3. False flame Check burner flame flame detector and flame relay 1K relay is not ON Check power supply at operation n terminal 7 Check flame relay To check if the controller is operating correctly apply a flame signal input to the controller by using a flame simulator Make sure that 2K relay is turned ON and the FLAME LED is lit The following table shows the required flame voltages FRS100C Standard model 2V min High sensitivity model 3V min IFRS100B Standard model 2V min How to connect the flame simulator 123514A B flame simulator Contact the terminal 5 lead wire to the probe end Contact the terminal 6 lead wire to the plug end 121708 flame simulator Contact the terminal 5 to the F lug Contact the terminal 6 to the G lug 1 Handling Precautions Keep the check time short and remove the simulator promptly after completion of the check Do not touch the terminals F and G during operation or during the check Doing so might cause electric shock 5 2 Chapter 6 SPECIFICATIONS B Specifications Rated Power Supply 100Vac 50 60 Hz 200Vac 50 60 Hz Allowable Voltage 15 to 10 of rated voltage Contact Rating 250Vac across terminals 3 4 3 8 Flame Sensitivity Ignition detection level Flame voltage 1V max Flame out detection level FRS100B series flame voltage 0 2V min FRS100C series flame voltage 0 4V min Flame Signal Output Use at least 0 9mm wire a max of 5m lon
4. No CP SP 1074E FRS100 Multiburner Control User s Manual Thank you for purchasing the FRS100 Multiburner Control This manual contains information for ensuring the correct use of the FRS100 It also provides necessary information for installation maintenance and trou bleshooting This manual should be read by those who design and maintain equipment that uses the FRS100 Be sure to keep this manual nearby for handy reference Yamatake Corporation RESTRICTIONS ON USE This product has been designed developed and manufactured for general purpose application in machinery and equipment Accordingly when used in applications outlined below special care should be taken to implement a fail safe and or redundant design concept as well as a periodic maintenance program Safety devices for plant worker protection Start stop control devices for transportation and material handling machines Aeronautical aerospace machines Control devices for nuclear reactors Never use this product in applications where human safety may be put at risk NOTICE Be sure that the user receives this manual before the product is used Copying or duplicating this user s manual in part or in whole is forbid den The information and specifications in this manual are subject to change without notice Considerable effort has been made to ensure that this manual is free from inaccuracies and omissions If you should find an
5. Standard model 3W max 3 1s Flame Rod FER n flame voltage 2V C7012A C7012C FRS100C100 100Vac 50 60Hz 7W max 3 x1s Minipeeper FRS100C200 200Vac 50 60Hz flame voltage 4 2V Ultraviolet Flame Detector FRS100C104 100Vac 50 60Hz 2s max c7eseh CIT FRS100C204 200Vac 50 60Hz flame voltage 4 2V High sensitivity FRS100C150 100Vac 50 60Hz 7W max 31s model FRS100C250 200Vac 50 60Hz flame voltage 3 5V FRS100C154 100Vac 50 60Hz 2s max flame voltage 3 5V FRS100C254 200Vac 50 60Hz 1 1 Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION B Names of parts FRS100 body FRS50A100 subbase sold separately r POWER LED green Indicates power ON OFF FLAME LED red Indicates flame detection 2K relay Indication DIN rail T EE Jese I i Cover removed Body mounting screw Connector exclusively for optional flame voltage meter sold separately Start check operation LED green Indicates start check operation 1K relay M3 5 terminal DNN rail Eo M3 5 terminal screw 8 DIN rail Subbase mounting holes 2 DIN rail mounting plate B Configuration Flame Detector FRS100B FRS100C Minipeeper Ultraviolet Flame C7035A C7027A Detector Optional Parts sold separately Lm Lem Subase FRSS0A100 00 Flame Meter Meter FRS60A Flame simulator for 123514B Flame Simulator for 123514A 121708 C7035A C7027A F
6. The power supply is marked H and G for the voltage and ground sides respectively Accordingly connect the voltage side H to terminal 1 and the ground side G to terminal 2 Burner flame monitoring a x itid V Flame amplifier circuit Flame voltage meter terminal Sub base Operation contact Contact output Start check completed Flame voltage 0 to 5Vdc Flame output Flame detector Voltage side H Ground side G o Handling Precautions The power supply is marked H and G for the voltage and ground sides respectively Accordingly connect the voltage side H to terminal 1 and the ground side G to terminal 2 Chapter 2 MOUNTING AND WIRING B Wiring the flame detector NCAUTION o Connect the blue signal lead from the Minipeeper Ultraviolet Flame Detector to terminal 5 F and the white lead to terminal 6 G If the power is turned ON with these leads miswired the built in UV tube may be damaged Wiring between the C7035 C7027 Minipeeper Ultraviolet Flame Detector and the FRS100C C7035 C7027 Terminal 5 F Blue ME Terminal 6 G White Permissible lead length Type of signal lead 2mm 600Vac IV indoor vinyl insulated power lead Permissible lead length Approx 200m Wiring between the Flame Rod and the FRS100B N Terminal 5 P Terminal 6 1l Permissible lead length Type of signal lead Hi
