FRS110 Multiburner Control FSG Relay User`s Manual
Contents
1. facilitate mounting removal wiring and maintenance Above 50mm min BESO FsG RELAy 9 POWER e IG BEE FSG RELAY POWER e IG RES FLAME RELAY e START epy POWER e IG O START epy ALARM e MV Below 20mm min 1 Handling Precautions e l there is room leave as much space as possible between the FRS and other FRS units to allow for heat radiation O START epy ALARM emy ALARM e Mv 20mm min e If ambient temperature is close to the allowable upper limit reduce the internal temperature of the control panel by mounting a panel cooler or a cooling fan Allowable ambient temperature upper limits e Gang mounting 45 C e Stand alone mounting 60 C 2 1 Chapter 2 MOUNTING AND WIRING 2 2 O Mounting direction e Mount so that the arrow on the subbase is facing upwards 0 IT AO ee nx mm KES EEN AN RA NEANEA N N CIJ CLICA LU a a a Q a LJ t O Mounting on a DIN rail O Mounting on panel directly 1 Slide the DIN rail locking tab downwards 2 Place the subbase on the DIN rail with the arrow on the subbase facing upwards 3 Slide the DIN rail locking tab to secure the subbase to the DIN rail 4 Wire the subbase terminals as instructed in section 2 2 Wiring 5 Pull the bottom of the cover forward to remove 6 Insert the FRS110 into the subbase with the display panel in front 7 Tighten the mounting screw in the center of the FRS110 attach it t2. ALARM MV 1 Space required for mounting and removing body 2 Space required for mounting and removing from DIN rail 6 2 Chapter 6 SPECIFICATIONS O FRS50A100 subbase sold separately Unit mm 41 M3 5 terminal screw 8 Subbase mounting DIN rail locking tab 6 3 Revision History date Nov 2006 CP SP 1214E ist Ein Yamatake Corporation Advanced Automation Company 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan URL http www azbil com Printed on recycled paper 07 azbil Specifications are subject to change without notice Printed in Japan 1st Edition Issued in Nov 2006 U
3. fuel 2 6 Chapter 2 MOUNTING AND WIRING E Wiring the surge absorber Wire as shown below when using a surge absorber model No 83968019 001 ordered separately for protection from lightning surge Voltage side H Voltage side H 5 U Power supply Ground side G Inter lead surge absorber f Faston receptacle AMP 187 IA Mounting bracket ground A A Power supply Ground side G Surge absorber 83968019 001 1 Handling Precautions e Use at least JIS C 3306 0 75mm power leads 30 strands 0 18mm in dia for wiring to the power supply e Attach a Faston receptacle AMP 187 to one end of the power leads and make the wires as short as possible e Ground the surge absorber mounting bracket by attaching to a grounded metal part such as the burner body 2 1 Chapter 3 OPERATION NW Sequence diagrams Power supply Power supply H Start switch G OO FRS110 e Pilot valve ln Ignition transformer 1 5 Mainvalve valve Reset switch 1 Combustion Combustion lamp 1 1 Flame amplifying circuit WK Flame detector e Normal operation Input Start input Term 8 Flame signal input Term Output Ignition transformer Term Intermittent pilot valve Term Main valve Term Alarm output Tem A Indicators IO OOOO O a K A A N POWER START Mu AS IG a GEN BEE me MV O fo AA Safety Time RUN Standby AL i Sta
4. FSG Flame Flame relay relay relay Ignition process The FRS110 ignites all pilot burners simultaneously and then detects the DHL DHL N ES After the pilot flame confirmation pilot flame period the FRS110 opens the main I I I I I I I I I I valve and ignites the main burner I O Asynchronous ignition and shutdown two burner case One main valve and one pilot valve are needed for each burner For extra safety redundant valves may be used as shown in the diagram The FRS110 ignites and shuts off En Zah 1 3 Chapter 2 MOUNTING AND WIRING 2 1 Mounting and Wiring the Subbase AN CAUTION Do not mount this control in the following locations e Where subject to corrosive chemicals or gases Such as ammonia sulfur chlorine ethylene compounds acid e Where subject to water spray or extreme humidity e Where subject to high temperatures e Where subject to continuous vibration Do not transport the FSG relay while it is mounted on a DIN rail Before transporting remove it from the subbase and pack it in its original packing case If it 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 O Mounting location As shown below keep a enough space around the control for heat radiation and to
5. No CP SP 1214E FRS110 Multiburner Control FSG Relay User s Manual Thank you for purchasing the FRS110 Multiburner Control FSG Relay This manual contains information for ensuring the correct use of the FRS110 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 FRS110 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 e Safety devices for plant worker protection e Start stop control devices for transportation and material handling machines e Aeronautical aerospace machines e 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 s
