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AUR450C User`s Manual

1. Ka K5 Load output Ignition transformer Interrupted pilot valve Intermittent pilot valve Main valve 6 Ld a Kf a a to ee ae Flame monitor output Alarm output LED display POWER Sequence display jm q 3 6 Interlock during Run state If the lockout interlock contact is disconnected or changed to OFF the system is locked out and an alarm is output On the AUR450C E1 interlock and P5 are displayed alternately Chapter 3 OPERATION Standby Pre purge Start Safety Pilot Main Trial RUN Lockout check Time Stabilization Interlock normal _ je a Power supply PB 2 a StopPB sd eno 100T Purge timmer aa pees eae an a nates cent 101X During the purge mg TT GL LLL 102X Purge end i er es Input Start contact input Power supply eee H Flame signal _ TEE E E E E EERE Relay output l l K1 O ee K2 ee K3 ee oe es K4 was K6 i ee S K7 Load output _Ignition transformer Interrupted pilot valve Intermittent pilot valve_ Main valve Flame monitor output Alarm output__ LED display SHUTTER FLAME ALARM START IG PV MV Sequence display 3 7 Chapter 3 OPERATION Inter
2. No CP SP 1264E AUR450C Dynamic Self Check Burner Controller User s Manual Thank you for purchasing the AUR450C Dynamic Self Check Burner Controller This manual contains information for ensuring the correct use of the AUR450C It also provides necessary information for installation mainte nance and troubleshooting This manual should be read by those who design and maintain equipment that uses the AUR450C 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
3. SHUTTER FLAME ALARM __ START IG PV MV Sequence display X 3 3 Chapter 3 OPERATION Start check error due to UV error If an error self discharge is detected during the start check and normal operation does not resume for 10 seconds the system is locked out In this case there is no flame monitor output and the FLAME LED does not light up On the AUR450C E3 UV error and P1 are displayed alternately Standby Pre purge Start check Lockout at alarm detection Intrck rior gun Power supply PB_ a EE Lee oe SO Stop PB Ie P ne TOOT Purge timme eae TOIX During the purje es O OOOO TO2x Purgeend ES lt a aa Sc mae ae Input i j Power supply Start contact input Flame signal _ Relay output Kie K2 K3 Ke ices ess KG tess re eae K7 z D J O a Ignition transformer Interrupted pilot valve Intermittent pilot valve Main valve Flame monitor output J J aLL Alarm OU I EEE li i i Load output i 1 L j j i f LED display i i l ELAME ALARM START IG PV MV i Sequence display ae 1 Pm ny Sai Ee i Pi I Self discharge 3 4 Input Rg ET Powersupply _ Saini e a p a a a Load output LED display Ignition failure Power supply
4. and red for less than 1 5 V The LED goes off if no flame is detected K6 is off Subbase Q241A104 sold separately Side cover Upper and bottom side covers can be removed when putting in the wiring Remove when knockouts are not used Mounting hole Mounting holes are used when the subbase is mounted on a panel Although there are 5 holes use the 4 at the corners to mount the device Use M4 screws Q241A104 Terminal block M3 5 screws for connection of external wiring O Note Hole for the body subbase screw This threaded hole mates with the body subbase screw which is used to attach the main body to the subbase Knockouts Remove knockout discs to run in the wiring There are 2 knockout holes on the upper bottom right and left sides and back 10 holes in total The sides upper and bottom covers have 2 different diameter holes to respond to any wiring situation Remove knockouts as needed e The shape and dimensions of the terminal block are shown below Wiring will be easy if crimp type terminal lugs suitable for the dimensions written below Chapter 1 OVERVIEW E Description of 7 segment display Sequence code display Normally a code is displayed corresponding to the present stage of the operation sequence The table below shows the di
5. E Precautions for designing equipment When designing facilities that include combustion safety equipment take the safety directives listed below into careful consideration e Safety Engineering Directives for Industrial Heating Furnace Combustion Equipment Health Labor and Welfare Ministry e General Safety Code for Industrial Combustion Furnaces JIS B 8415 e Safety Engineering Directives for Industrial Gas Combustion Equipment The Japan Gas Association e In the U S Combustion Safety Guidelines National Fire Protection Association NFPA86 99 e In Europe Industrial thermoprocessing equipment Safety requirements for combustion and fuel handling systems EN 746 2 1997 Be sure to refer to the laws and standards of the relevant country when designing equipment Important safety points 1 Directly connect the load to this device 2 Structure the interlock so that power to the load can be directly turned off 3 Use the start check circuit during startup do not short out the start contact input 4 Do not make a manual operation circuit or other bypass circuit for any load 5 Use a redundant shutdown system for both main valve and pilot valve Precautions for system design Use external equipment to make a purge function taking into consideration the purge conditions and time settings E Model selection table The following shows the model selection table for this device model No time compliance response time suppl