7. response test This test should be carried out on any equipment that uses an ultraviolet flame detector The test is to check whether or not the ultraviolet flame detector responds to UV rays emitted from the ignition spark Ultraviolet Flame Detector NCAUTION Make sure that the ultraviolet flame detector cannot detect UV rays emitted by sources other than the burner If the ultraviolet flame detector responds to other UV sources it will judge that there is a flame even if the burner flame is out As a result fuel will continue to be supplied causing a very serious explosion hazard Carry out the following test to check whether or not the ultraviolet flame detector or flame rod responds to the UV rays emitted from the ignition spark so that the FLAME LED lights up 1 Close the manual fuel valves of the pilot and main burner 2 Start operation and measure the flame voltage during the pilot ignition sequence to check for any influence from UV rays 3 If the FLAME LED lights up carry out the following adjustment referring also to the equipment user s manual Move the position of the ultraviolet flame detector or ignition spark rod so that the ultraviolet flame detector is not influenced by UV rays nstall a shield for example to prevent UV rays from the spark from entering the optical path of the ultraviolet flame detector and adjust so that the influence of the spark on the flame voltage is 0 4Vdc or less 4 5 C
8. t i i Combustion lamp Input Operation input terminals 7 3 Ignition switch Output Ignition transformer Pilot valve Main valve Indication POWER LED FLAME LED Start check LED 1K relay Combustion lamp Input Operation input terminals 7 3 Ignition switch Output Ignition transformer Pilot valve Flame failure V Main valve i Indication POWER LED FLAME LED Start check LED 1K relay Combustion lamp Chapter 3 EXPLANATION OF OPERATION Operation FRS100 Operation Equipment State 3 2 Power switch ON limit switch ON Operation contact ON Ignition switch ON Do not leave ignition switch ON Pilot burner normally lights in 5 to 10 seconds Ignition switch OFF Operation contact Flame failure e Power is applied across the 100V or 200V and OV power terminals on the equipment the POWER LED lights up Start check is carried out by energizing terminal 7 and the 1K relay turns ON the start check LED lights up If there is a false flame the 1K relay does not output to terminals 4 and 8 as it is not energized and the ignition operation is not started Voltage is applied to the pilot valve and ignition transformer from terminal 8 initiating each of their operations When the flame detector detects the pilot burner flame the 2K relay turns ON the FLAME LED lights up The pilot valve is held open from termin
9. the burner ignition time which the equipment manufacturer specifies Excessively long ignition time might cause fuel to accumulate in the combustion chamber and an explosive air fuel mix to form resulting in the risk of a serious explosion Before carrying out the pilot turndown test or ignition spark response test be sure that all manual fuel valves are closed Do not operate the control without completing the tests described in this chapter and the tests specified by the equipment manufacturer If the flame detector is set so that it detects a pilot flame that is too small to ignite the main burner this control will not be able to recognize a flame failure in the main burner In this case fuel would continue to be supplied causing a serious explosion hazard Be sure to carry out the pilot turndown test carefully e eoo e OO If the pilot turndown test must be carried out repeatedly completely shut down all equipment each time the test is finished and completely discharge unburned gas or fuel that has accumulated in the smoke ducts and combustion chamber Failure to discharge unburned gas or fuel may result in an explosion A WARNING After the pilot turndown test is completed turn the power switch OFF to turn the power OFF Be sure to restore all test jumper leads limit switches and control settings used in the test to their original settings If this control is operated without these components restore