6. a ray and X ray sources Diffraction analyzer Electron microscope X ray machine High voltage vacuum switch High voltage capacitor Radioactive isotope All other gamma ray and X ray sources NW Safety shutoff test Carry out the safety shutoff test when all operating adjustments have been completed e Pilot ignition failure non ignition 1 Close the pilot manual valve and the main manual valve 2 Press the start switch to start operation 3 The pilot valve opens upon pilot ignition However since the pilot cannot light the flame relay FLAME LED should not light up Make sure that the main valve controlled by the FSG relay does not open e Flame failure during normal combustion 1 Open the pilot manual valve and the main manual valve 2 Press the start switch to start operation 3 After the ignition sequence has proceeded normally and normal combustion main valve open has begun close the pilot manual valve and the main manual valve to turn the burner flame off At this time make sure that the flame failure is detected and that the safety shutoff occurs 4 6 Chapter 5 MAINTENANCE AND INSPECTION N WARNING Before removing or mounting the FRS110 be sure to turn the power OFF Q Failure to do so might cause electric shock AN 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 iq
7. ame 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 that the ultraviolet flame detector does not respond to the UV rays emitted from the ignition spark 1 Close the pilot manual valve and the main burner manual valve 2 Begin operation and measure the flame voltage during the pilot ignition sequence to check for any influence from UV rays 3 If the FLAME LED of the flame relay lights up make one of the following adjustments referring also to the equipment user s manual e Move the ultraviolet flame detector or ignition spark rod so that it is not affected e Install 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 Chapter 4 TRIAL RUN ADJUSTMENT O 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 flame detector Make sure that these UV sources do not influence operation of the ultraviolet flame detector under any operating conditions UV relay sources 1260 C or higher red hot chamber wall Sparks ignition transformer welding arc lightning Gas laser Sunlamp Sterilizing lamp Strong flashlight in direction of UV photoelectric tube All other UV sources Gamm
8. ble voltage range Adjust the voltage Y Check pilot burner and ignition transformer and wiring Ignition spark response test N e Check burner Is the FRS100 FLAME LED off Disconnect the flame Y detector Turn the start switch on Does the FLAME LED FRS100 turn on Did the FLAME LED FRS100 turn off Does the flame voltage exceed 1 0V Replace the FRS100 Y Check the burner Y Check the flame detector N Does the flame simulator make the FLAME LED light up Did the start check LED FRS100 light up Does the main burner ignite eCheck voltage and wiring of terminal 7 FRS100 eCheck the start switch Is there voltage between terminals 7 and 2 Did the start check LED FRS100 light up Close the main manual valve JJ D Oo eb O 0 D O 7 J ep _ 4 O Check voltage and wiring of terminal 8 FRS110 Check the main burner eCheck the burner and wiring Is the flame extinguished e Check for main valve leakage e Check burner Y Was an alarm signal output Y Check alarm operation Replace the FRS110 Normal state 5 2 Chapter 6 SPECIFICATIONS E Specifications Start Check Time 2s max Application Batch operation of oil gas and oil gas mixed combustion equipment Safety Time ignition trial time 8x2s 4 1s 8 2s 4 1s Reset r
9. cannot be ensured Do not extend the lead wires of the reset input for more than the allowable wiring length of 10 meters Never input a reset command from a remote location where burner status cannot be checked If the FRS110 locks the burner out be sure to remove the cause before resetting Do not repeatedly enter the reset input Doing so could cause an explosion 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 report 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 CAUTION The FRS110 has extremely important functions for safe operation of equipment Follow the instructions in the user s manual to ensure safe use Do not transport the FSG relay while it is mounted on a DIN rail Before transporting remove it from the subbase and pack it in its original packing case If it 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 the FSG relay in the following locations Near corrosive chemicals or gases ammonia sulfur chlorine ethylene compounds acid etc Where subject to water spray or extreme h