6. Gas laser Sunlamp Disinfecting lamp ultraviolet lamp fluorescent lamp Strong flashlight toward UV sensor Gamma ray and Regression analyzer X ray source Electron microscope X ray camera High voltage vacuum switch High voltage capacitor Radioisotope Other sources producing ultraviolet rays gamma rays and X rays 4 5 Chapter 4 TRIAL RUN ADJUSTMENT Hm Safety shutoff test After all operational adjustments have been completed carry out the safety shutoff test Pilot ignition failure ignition failure 1 Close the pilot and main manual fuel valves 2 Press the start switch gt gt Operation begins 3 Normally for pilot burner ignition the pilot valve opens Check that there is lockout with the FLAME LED not lit so that the main valve does not open if the flame fails Flame failure during RUN state 1 Open the pilot and main manual fuel valves 2 Press the start switch to begin operation 3 When the sequence has progressed correctly and normal combustion has begun main valve has opened close the pilot and main manual fuel valves to put out the burner flame Then check that flame failure is detected and that safety shutoff is correctly activated Interlock operation check Activate each interlock and check that the system is locked out o Handling Precautions e Be sure to continue the reset input for more than 1 second A reset input less than 1 second long may not cancel the lockout
7. This device drives the shutter of the AUD300C and continuously checks the tube unit of the AUD300C and its own flame detection circuit while flame detection is performed If the tube unit or flame detection circuit fails the system is locked out Lockout with no restart until the system is reset occurs at the time of interlock activation ignition failure or flame failure ensuring safe operation The AUR450C has a 7 segment display and communications function Flame volt age sequence status and alarm codes are displayed For effective maintenance and troubleshooting a personal computer can be used to read data such as the system status before the occurrence of various errors past alarm history operation time and number of combustion starts 1 Safety standards This product is certified to meet standards as noted below Approval Reference No CE marking EN298 CE 0063BS1427 UL listing UL372 File No MH27717 Self declaration of conformity to standards is not permitted for combustion safe ty equipment 2 Ignition sequence Either 4 second or 8 second Safety Time ignition trial time is selectable by model number Either an intermittent or an interrupted pilot can be used selec table by output terminal 3 Instrumentation and handling This model requires less mounting space than a conventional model because of its compact design Since wiring can be done at the subbase mounting or dis mounting the controller can be done
8. and omissions If you should 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 2007 Yamatake Corporation ALL RIGHTS RESERVED IF SAFETY PRECAUTIONS J 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 Warnings are indicated when mishandling this A WAR N I N G product might result in death or serious injury Cautions are indicated when mishandling this AN CAUTION product might result in minor injury to the user or only physical damage to the product E Examples AN Use caution when handling the product S The indicated action is prohibited Q Be sure to follow the indicated instructions WARNING This device does not have a prepurge function Use this device as part of a system whose design gives careful consideration to the prepurge timer and ignition sequence timing following established safety guide lines Connect loads ignition transformer solenoid valve et
9. and sequence code are alternately displayed After reset flame volt age display resumes 1 6 Chapter 1 OVERVIEW Flame voltage display Flame voltage is displayed as 2 digits If the 7 segment display shows 3 2 it means 3 2V Event display When a pre selected preset event occurs the orange EVENT LED lights up If the DISP switch is pressed while EVENT is lit up an event code from the table below is displayed However the event code is not displayed if lockout has occurred Ignition delay ON when the ignition delay time exceeds the preset value Shutter cycle count upper value ON when the shutter cycle count exceeds the upper preset 1 minute value Shutter cycle count lower value ON when the shutter cycle count drops below the lower 1 minute preset value Operation time for event ON when the time since startup exceeds the preset value Combustion time for event ON when the steady combustion time exceeds the preset value Combustion count for event ON when the combustion count exceeds the preset value Flame voltage upper value ON when the flame voltage exceeds the preset value during steady combustion display code P5 Flame voltage lower value ON when the flame voltage drops below the preset value during steady combustion display code P5 o Handling Precautions e In the factory default settings no event is set up For this reason when the device is used for the first time there is no EVENT display or eve