10. EW AND PRODUCT CONFIGURATION Malis P 1 1 MIC 1 1 B Model listing cnc erre recorrer ene eio tore norunt eua unte rna un nnne 1 1 B Names of parts ecieiisueceeecenor cre ai 1 2 B Configuration ieiuna Lee iine eU Dein eeu eiue uie cua pedes 1 2 MOUNTING AND WIRING Mounting and Wiring the Subbase eese nnne 2 1 WY LUMI ec 2 4 B Wiring overview eereureeee nenne ener nnne nnnm nnne ennemis nnns 2 5 B Wiring the flame detector eese nnne 2 6 B Wiring the solenoid valve eere nnn 2 7 B Wiring the surge absorber eere nnne nnn 2 8 EXPLANATION OF OPERATION B Manual ignition intermittent pilot eene 3 1 B Burner flame monitoring cereum 3 3 ADJUSTMENTS FOR TRIAL OPERATION E Outline nrc einen ecu Eme 4 1 B How to measure the flame signal eere 4 2 B Pilot turndown test senini 4 3 E ignition spark response test 1eeeeeeeeeeeeenennnneeennn nnns 4 5 B Safety shutoff test eecccinieieeee cer eceeiece nter Len nunne nnne ena nnnm u aimer ras 4 6 MAINTENANCE AND INSPECTION B inspection cycle eeeeeseeeeeeneee eene enne nnne nnne nnn nnne 5 1 B Troubleshooting
11. NTS FOR TRIAL OPERATION 4 4 6 Slowly open the manual valve for the pilot until the pressure matches the pressure immediately before the combustion lamp went out Then press the ignition switch again to ignite the pilot 7 Release the ignition switch Make sure that the main burner ignites without any problem in one second or less when the main burner manual valve is opened 8 Change the pressure from the minimum to the maximum value and repeatedly ignite the main burner several times Make sure that the main burner ignites without any problem every time 9 If the main burner does not ignite properly the reason is probably that the pilot flame is too small Increase the size of the pilot flame and carry out the following adjustment Either slightly take the monitor line of the flame detector away from the axis of the pilot flame or stop the iris down to correct the visible flame size Set the flame size so that the main pilot ignites without problem at the minimum flame sensitivity 10 After making this adjustment repeat steps 5 to 8 and make sure that main burner ignition is reliable 11 When this test is completed return the manual valve for the main burner to its fully open position Then make sure that the flame signal is appropriate 12 Remove any jumper leads connected to limit switches during this test to restore to their original conditions Chapter 4 ADJUSTMENTS FOR TRIAL OPERATION B ignition spark
12. al 4 via the 1K and 2K contacts The main valve is energized by resetting the ignition switch contact The pilot valve main valve and combustion lamp are de energized and operation stops The start check LED and FLAME LED go out The 2K relay becomes de energized after the flame response the combustion lamp goes out the main Ready for ignition Ignition transformer stops Pilot valve opens Main valve opens Pilot valve closes Main valve closes Combustion lamp out Pilot valve closes Main valve closes valve closes the pilot valve closes and the equipment Combustion lamp out stands by for re ignition the FLAME LED goes out Chapter 3 EXPLANATION OF OPERATION B Burner flame monitoring x Internal Circuit ee Start check circuit Flame voltage measuring terminal Subbase Operation contact Flame voltage 0 to 5Vdc Voltage side H Ground side G Normal Operation Input Operation input terminals 1 7 Flame detection F G terminals 5 6 Output Start check output terminals 3 8 Flame output terminals 3 4 Indication POWER LED FLAME LED 2K Start check LED False Flame Operation Input Operation input terminals 1 7 Flame detection F G terminals 5 6 Output Poi Start check output terminals 3 8 a Flame output terminals 3 4 tot Indication bo POWER LED j FLAME LED i Start check LED fog Operation W
13. d it might be damaged or a gas leak or explosion might result Do not touch terminal F or the flame detector cable connected to terminal F Failure to pay attention to this warning might cause electric shock An electric charge remains in the terminal F and the connected signal cable even after the power is turned OFF CAUTION Make sure that the ultraviolet flame detector cannot detect UV rays emitted by sources other than the burner If the ultraviolet flame detector responds to other UV sources it will judge that there is a flame even if the burner flame is out As a result fuel will continue to be supplied causing a very serious explosion hazard This control has extremely important functions for safe operation of equipment Follow the instructions in the user s manuals to ensure safe use Do not transport this control while it is mounted on a DIN rail Before transporting the control remove it from the subbase and pack it in its original packing case If this control is transported on a DIN rail it might fall off and be damaged Mounting wiring maintenance inspection and adjustment should be carried out by a specialist who has been trained in how to handle burners and combustion safeguard equipment Do not mount this control in the following locations Near corrosive chemicals or gases ammonia sulfur chlorine ethylene compounds acid etc Where subject to water spray or extreme humidi