10. cdseceeestedecadessiesanuscnccteesneenecessnecosactenncorceas ant 2 3 E Wiring diagrams FSG relay and flame relay u u200220000000000n0000n 2 4 E Wiring the power supply and the solenoid valve uu2200200002000an0nan00n 2 4 E Wiring the surge absorber 2220 200020000a00nan0nan0nnnunnanunanunnnnnnannnanunnnnnn 2 7 OPERATION E Sequence dad AM Siria ici 3 1 Operation details acccivntinia id ai cs 3 3 TRIAL RUN ADJUSTMENT E COVE WI Wiscianianana Tan ee Eee nenne 4 1 NW How to measure the flame signal uuuusnnaanunnnnnnnnnnnnunnnnnnnnnunnennnnnnnnnnnnn 4 2 mM Pilot turndown TOS unicidad 4 3 M Ignition spark response test uuusuuuunanunnnnnnnnnnannnnnnnnannnanunnnnnnnnnnanunnnnnn 4 5 E Safety Shutoff tesi suspann iaaa Aai 4 6 MAINTENANCE AND INSPECTION XA Cy CS isaac ecient anne 5 1 A AR 5 2 SPECIFICATIONS E SDECIHICAHONS zent nennen rear hehe 6 1 M External dimensions unu u 0 0 H Hnnn ann nun nn nn nn nun nnnnununn an nn ann nn un nn ann nn un un nn 6 2 vi Chapter 1 MW Overview MW Features OVERVIEW The FRS110 multiburner control FSG relay hereafter referred to as the FSG relay or the FRS110 is equipped with a burner ignition control function When used in combination with the FRS100 flame relay functioning as a flame detector the FSG relay is suitable for use in batch operation intermittent combustion equipment At startup if there is any pr
11. d and the regular combustion Main valve opens run begins elgnition transformer stops If the power to terminal 8 is turned OFF relays K1 elgnition transformer and K2 are turned OFF stops eMain valve closes e Ignition failure operation Input conditions FRS110 operation System status Start contact terminal 8 ON Flame signal input terminal 4 OFF After power reaches terminal 8 and after the start elgnition transformer check time has elapsed relay K1 is turned ON starts operating eIntermittent pilot valve Relay K1 remains ON during the Safety Time ignition opens trial time If there is no flame signal input to terminal 4 by the elgnition transformer end of the Safety Time ignition trial time relay K1 stops turns OFF and an alarm signal terminals A B is output Intermittent pilot valve closes eAlarm output e Flame failure operation Input conditions FRS110 operation System status Flame signal input terminal 4 OFF If flame failure occurs during the regular combustion elntermittent pilot valve run the flame signal turns OFF relays K1 and K2 closes turn OFF and an alarm signal is output to terminals Main valve closes A and B eAlarm output e False flame operation Input conditions FRS110 operation System status Flame signal input terminal 4 ON Start contact terminal 8 ON If when power is supplied to terminal 8 a flame signal has already been input t
12. dance of 100kQ or more O to 5Vdc range 3 Refer to the following table for voltage Flame detector Recommended Checklist flame voltage Minipeeper Ultraviolet 2Vdc min e Make sure that the flame is correctly Flame Detector monitored C7027A or C7035A e The front of the flame detector must be free of dirt e The monitoring tube must not be blocked with soot 4 If the flame signal fluctuates check the flame detector mounting position and wiring again Chapter 4 TRIAL RUN ADJUSTMENT E Pilot turndown test This test is for checking that even if gas pressure and air pressure are at their worst any pilot flame that can be detected by the flame detector will reliably ignite the main burner WARNING If the flame detector is set so that it detects a pilot flame that is too small to ignite the main burner flame failure in the main burner will not be detectable 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 and combustion chamber Failure to discharge unburned gas or fuel may result in an explosion After the pilot turndown test is completed turn the power OFF Be sure to restore all test jumper leads limit switche
13. esponse time 2s max Behavior at flame failure Lockout 20 to 60 C 20 to 45 C Allowable ambient temperature Stand alone mounting Gang mounting 2 units or more Allowable storage 20 to 70 C temperature Ambient humidity 90 RH or less at 40 C without condensation 5m s max 10 to 55Hz or less for 2h each in X Y and Z directions when mounted on panel directly Vibration resistance Insulation resistance 50MQ min between terminals and ground terminal by 500Vdc megger except reset input terminals C and D Dielectric strength Product life Body color Mounting method Mass Optional parts sold separately O Contact rating No failure after apply ing 1500Vac for 1min or 1800Vac for 1s between terminals and ground terminal except reset input terminals C and D 100 000 operations at room temperature and humidity and rated voltage Gray DIN rail mounting or wall mounting using the FRS50A100 subbase FRS110B Approx 270g FRS50A100 subbase Approx 70g Mounting subbase Lightning surge absorber Model No FRS50A100 Model No 83968019 001 Terminal Contact rating Ignition transformer 300VA Intermittent pilot valve 200VA 200VA 6 1 Chapter 6 SPECIFICATIONS E External dimensions O FRS110 plugged into FRS50A100 subbase 99 1 Unit mm DIN rail FRS50A100 subbase sold separately FRS110 2 FRS110 FSG RELAY eo POWER elG e START o PV e