10. device in an instrument panel with IP54 or equivalent protection Installation wiring inspection adjustment etc should be carried out by a trained and experienced technician who has knowledge and technical skills related to combustion equipment and flame safeguard control devices Make sure the load connected to each terminal does not exceed the rating indicated in the specifications If timers and auxiliary relays are needed for additional functions select ones with high reliability and be sure to design the circuit correctly When installing and wiring be sure to follow the instructions in this manual and in the user s manual for the combustion equipment The ignition transformer ground lead should be connected directly to the burner body or to a metallic part electrically connected to the burner body Run the high voltage ignition transformer cable separately and keep it at least 10 cm away from this device Keep power lines and ignition transformer high voltage cables separate from the AUD300C 500C cables and from the external reset input cable Make sure that ignition transformer high voltage cables are properly connected to prevent faulty contact Faulty contact might generate high frequency radio waves which can cause malfunction Always connect the power supply last Otherwise touching a terminal accidentally could result in electric shock or damage Always supply electric power at the
11. temperature and humidity and rated voltage and load Max tightening torque Subbase mounting screws 1 5 Nem Body subbase screw 0 5 Nem M3 5 terminal screws 1 0 Nem Mounting method Mounted on subbase 103mm D X 103mm W X 109mm H Total height including subbase is 139 mm Approx 600 g approx 830 g including subbase 2 CE EN298 CE 0063BS1427 UL UL372 File No MH27717 Classification according to BBLLXK EN298 Electrical specifications Item Description Power supply voltage 100 120 200 230 Vac 50 60 Hz Allowable voltage range 85 to 110 of power supply voltage 15 W max including both AUR450C and AUD300C 500C Dielectric strength Between ground and primary terminals 11 to 24 and Between primary terminals 11 to 24 and secondary terminals 1 to 10 1500 Vac 50 60Hz for 1 min or 1800 Vac 50 60Hz for 1 s 10 mA max leak current Insulation resistance 50 kQ min with 500 Vdc megger between ground and primary terminals 11 to 24 6 1 Chapter 6 SPECIFICATIONS 6 2 Communication specifications Item Description transmission mode Balanced transmission line 3 wire system Transmission speed bps 1200 2400 4800 9600 19200 Transmission distance 500 m max Communications system Half duplex Synchronization Start stop Data format 8 bits 1 stop bit even parity 8 bits 2 stop bits no parity Error detection Parity check Station address 0 to F at 0 communications are disabled Connection
12. valve wiring is connected correctly as shown in the figure above current does not flow through the solenoid valve even if a ground fault occurs due to faulty insulation on the high voltage side Therefore the valve does not open and fuel does not flow out Incorrect connection Ground fault High voltage side H Power supply Grounded side G juawidinba uosnqwog gt Fuel If the valve wiring is connected to the high voltage side current flows through the solenoid valve if a ground fault occurs as shown in the figure above Therefore the valve opens in spite of the AUR450C and fuel flows out Chapter 2 MOUNTING AND WIRING E Wiring for continuous measurement of flame voltage To measure the flame voltage remove the cover from the flame voltage terminal and connect a signal wire to it o Handling Precautions e Always use an IV cable with a size of 0 75 mm or more for signal lines The wiring length must be 10m or less e Connect a measuring instrument to the AUR450C having an input imped ance of 100kQ2 or more and connect a pen recorder having an input impedance of 1M or more Removing the terminal cover o Handling Precautions Do not push the terminal cover It may crack Required tool a screwdriver 1 Insert the screwdriver between the terminal cover and terminal 2 Gently raise the grip of the screwdriver 2 9 Chapter 2 MOUNTING AND WIRING Mounting the