14. e taking into consideration the following factors Type of equipment Ambient conditions of installation site dust temperature etc The effect of burner failure on equipment operation 1 Carry out the safety shutoff test described in Chapter 4 ADJ USTMENTS FOR TRIAL OPERATION once per month 2 Inspect the monitor window on the ultraviolet flame detector the flame rod etc for dirt and clean as necessary 3 Check the temperature where the ultraviolet flame detector is installed 4 Measure the flame voltage at least once per month to check its state If equipment will be seriously damaged by a burner failure carry out this inspection more frequently 5 1 Chapter 5 MAINTENANCE amp INSPECTION B Troubleshooting If a problem occurs remove the front cover of the controller Determine the operating state of the controller and type of trouble by checking the start check POWER and FLAME LED display states The start check LED is located in the center inside the cover and the POWER and FLAME LEDs are located on the front display O LED out LED iit POWER Start check LED FLAME Results Remedy check items LED LED Before The power is not ON Check panel power switch and startup wiring terminal 7 OFF After startup The flame is being terminal 7 detected normal ON operation The flame has not Check flame detector burner been detected flame relay valves ignition transformer and flame relay
15. e the internal temperature of the control panel by mounting a panel cooler or a cooling fan Allowable ambient temperature upper limits Gang mounting 45 C Stand alone mounting 60 C 2 1 Chapter 2 MOUNTING AND WIRING 2 2 Mounting direction DIN rail mounting Mount so that the arrow on the subbase is facing upwards ERRENA FLAME RELAY POWER FLAME 1 Pull the DIN rail fixing plate downwards 2 Place the controller on the DIN rail so that the arrow on the subbase is facing upwards 3 Press in the DIN rail fixing plate to fix onto the DIN rail 4 Wire the subbase terminals as instructed in 2 2 Wiring 5 Pull the bottom of the controller cover downwards to remove 6 Press the controller into the subbase with the display facing upwards 7 Tighten the mounting screw on the center of the body to fix onto the subbase with a maximum torque of 0 3N m 8 If necessary wire the flame voltage meter terminal 9 Mount the cover on the control body Chapter 2 MOUNTING AND WIRING Direct panel mounting 1 Drill two M4 mounting holes in the panel so that the arrow on the subbase will be facing upward 4s a M4 2 locations cm 2 Attach the two mounting holes on the subbase to the panel using two M4 screws at a maximum torque of 0 7N m 3 Wire the subbase terminals as instructed in 2 2 Wiring 4 Pull the bottom of the controller cover downwards to remove
16. e user that specific actions are Filled in black circles instruct the user to carry out a specific obligatory action to prevent possible danger These icons graphically represent the actual action to be carried out The example on the left instructs the user to remove the plug from the outlet A WARNING Before removing mounting or wiring the FRS100 be sure to turn the power OFF Failure to do so might cause electric shock Do not touch the terminals on this control Doing so might result in an electric shock eoe This control is for batch operation at least one start and stop in 24 hours of operation that utilizes the start check function Do not use this control for continuous operation combustion for 24 hours or longer Instead use a self checking Protectorelay AUR300 AUR350 AUR450 or R4332B etc which continuously checks the flame detector and flame detector circuit and use a compatible flame detector AUD300 or C7076 etc This control does not have the prepurge timing and sequencing functions necessary for burner ignition Take timer and sequence functions into consideration when designing your control system Do not connect the solenoid valve to the voltage side If a ground fault occurs ground current will flow to the solenoid valve and open it causing fuel to flow regardless of the state of this control Prevent the pilot and main burner ignition times from exceeding
17. error or omis sion please contact Yamatake Corporation In no event is Yamatake Corporation liable to anyone for any indirect special or consequential damages as a result of using this product 1999 Yamatake Corporation ALL RIGHTS RESERVED N SAFETY PRECAUTIONS J B About Icons The safety precautions described in this manual are indicated by various icons Please be sure you read and understand the icons and their meanings described below before reading the rest of the manual Safety precautions are intended to ensure the safe and correct use of this prod uct to prevent injury to the operator and others and to prevent damage to proper ty Be sure to observe these safety precautions AN WAR N N G Warnings are indicated when mishandling this product might result in death or serious injury CAUTI O N Cautions are indicated when mishandling this product N might result in minor injury to the user or only physical damage to the product B Examples wrongful operation or misuse of this product These icons graphically represent the actual danger The example on the left warns the user of the danger of electric shock Triangles warn the user of a possible danger that may be caused by prohibited to prevent possible danger These icons graphically represent the actual prohibited action The example on the left notifies the user that disassembly is prohibited G White circles with a diagonal bar notify th