14. eters Never input a reset command from a remote location where burner status cannot be checked 2 3 Chapter 2 MOUNTING AND WIRING E Wiring diagrams O FRS110 with one flame relay FRS100 Power supply Power supply H Start switch G OO FRS110 Eu 1 Power circuit 2 Pilot valve Ignition transformer 1 Ignition circuit a Reset switch 1 17 aay 1 Power circuit 2 ig _ Start check E u circuit Combustion lamp 1 Flame detector 1 Handling Precautions e The power supply is marked H and G for the voltage and ground sides respectively Connect the voltage side H to terminal 1 and the ground side G to terminal 2 e Install the ignition transformer directly on the burner itself or on a metallic part electrically connected to the burner e Use 2mm wire with indoor PVC insulation at each terminal e Use indoor PVC insulated wire at least 0 75mm 2 30 strands 0 18mm in dia for power connections 2 4 Chapter 2 MOUNTING AND WIRING O FRS110 with two flame relays FRS100 Power supply Power supply H G Start switch l PP CR2 CR3 CR4 yCR5 cra Stop switch o o gt Y WN ca Start CR1 Reset switch 1 DL ij E a confirmation timer en Alarm 1 Main Ignition timer i Combustion lamp 2 Flame detector 2 e CRS CRS era aan CRS CRS 1 Handling Precautions e The power supply is marked H and G for the voltage and ground sides res
15. hould find an 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 2006 Yamatake Corporation ALL RIGHTS RESERVED Er SAFETY PRECAUTIONS WE E 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 N WA R N f 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 E Examples Triangles warn the user of a possible danger that may be caused by 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 White circles with a diagonal bar notify the user that specific actions are prohibited to prevent possible danger These icons graphically represent the actual prohibited action The example on the left notifies the user
16. ions when wiring Make sure that ignition transformer high voltage cables are properly Q connected to prevent contact failure Poor contact might generate high frequency radio waves resulting in noise in radios or other electrical appliances or causing malfunction Also 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 C Handling Precautions Handling Precautions indicate items that the user should pay attention to when handling the FRS110 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 Contents SAFETY PRECAUTIONS Conventions Used in This Manual Chapter 1 Chapter 2 2 1 2 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 OVERVIEW E OU sita olaaa 1 1 E Fate naaa iii aiii 1 1 ME Names and functions u unuaua0anananananannnnnnnnnnnnnn nun nun nun nn nn rra 1 2 E Recommended flame relays and flame sensorS u22 222000an000an0n0nn 1 2 E FSG system configuration oncoonncconnccococenonncnnnnncnnnnenanononarennnnrnnnnrenannnnannnnns 1 3 MOUNTING AND WIRING Mounting and Wiring the Subbase uuu 2u002a2002an002an00nanunnnnunnnnnnnnnnunnnnunn 2 1 o oe oaeeeeeees sescis cs taeasiwc
17. ke 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 O Required items e Tester input impedance of 100kQ or more Range 0 to 300Vac 0 to 5Vdc e Two jumper leads with crocodile clips AWG14 2mm or more approximately 30cm long e Insulation tester S00Vdc megger O Preliminary inspection e Check all wiring e Make sure that the controller is mounted at a location within the permissible ambient temperature e Make sure that the flame detector is properly mounted For details see the flame detector user s manual 4 1 Chapter 4 TRIAL RUN ADJUSTMENT e Disconnect the loads and flame detector wiring Measure the insulation resistance between the terminals and panel ground and make sure that the resistance is 50OMQ or more using an insulation tester or megger of 500Vdc or more e Valves and cocks on each of the fuel lines must be closed and the fuel chamber must be thoroughly purged E How to measure the flame signal 4 2 1 Start the equipment 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 holes for terminals A and B at the bottom front of the flame relay as shown below 4 FRS100 FLAME RELAY O POWER OFLAME Terminal A Terminal B Tester Input impe
18. 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 FSG relay without completing the tests described O in Chapter 4 and the tests specified by the equipment manufacturer If the flame detector is set so that it detects a pilot flame that is too O small to ignite the main burner flame failure in the main burner will not be detectable 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 Q 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 After the pilot turndown test is completed turn the power OFF Be sure Q to restore all test jumper leads limit switches and control settings used in the test to their original settings A WARNING Connect the power source last to prevent electric shock or damage If the power line accidentally touches the wrong terminal electric shock or damage might result Connect the load ignition transformer solenoid valve etc to the output terminals directly If it is not directly connected combustion safety