13. voltage and frequency stated on the model label of this device In keeping with technical standards for electrical equipment the burner body must have an earth ground connection with a resistance of less than 100 Q CAUTION After the wiring is complete be sure to check that it is correct Incorrect wiring may cause damage or faulty operation Make sure that the flame detector does not detect the ignition spark If the flame detector can detect the spark change the detector s line of sight or change the ignition electrode s position Only an experienced technician who has knowledge and technical skills related to combustion equipment and combustion safety should carry out the pilot turndown test This product is equipped with functions that are extremely important for the safe operation of combustion equipment Carefully follow the instructions for its use that are given in this user s manual If the safety shutoff has been activated check all of the items on the checklists in chapter 4 TRIAL RUN ADJUSTMENT before restarting the equipment When doing a maintenance inspection of the burner be sure to do the pilot turndown test Inspection must be done at least once a year Conduct periodic inspections in accordance with the user s manual of the equipment manufacturer When cleaning the burner clean the flame detector as well For transportation or storage of this device remove it f
14. while an alarm code is displayed the display changes to flame voltage e When lockout is reset the display reverts to its state before lockout 5 2 Chapter 5 MAINTENANCE AND INSPECTION E Fault inspection flowchart 7 WARNING Before wiring mounting or removing this device be sure to turn the power off Wiring with the power on can result in an electric shock When there is a problem with the equipment follow the following inspection pro cedure Turn the start switch OFF and press the reset switch to reset the operation rf Does the Does the POWER LED pilot burner ignite light up e Check the power switch and fuse for the panel e Check the wiring Is there voltage between terminal 14 and each of terminals 19 21 and 22 e Check the pilot ignition transfor mer and wiring e Ignition spark response test e Check the burner Does the FLAME LED of this device go out Does the FLAME LED of this device light up Turn on the start contact Is the flame voltage more than 1 5V Does the FLAME LED go out Does the FLAME LED light up with a flame simulator Y N e Check the burner e Check the flame detector N Is there voltage between terminals 20 and 14 e Check the voltage and wiring of the start input terminal ee terminal 16 of this device e Check the start contacts Check the burner False flame e Check the flame d
15. with ease Flame monitoring output and alarm output contacts can be used as independent non voltage contacts There is an input terminal for remote reset or reset can be done from the operating panel 4 Display function The LED indicators which are especially useful for maintenance and trou bleshooting can be used to check the progress of the ignition sequence the sta tus of flame detection alarms and the occurrence of events The LED indicators change color green orange red depending on the flame voltage level The 7 segment display is used to check sequence codes alarm codes and event codes 1 1 Chapter 1 OVERVIEW m System structure This device is used to control the flame of combustion equipment and is used in a system like the one shown below High limit controller Controller Air pressure low limit interlock Exhaust gas Flame detector T C T C Combustion chamber Gas pressure low limit interlock Combustion Gas pressure upper limit Ignition equipment interlock transformer m Safety assurance functions This device performs functions that are vital for burner operation and flame moni toring 1 Combustion monitoring and safety shutdown e Detects burner flame failure and shuts down the fuel supply immediately e Incase of ignition failure or flame failure shut down each value ignition trans former in a predetermined sequence 2 Startup operat
16. 3306 e Terminal screws for the external reset input terminal numbers 9 and 10 are not assembled When using the external reset input wire to the sub base using the included terminal screws e For the external reset input signal and flame voltage output signal use IV wire 0 75mmZ2 in cross sectional area Wire length should be 10m max e Although terminals with a ground mark are provided on the subbase this device is not grounded 2 5 Chapter 2 MOUNTING AND WIRING Connecting to a surge absorber When using the optional surge absorber as a protective measure against lightning connect it as shown below Model No 83968019 001 sold separately AUR450C High voltage side H ae e Power supply Grounded side G Surge absorber 83968019 001 Flat terminal FS4 8 series terminal side ii ree bracket side grounded side fi Terminal Surge absorber Mounting bracket 99909013 eo SS o Handling Precautions e Connect an FS4 8 series flat connector AMP s 187 series receptacle or equivalent to one end of the electric cable keeping the wiring as short as possible e The grounded side of the metallic bracket for mounting of the surge absorber is connected internally so it makes good electrical contact Mount this bracket on a metallic part such as the burner chassis to con nect the ground wire E Connection to the AUD300C Wire the AUD300C as shown below AUD300C i AUR450C o H