18. functions Be sure to ground this control using a lead with a resistance of less than 1000 and be sure to ground the burner body Bundle power leads ignition transformer high voltage cables and flame detector leads separately from each other Keep ignition transformer high voltage cables at least 10cm away from the flame relay Make sure that ignition transformer high voltage cables are properly connected to prevent faulty contact Faulty contacts might generate high frequency radio waves resulting in noise in radios or other electrical appliances or causing malfunction Connect the ignition transformer ground lead directly to the burner body or to a metal part that is electrically connected to the burner body After wiring be sure to check the wiring connections Operating the control with wires wrongly connected might cause damage or malfunction e e Q Q o e o e e e o e 2 4 Chapter 2 MOUNTING AND WIRING B Wiring overview Manual ignition intermittent pilot Fa P m Internal Circuit Start check circuit Ta Vw Power S id B Flame amplifier O O a input circuit Q Q Flame voltage 1K oo ae IR qe 6e 4o Lm meter terminal Sub base D 2 R S e Q B b d Buc x 2 Ignition contact O D O aoe ip Limit Flame Switch Combustion Ignition detector Flame voltage lamp transformer 0 to 5Vdc Voltage side H Ground side G Handling Precautions
19. g with IV indoor vinyl insulation Output terminals A and B on body Input impedance of externally connected equipment 100kQ min Ambient Temperature Stand alone mounting 20 to 60 C Gang mounting 2 units or more 20 to 45 C Ambient Humidity 90 RH 40 C condensation not allowed Vibration Resistance 4 9m s max 10 to 60Hz for 2h each in X Y and Z directions when directly mounted on panel 50MO min between terminals and ground terminal by 500Vdc megger Dielectric Strength No failure after applying 1500Vac for 1min or 1800Vac for 1s between terminals and ground terminal excluding flame detector input of terminals 5 and 6 Lightning surge 10kV 1 2 x 50us JEC 187 surge impedance 750 or more when the following surge absorber is attached to a power supply contact terminal 2 and the ground terminal Recommended surge absorber 83968019 001 100 000 operations at room temperature and humidity and rated voltage Mounted on DIN rail or screw mounted when using the FRS50A100 subbase FRS100B Approx 270g FRS100C Approx 270g FRS50A subbase Approx 70g Optional Parts Subbase Model No FRS50A100 sold separately Flame Simulator for C7035A C7027A Model No 1231514B Lightning surge absorber Model No 83968019 001 Flame Meter Model No FRS60A Flame Simulator for Flame Rod Model No 1235144 121708 6 1 Chapter 6 SPECIFICATIONS B External dimensions External dimensions when FRS100 is moun
20. gh frequency coaxial cable 5C2V 7C2V Permissible lead length Approx 30m Wiring between the C7012A C Ultraviolet Flame Detector and the FRS100B Blue F Yellow G Terminal 5 Terminal 6 Permissible lead length Type of signal lead High frequency coaxial cable 5C2V 7C2V Permissible lead length Approx 50m 2 6 Chapter 2 MOUNTING AND WIRING B Wiring the solenoid valve NCAUTION S Do not connect the solenoid valve to the voltage side If a ground fault occurs ground current will flow to the solenoid valve and open it causing fuel to flow regardless of the state of this control Correct connection Voltage side H iFlame relay FRS100 Ground fault Combustion unit Valve closed Fuel Ground current will not flow to the solenoid valve if the valve is wired as shown in the figure above even if faulty insulation on the voltage side H causes a ground fault Accordingly the valve will not open eliminating the risk of fuel discharge Wrong connection Ground fault Voltage side H Combustion unit Valve open h Fuel Ground current will flow to the solenoid valve if the valve is wired as shown in the figure above and if a ground fault occurs Accordingly the solenoid valve will open regardless of the flame relay causing fuel discharge 2 7 Chapter 2 MOUNTING AND WIRING B Wiring the surge ab