19. ndby Start Check Time Chapter 3 OPERATION 3 2 e Ignition failure Input Start input Flame signal input Output Ignition transformer Intermittent pilot valve Main valve Alarm output Indicators POWER START IG PV MV AL e Flame failure Input Start input Flame signal input Output Ignition transformer Intermittent pilot valve Main valve Alarm output Indicators POWER START IG PV MV AL Term 8 Tem 4 po Term 6 Term A B A Safety Time Alarm Standby Start Check Time Term Term Term Term Term Term RUN Alarm Note The Flame Failure Response Time the time from flame failure to flame signal shutoff is dependent upon the FRS100 flame relay specifications Safety Time means pilot flame establishing period NW Operation details e Normal operation Input conditions FRS110 operation System status Start contact terminal 8 ON Flame signal input terminal 4 ON Start contact terminal 8 OFF Chapter 3 OPERATION After power reaches terminal 8 and after the start elgnition transformer check time has elapsed relay K1 is turned ON starts operating eIntermittent pilot valve Relay K1 remains ON during the Safety Time ignition opens trial time If terminal 4 receives flame signal input by the end of elntermittent pilot valve the Safety Time ignition trial time relay K1 remains opens ON relay K2 is energize
20. o terminal 4 the FRS110 does not begin the ignition trial but waits until the flame signal stops 3 3 Chapter 4 TRIAL RUN ADJUSTMENT AX WARNING Make sure that the pilot and main burner ignition times do not exceed 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 mounting or wiring the FRS110 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 this control without completing the tests described in this chapter and the tests of specified by the equipment manufacturer If the FRS110 locks the burner out be sure to remove the cause before resetting Do not repeatedly enter the reset input Doing so could cause an explosion E Overview of adjustments The following table shows the items described in this chapter Applicable FSG systems Flame signal measurement All Pilot turndown test Systems using a pilot burner Ignition spark response test Systems using an ultraviolet flame detector 1 Handling Precautions e After completing the above ma
21. o the subbase using a maximum torque of 0 3N m 8 Wire the alarm output signal and reset signal 9 Reattach the cover 1 Drill two M4 mounting holes in the panel so that the arrow on the subbase will be facing upward 2 Attach the subbase to the panel using two M4 screws at a maximum torque of 0 7N m 1 Handling Precaution e Do not tighten the subbase mounting screws with a torque exceeding the maximum 3 Wire the subbase terminals as instructed in section 2 2 Wiring 4 Pull the bottom of the cover forward to remove 5 Insert the FRS110 into the subbase with the display part upwards 6 Tighten the mounting screw in the center of the FRS110 to attach it to the subbase using with a maximum torque of 0 3N m 7 Wire the alarm output signal and reset signal 8 Reattach the cover Chapter 2 MOUNTING AND WIRING 2 2 Wiring AX WARNING Connect the power source last to prevent electric shock or damage If the power line accidentally touches the wrong terminal electric shock or damage might result Connect the load ignition transformer solenoid valve etc to the output terminals directly If it is not directly connected combustion safety cannot be ensured AN CAUTION 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
22. oblem with the FRS110 or with the flame relay burner ignition is prevented The FRS110 has both a safe start function and a combustion safety shutoff function that closes the gas shutoff valve if a flame failure signal is received from the FRS100 during operation A multiburner combustion safety control can easily be made by combining one FRS110 with multiple flame relays Note that the FRS110 does not provide a prepurge timer function The FRS110 can control synchronous multiburner ignition and shutdown when combined with multiple flame relays e Upon startup the FRS110 s start check function is activated If anything is abnormal the FRS110 ensures safety by stopping the ignition process Also if there is an ignition failure or flame failure the FRS110 maintains safety by initiating burner lockout The FRS110 s safe design ensures that the burner cannot be started until an external reset signal is received e When lockout occurs an alarm output signal is sent via the alarm contacts Because of its compact design the FRS110 can be plugged into a wiring subbase which can be mounted by screws or on a DIN rail e LED indicators allow an easy status check of power start signal input alarm situation ignition transformer pilot valve and main valve 1 1 Chapter 1 OVERVIEW mM Names and functions O FRS110 LED indicators POWER green IG red FRS50A100 subbase sold separately Power ON OFF Ignition transforme