17. 4 6 Chapter 5 MAINTENANCE AND INSPECTION 7 WARNING Before wiring mounting or removing this device be sure to turn the power off Wiring with the power on can result in an electric shock Even after the power to this device is turned off terminal F continues to hold an electrical charge To avoid electrical shock do not touch terminal F CAUTION Installation wiring inspection adjustment etc should be carried out by a trained and experienced technician who has knowledge and technical skills related to combustion equipment and flame safeguard control devices If the safety shutoff has been activated check all of the items on the checklists in chapter 4 TRIAL RUN ADJUSTMENT before restarting the equipment When doing a maintenance inspection of the burner be sure to do the pilot turndown test Inspection must be done at least once a year Conduct periodic inspections in accordance with the user s manual of the equipment manufacturer When cleaning the burner clean the flame detector as well E Frequency of maintenance and inspection Determine an appropriate frequency for maintenance and inspection work by con sidering e the equipment type e ambient conditions dust or temperature of the location e damage or negative effects if the burner is shut off for some reason during operation of the equipment Inspections Inspection frequency Safety shutoff test for details refer to Once a month or more gt Cha
18. 5 bie dd ok choad ci eas dae ideees taecaepeeeeed ia deste ieaeknees tokens 2 4 M Wiring diagram 6 cece cece cece cece e eee e cece cence eee enecenees 2 5 HM Connection to the AUD300C cece cece cece cece ec ceecenceeeees 2 6 E Checking the connection between the controller and the AUD300C 500C 2 cece cece cece cette cece eect eee nee nets eeeeeees 2 7 HM Wiring to a Solenoid valve eee cece cece cece e eee e eee eeeeeees 2 8 E Wiring for continuous measurement of flame voltage 2 9 2 3 Communications connections s s essssesesesessesecessesecseseee 2 11 M Smart Loader connection ssssessssssssesessosesessosesesso 2 11 mM Connection of RS 485 communications ee sees ee eee eens 2 11 HM Connection to a 3 wire SySteM cece cece cece eee c tence cece 2 12 HM Connection to a 5 wire SySteM eee cece cece cence cece ee ceeees 2 12 Chapter 3 OPERATION E Wiring diagram and internal block diagram sesssesssssseseses 3 1 M Sequence charts sec ee cece e cece cece cence eee eeeeeeeeeeeeeees 3 2 Chapter 4 TRIAL RUN ADJUSTMENT HM Outline of adjustMent cece cece cece cece nent cece cece ences 4 1 HM Preliminary inspection cece cece cece cece e eee e eee eeeeeees 4 2 E Measurement of flame voltage flame signal sseeeeee 4 2 E Pilot tUrMnmdOwn t Stsivicscse ccc ccsceiscdces isone rra
19. D300C 500C responds to other ultraviolet rays flame failure in the burner will not be detected As a result fuel will continue to be discharged causing a serious explosion hazard OO 000 OD OC Do not connect a solenoid valve to the high voltage side of the circuit If a ground fault occurs the ground fault current may energize and open the solenoid valve This device will not be able to prevent the valve from opening and fuel from flowing out Even after the power to this device is turned off terminal F continues to hold an electrical charge To avoid electrical shock do not touch termi nal F WARNING Carry out the pilot turndown test carefully If the flame detector is set so that it detects a pilot flame that is too small to ignite the main burner this device will not be able to detect a flame failure in the main burner In that case fuel will continue to be supplied causing a serious explo sion hazard Before the pilot turndown test or ignition spark response test make sure that all manual fuel valves are closed 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 ducts and combustion chamber Failure to discharge unburned gas or fuel may result in an explosion When the pilot turndown test is complete turn OFF the power switch to shut down t
20. PB _ check Safety Time out and an alarm is output On the AUR450C E4 ignition failure and P2 are displayed alternately IStandby Pre purge Start Lockout Stop PB A 100T Purge timmer 101X During the purge T02X Purge end Interlock Relay output Rls oe K2 K3 K4 K5 K6 K7 Ignition transformer Interrupted pilot valve Intermittent pilot valve Main valve Flame monitor output Alarm output FLAME ALARM START IG PV MV Sequence display ae Chapter 3 OPERATION If ignition is not detected after the ignition trial time period the system is locked 3 5 Chapter 3 OPERATION Flame out If a flame out is detected during Run the system is locked out and an alarm is out put On the AUR450C E5 flame failure and P5 are displayed alternately Standby Pre purge Start Safety Pilot Main Trial RUN Flamd Lockout j check Time Stabilization Jailurg Interlock normal __ _ Se ee ee ee eee Power supply PB 2 mg oe oe oe ee ee es Se Se StopPB 100T Purge timmer n 101X During the purge mm MMMM LMM Lnn 1o2x Puge ead i j a Input Powersupply ___ i Start contact input oF Interlock l SS a a a a Flame signal _ Relay output Kass K2 K3