21. hapter 4 ADJUSTMENTS FOR TRIAL OPERATION Cautions Regarding UV Sources Other Than Flames The table below shows sources other than flames that emit UV rays that can be detected by the ultraviolet flame detector Make sure that these UV sources do not influence operation of the ultraviolet flame detector under any operating conditions UV generating sources 1260 C or higher red hot chamber wall Sparks gnition transformer Welding arc Lightning Gas laser Sunlamp Sterilizing lamp Strong flashlight in direction of UV photoelectric tube Gamma ray and X ray sources Diffraction analyzer Electron microscope X ray machine High voltage vacuum switch High voltage capacitor Radioactive isotope All other UV gamma ray and X ray sources B Safety shutoff test Carry out the safety shutoff test when all operating adjustments have been completed Pilot ignition failure non ignition 1 Close the manual fuel valves of the pilot and main burner 2 Press the ignition switch to start operation 3 The pilot valve opens upon pilot ignition However since the pilot cannot light the FLAME LED does not light and the main valve does not open Do not continuously hold down the ignition switch Flame failure during normal combustion 1 Open the manual fuel valves of the pilot and main burner 2 Press the ignition switch to start operation 3 After the ignition sequence has proceeded normally and the steady co
22. hen the operation contact turns ON the 1K relay turns ON at completion of the start check and terminals 3 8 turn ON The start check LED lights up in sync with terminals 3 8 turn ON When the flame is detected the 2K relay turns ON and terminals 3 4 turn ON The FLAME LED lights up in sync with terminals 3 4 turn ON 3 3 Chapter 4 ADJUSTMENTS FOR TRIAL OPERATION NWARNING Prevent the pilot and main burner ignition times from exceeding the burner ignition time which the equipment manufacturer specifies Excessively long ignition time might cause fuel to accumulate in the combustion chamber and an explosive air fuel mix to form resulting in the risk of a serious explosion Do not touch the terminals during trial operation adjustments Doing so might result in an electric shock Before removing or mounting the FRS100 be sure to turn the power OFF Failure to do so might cause electric shock Before carrying out the pilot turndown test or ignition spark response test be sure that all manual fuel valves are closed Do not operate the control without completing the tests described in this chapter and the tests of specified by the equipment manufacturer B Outline The following table shows the test adjustment items described in this chapter Applicable Unit Flame signal measurement method All units Pilot turndown test Units using the pilot burner Ignition spark response test All units Safety shutdown test All unit
23. lame Rod Lightning surge absorber 8396801 9 001 Ultraviolet Flame Detector C7012A C Flame Rod C7007A C7008A 1 2 Chapter 2 MOUNTING AND WIRING 2 1 Mounting and Wiring the Subbase NCAUTION Do not mount this control in the following locations Near corrosive chemicals or gases ammonia sulfur chlorine ethylene compounds acid etc Where subject to water spray or extreme humidity Where subject to high temperatures Where subject to continuous vibration Do not transport this control while it is mounted on a DIN rail Before transporting the control remove from the subbase and pack it in its original packing case If the controller is transported on a DIN rail it might fall off and be damaged When mounting or wiring be sure to follow the instructions in this user s manual and manuals provided by the equipment manufacturer or other device manufacturers Mounting location Maintain space around the control as shown below for heat radiation and to facilitate mounting removal wiring and maintenance Above 50mm min ESRB FLAME RELAY POWER MRS FLAME RELAY POWER RSM FLAME RELAY R Powe FLAME 20mm min e o o 20mm min Below 20mm min Handling Precautions f there is room leave as much space as possible between the FRS and other FRS units to allow for heat radiation If ambient temperature is close to the allowable upper limit reduc
24. mbustion cycle main valve open has begun close the manual fuel valves for the pilot and main burner to turn the burner flame off At this time make sure that the flame failure is detected and that the safety shutoff operates 4 6 Chapter 5 MAINTENANCE AND INSPECTION Z WARNING Before removing or mounting the FRS100 be sure to turn the power OFF Failure to do so might cause electric shock Do not touch the terminals on this control Doing so might result in an electric shock Do not touch terminal F or the flame detector cable connected to terminal F Failure to pay attention to this warning might cause electric shock An electric charge remains the terminal F and the connected signal cable even after the power is turned OFF A CAUTION Mounting wiring maintenance inspection and adjustment should be carried out by a specialist who has been trained in how to handle burners and combustion safeguard controllers When the controller is restarted after the safety shutoff check all items described in Chapter 4 ADJUSTMENTS FOR TRIAL OPERATION Before carrying out maintenance and inspection on the burner be sure to carry out the pilot turndown test Carry out this test at least once every year Periodically maintain and inspect the equipment as instructed in the equipment manufacturer s user s manuals When cleaning the burner also clean the flame detector B Inspection cycle Determine an inspection cycl