23. pectively Connect the voltage side H to terminal 1 and the ground side G to terminal 2 e Install the ignition transformer directly on the burner itself or on a metallic part electrically connected to the burner e Use 2mm wire with indoor PVC insulation at each terminal e Use indoor PVC insulated wire at least 0 75mm2 30 strands 0 18mm in dia for power connections 2 5 Chapter 2 MOUNTING AND WIRING E Wiring of power supply and solenoid valve CAUTION 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 relay Voltage side H Ground fault Combustion unit Valve closed gt Fuel O Correct wiring When wiring is done correctly as shown in the above figure ground fault current cannot flow to the solenoid valve even 1f the fault was caused by an insulation failure on the voltage side H Therefore the valve does not open and there 1s no danger of fuel discharge Ground fault Voltage side H O p i nn i FRS110 i ME FSG relay AN Power supply 5 p 3 S l l l b Ground side G rt 212 l l N L 5 O en Valve open OA Fuel O Incorrect wiring If the valve is connected to the voltage side as illustrated above ground fault current will flow to the solenoid valve and open it discharging
24. r START green ON OFF me FSG RELAY Start contact PV red POWER O1s ON OFF Intermittent pilot valve OSTART Pv ALARM red ON OFF SEN Alarm ON OFF MV red Main valve ON OFF Cover removed Body mounting screw Dedicated connector for optional flame voltage meter sold separately M3 5 terminal screws N locking tab l Terminals for reset switch Terminals for alarm output O FRS50A100 subbase sold separately M3 5 terminal screws 8 PILLEN HS ES TE IN aN A su SEZSIZSEZ gt SEO ES E Pe a i LLI Subbase mounting holes 2 DIN rail locking tab E Recommended flame relays and flame sensors O Flame relay and flame detector Flame detector FRS100B Ultraviolet Flame Detector C7012A C Flame Rod C7007A C7008A FRS100C Minipeeper Ultraviolet Flame Detector C7027A C7035A O Optional parts sold separately Lightning surge absorber 8396801 9 001 Chapter 1 OVERVIEW E FSG system configuration The FRS110 provides ignition control while the FRS100 flame relay detects the flame To construct a multiburner system take the following items into consideration e Burner ignition and shutdown sequences e Method of safety shutdown in the event of flame failure O Synchronous ignition and shutdown two burner case Only one main valve and one pilot valve are needed for two burners For extra safety redundant valves may be used as shown in the diagram
25. s and control settings used in the test to their original settings If this control is operated without restoring the Original settings equipment damage gas leak or explosion might result CAUTION Q Only an experienced specialist who has knowledge and technical skills related to combustion equipment and combustion safety shoud carry out the pilot turndown test 1 Handling Precautions e If fuel pressure limit switches are open in use during this test connect jumpers to set the limit switches ON O 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 and then turn the start switch on The pilot will ignite 5 Close the pilot manual valve slowly The pilot flame will gradually grow smaller Continue to close the manual valve until the flame detector can no longer detect the flame At this point flame relays 1K and 2K turn OFF and lock out Record the pressure just before the 2K flame relay turns off 4 3 Chapter 4 TRIAL RUN ADJUSTMENT 4 4 6 Then open the pilot manual valve slowly until the pressure matches the pressure just before the 2K flame relay turned off 7 Reset the FSG relay and restart the equipment and then press the ignition switch again to 1gnite the pilot 8 Make sure that the main burner ignites smoothly in one second or less when the main manual valve i
26. s opened 9 Change the gas pressure from minimum to maximum and ignite the main burner 5 6 times Make sure that the main burner ignites smoothly every time 10 If the main burner does not ignite the reason is probably that the pilot flame is too small Make the pilot flame larger and carry out the following adjustment e Either move the flame detector s line of sight slightly away from the axis of the pilot flame or put in a diaphragm to correct the flame size Set the flame size so that the main burnert ignites without fail at the minimum flame voltage 11 After adjusting repeat steps 5 to 8 and make sure that main burner ignites without fail 12 After this test is completed return the main manual valve to its fully open position Then make sure that the flame signal is appropriate 13 Take off any jumper leads connected to limit switches during this test to restore them to their original condition Chapter 4 TRIAL RUN ADJUSTMENT E Ignition spark response test This test should be carried out on any equipment that uses an ultraviolet flame detector The test 1s to check that the ultraviolet flame detector does not respond to UV rays emitted from the ignition spark O Ultraviolet Flame Detector AN 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 report that there is a fl