25. nd combustion chamber Failure to discharge unburned gas or fuel may result in an explosion After the pilot turndown test is completed turn the power switch OFF to turn the power OFF Be sure to restore all test jumper leads limit switches and control settings used in the test to their original settings If this control is operated without these components restored it might be damaged or a gas leak or explosion might result NCAUTION o The pilot turndown test must be carried out by an experienced specialist having sufficient knowledge of burners and combustion safeguards o Handling Precautions f fuel pressure limit switches are open in use during this test connect jumpers to set the limit switches ON Procedure 1 Turn the power switch OFF 2 Close the manual valve for the pilot and for the main burner to stop the gas flow 3 Open the pilot manual valve 4 Turn the power switch ON followed by the start switch Then press the ignition switch on the controller The pilot will ignite and the pilot valve will open Ignition will begin and the combustion lamp will light Release the ignition switch 5 Slowly close the pilot manual valve The pilot flame will gradually grow smaller Continue to close the manual valve until the flame detector can no longer detect the flame Turn the 2K relay OFF and write down what the pressure was immediately before the combustion lamp went out 4 3 Chapter 4 ADJUSTME
26. oles to connect to terminals A and B at the bottom front of the controller as shown below FRS100 FLAME RELAY Terminal B Terminal A Tester N Input impedance 100kQ or more Black Red 0 to 5Vdc range 3 Refer to the following table for voltage values Recommended flame voltage Checklist Make sure that flame monitoring is correct The front of the flame detector must be free 2Vdc min of dirt The monitoring tube must not be blocked with soot 4 If the flame signal fluctuates check the flame detector mounting position and wiring again 4 2 Chapter 4 ADJUSTMENTS FOR TRIAL OPERATION B Pilot turndown test This test is for checking that the pilot flame is transferred to the main burner when the flame detector detects the pilot flame even if gas pressure and air pressure are at their worst Z WARNING If the flame detector is set so that it detects a pilot flame that is too small to ignite the main burner this control will not be able to recognize a flame failure in the main burner In this case fuel would continue to be supplied causing a serious explosion hazard Be sure to carry out the pilot turndown test carefully If the pilot turndown test must be carried out repeatedly completely shut down all equipment each time the test is finished and completely discharge unburned gas or fuel that has accumulated in the smoke ducts a
27. on Jan 2007 May 2005 uni i WAMATAKE azbil Yamatake Corporation Advanced Automation Company 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan URL http www azbil com Printed on recycled paper 07 Specifications are subject to change without notice Printed in Japan 1st Edition Issued in Oct 1999 K 13th Edition Issued in Jan 2007 U
28. ribed in Chapter 4 ADJUSTMENTS FOR TRIAL OPERATION Before carrying out maintenance and inspection on the burner be sure to carry out the pilot turndown test Carry out this test at least once every year When cleaning the burner clean the flame detector also When mounting or wiring be sure to follow the instructions in this user s manual and manuals provided by the equipment manufacturer or other device manufacturers Follow all applicable regulations when wiring Make sure that ignition transformer high voltage cables are properly connected to prevent faulty contact Faulty contacts might generate high frequency radio waves resulting in noise in radios or other electrical appliances or causing malfunction e coco OS oecccecececeo Connect the ignition transformer ground lead directly to the burner body or to a metal part that is electrically connected to the burner body Conventions Used in This Manual The following conventions are used in this manual 1 Handling Precautions Handling Precautions indicate items that the user should pay attention to when handling the FRS100 Note Notes indicate information that might benefit the user 1 2 3 Numbers within parentheses indicate steps in a sequence or parts of an explanation SAFETY PRECAUTIONS Conventions Used in This Manual Chapter 1 Chapter 2 2 1 2 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 OVERVI
29. s 1 Handling Precautions After adjusting the above items make sure that all of the adjustment requirements are satisfied All of the adjustment requirements must be satisfied by the final mounting position of the flame detector Required items e Tester input impedance 100k 2 or more Range 0 to 300Vac 0 to 5Vdc e Two jumper leads with crocodile clips AWG14 2mm or more approximately 30cm long nsulation tester 500Vdc megger Preliminary inspection Check all wiring locations Make sure that the controller is mounted at a location within the permissible ambient temperature Make sure that the flame detector is properly mounted For details see the flame detector user s manual 4 1 Chapter 4 ADJUSTMENTS FOR TRIAL OPERATION Disconnect the loads and flame detector wiring Measure the insulation resistance across the terminals and panel ground and make sure that the resistance is 50M or more using an insulation tester or megger of 500Vdc or more Valves and cocks on each of the fuel lines must be closed and the fuel chamber must be thoroughly purged B How to measure the flame signal 1 Handling Precautions When the high sensitivity model is used limit the flame voltage to 4 5V 1 Start the controller and measure the flame voltage for each burner under various conditions at startup normal operation etc 2 When measuring the flame voltage insert the tester probes into the h
30. sorber Wire as shown below when using a surge absorber model No 83968019 001 ordered separately for protection from lightning surge Voltage side H Q Ground side G Surge absorber 83968019 001 1 Handling Precautions Use a JIS C 3306 0 75mm power lead lead diameter 0 18 30 strand or higher for wiring to the power supply Attach a Faston receptacle 187 made by AMP to one end of the power lead and make the wire connection as short as possible Ground the surge absorber mounting bracket by attaching to a grounded metal part such as the burner body 2 8 Chapter 3 EXPLANATION OF OPERATION B Manual ignition Intermittent pilot C 1K Vx Internal Circuit Start check circuit 2K rv VANI Power Flame amplifier O O fant input circuit Q Q Flame voltage af poe Kk 2 00 0 202222222 meter terminal E Sub base 2 mf 9 o 0o 9 W b b Operation O D O x contact O b of lf o Ignition T switch Limit Flame Switch Combustion Main Pilot Ignition detector Flame voltage lamp valve valve transformer 0 to 5Vdc Voltage side H Normal Operation False Flame Operation Flame Failure Operation Ground side G Input Operation input terminals 7 3 Ignition switch Output Ignition transformer Pilot valve Main valve Indication POWER LED FLAME LED Start check LED 1K relay TE m i Flame failure response 3 s
31. ted on FRS50A100 99 1 Unit mm DIN rail Subbase FRS50A100 sold separately FRS100 JA A i CES NUN M c Dimensions required for mounting and removing body 2 Dimensions required for mounting and removing from DIN rail 6 2 Chapter 6 SPECIFICATIONS FRS50A100 subbase M3 5 terminal screw 8 Subbase mounting holes 2 l ees jan n H l SA TAN LL DIN rail DI 7 U iil SCR DIN rail mounting plate 6 3 Revision History date GPSPAWETSEd 7000 Nov 2000 Unpacking deleted Power supply specifications added May 2001 Handling Precautions added Hn How to connect the flame simulator added EE 2002 Output items corrected Pilot Value Main Value Pilot Valve Main Valve Vibration Resistance Changed 5234 9m s RESTRICTIONS ON USE changed 4 2 Insulation resistance corrected 100M 2 to SOMQ 7th jeu R4334A was deleted from the 3rd item jemi j 5 1 One item was added to warning 8th Edition 2 6 6 1 Class IV 2mm changed into IV Indoor Vinyl 0 9mm Lightning surge Specifications No 10013 deleted 6 1 9th Edition 2 6 IV Indoor Vinyl 0 9mm gt 2mm changed a Handling Precautions changed Normal operation FLAME LED changed to FLAME LED 2K a i aa on G6 Operation changed Tath Eaton i re dung Feb 2004 Feb 2005 May 2005 Dec 2005 May 2006 10th Editi
32. ty Where subject to high temperatures Where subject to continuous vibration for a long time After wiring be sure to check the wiring connections Operating this control with wires wrongly connected might cause damage or malfunction iii ANCAUTION Be sure to wire the power supply last of all Touching terminals by mistake with the power ON might cause an electric shock or malfunction Make sure that the loads connected to the terminals do not exceed the specified ratings Make sure that power of the same voltage and frequency as indicated on the model number label is supplied to the control When configuring control circuits select reliable timers and auxiliary relays as necessary for additional functions Be sure to ground this control using a lead with a resistance of less than 1000 and be sure to ground the burner body Bundle power leads ignition transformer high voltage cables and flame detector power leads separately from each other Make sure that ignition transformer high voltage cables are bundled separately Keep these cables at least 10cm away from this control Connect the blue signal lead from the Minipeeper Ultraviolet Flame Detector to terminal 5 and the white lead to terminal 6 If the power is turned ON with the Minipeeper Ultraviolet Flame Detector wired wrongly the UV tube might be damaged When equipment is restarted after the safety shutoff check all items desc
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