27. that disassembly is prohibited 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 WARNING Before removing mounting or wiring the FRS110 be sure to turn the Q power OFF Failure to do so might cause electric shock Do not touch the terminals on the FSG relay Doing so might result in SU an electric shock This FSG relay is for batch operation at least one start and stop in 24 Q hours of operation needing a safe start feature When using this product for continuous operation continuous combustion for 24 hours or longer combine it with the R4332A or R4332B which have a self checking function This FSG relay does not have the prepurge timing functions necessary Q for burner ignition Take timer functions into consideration when designing your control system Do not connect the solenoid valve to the voltage side S 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 relay Make sure that the pilot and main burner ignition times do not exceed 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
28. 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 FSG relay 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 Keep power lines and ignition transformer high voltage cables separate from the flame detector wires Run the ignition transformer high voltage cable separately and keep it at least 10cm away from the FSG relay Make sure that ignition transformer high voltage cables are properly connected to prevent contact failure Poor contact might generate high frequency radio waves resulting in noise in radios or other electrical appliances or causing malfunction Also 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 this device with wires wrongly connected might cause damage or malfunction In setting the timer follow the Japan Gas Association s Safety Engineering Directives for Industrial Gas Combustion Equipment or similar guidelines Do not extend the lead wires of the reset input for more than the allowable wiring length of 10 m
29. uipment If this control is replaced check all items described in Chapter 4 TRIAL RUN ADJUSTMENT Before maintenance and inspection of the burner be sure to do 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 users manuals E Inspection cycle Determine an inspection cycle taking into consideration the following factors e Type of equipment e Ambient conditions at the installation site such as dust and temperature e The effects of burner failure on equipment operation 1 Carry out the safety shutoff test described in Chapter 4 TRIAL RUN ADJUSTMENT once per month 2 Inspect the monitoring window on the flame detector the flame rod etc for dirt and clean as necessary 3 Measure the flame voltage at least once per month to check its status If burner shutdown will result in significant loss carry out this inspection more frequently del Chapter 5 MAINTENANCE amp INSPECTION E Troubleshooting If there is some problem with the equipment use the following check procedure Turn off the start switch and then push the reset x switch Does the pilot burner light up Does the POWER LED light up Is there voltage between terminals 5 3 6 and 2 Check the switches and Y fuses for the power Check the wiring Is the power within the allowa
30. umidity 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 device with wires wrongly connected might cause damage or malfunction CAUTION Make sure that the loads connected to the terminals do not exceed the Q specified ratings Make sure that power of the same voltage and frequency as indicated Q on the model number label is supplied to the FSG relay Q When configuring control circuits select reliable timers and auxiliary relays as necessary for additional functions Be sure to ground this device using a lead with a resistance of less O than 100 and be sure to ground the burner body Keep power lines and ignition transformer high voltage cables separate O from the flame detector wires Run the ignition transformer high voltage cable separately and keep it Q at least 10cm away from the FSG relay When equipment is restarted after a safety shutoff check all items Q described in Chapter 4 TRIAL RUN ADJUSTMENT Before maintenance and inspection of the burner be sure to do the Q pilot turndown test Carry out this test at least once every year Q When cleaning the burner clean the flame detector also Q When mounting or wiring be sure to follow the instructions in this users manual and manuals provided by the equipment manufacturer or other device manufacturers Q Follow all applicable regulat
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