21. Signal wire Ground wire Mounting 0 Indoors L Equipment room U Outdoors Device cover Yes UNo Dirt or dust on UV ray detector glass U UV sensor signal line F G wiring check Qok U Reversed connection Environment 1 Ambient temperature Ambient humidity Dew condensation Corrosive atmosphere Other Equipment ils Main burner Model Maker name Capacity Pilot burner Model Maker name Capacity kW Kcal h Fuel type and composition Pilot burner Main burner Valve train draw in the space below Special notes Flame detector mounting drawing control mode ON OFF proportional etc equipment drawing valve train environment layout flammable materials hazardous materials obstacles 5 4 Chapter 6 SPECIFICATIONS E Specifications General specifications AUD300C1000 AUD300C2100 AUD500C For normal operation 2 s max If alarm is detected 10 2 s 4 1 s or 8 2 s depending on model Main trial time 73s Start check error detection 10 2s time Nominal 1 5 s max 2 s nominal 3 s max 4 s Reset response time 1 s max Range of flame voltage output 0 to 5 V IV wire 0 75 mm min for signal line wiring length of 10 m max Input impedance of connected instruments 100 kQ min Flame sensitivity Flame out detection 0 6 V min Flame establishment 1 5 V max Service life 7 years or 100 000 operation cycles max at room
22. With the controller positioned so that the body subbase screw is near the bot tom latch the hook on top and then lower the controller so that it meets the sub base Push the controller against the subbase so that the terminals make contact 2 Tighten the body subbase screw to secure the controller to the subbase The maximum tightening torque of the screw is 0 5N m 3 Attach the code key label to the panel or some other easy to see location near the controller so that when an alarm occurs it will be easily identifiable AUR450 7 7 x KRR 7 segment display yoryAI F 75 ha F 4Ny ka K Sequence code Alarm code Event code iM Ri Ag RI Ag oy Desdistion Display Description Display Description J5 13 H7177 KER P ay EO Stan check alarm A1 fee delay p 475 9 9B yxy SHERI P1 AZ f2277 E1 interlock alarm A2 searosscanone atm TEE UKA yry SEVERE PR P2 Savina E2 Esta A3 ideene N4 Oy hAYY URS 4 Ny hE STA P3 pidrSiabigation ES Wam A4 Operation tie for event 242 KIIPI TEK 4 A gt RRR P4 Main Trial E4 Ignition failure A5 Combustion time for event EHR K ANY ARREZ P5 Fay ES Famotaiue A6 Sainte ces AAY ha KI EVENT LED ATARI A7 ZV LEER DISPA4 y FERTILE LU RRLET Far eager erg ab An event code is displayed if the DISP switch is pressed A8 7v LEEFR while EVENT is lit up Fame votage lower seting abe E Dismounting
23. andling Precautions e The signal wires of the AUD300C blue and yellow have specific polari ties Connect the blue wire to terminal 1 F of the AUR400C 450C and the yellow wire to terminal 2 G Reversing the signal wires may cause the tube unit to break or malfunction e To extend the wiring use 2mm 600V vinyl insulated IV cable with a length of 200m or less 2 6 Chapter 2 MOUNTING AND WIRING Checking the connection between the controller and the AUD300C 500C 2 7 Required equipment digital tester To verify that the controller is correctly connected check the polarity between ter minals F and G of the AUD300C 500C with a digital tester as shown below If the polarity is positive the connection is correct If it is negative the connection is reversed In this case redo the connection correctly tester probe red tester probe black TE Terminal F Yellow lead Blue lead Chapter 2 MOUNTING AND WIRING E Wiring to a solenoid valve 7 WARNING S Do not connect a solenoid valve to the high voltage side of the circuit If a ground fault occurs the ground fault current may energize and open the solenoid valve This device will not be able to prevent the valve from opening and fuel from flowing out Correct connection AUR450C High voltage side H Power supply Grounded side G Ground fault juawdinba uosnqwog Valve closed When the
24. ard Sea Saltese Ga ee eres ERE aoe erre 1 1 DFU S os invecsice faces aisecdid sees sise serail ENEE DE aod ceieloriete Sobers ae ayers eeatd ve 7A eaiere 1 1 Me System Structure cece cece e cece cece eee eee eee e eee eeeeeeeees 1 2 M Safety assurance fUNCtIONS eee cece cece cece eee e tence ee enees 1 2 E Precautions for designing equipment eee cece reece ee eees 1 3 HM Model Selection table 2 s scsccccsccscccscvecesscccvescsevsessecvese 1 3 E Optional devices cece eee cece e cece eee eee tence eee eeeeeeees 1 4 M Standards compliance ssssssesssesessssesesssseseseeseeseeee 1 4 E Names and functions of parts eee cece e cece eee e tence ee enees 1 4 E Description of 7 segment display sseeee cece cece ee eeeeeeee 1 6 M Terminal block Signals seeeeee cece cece cece erence nec enees 1 8 Chapter 2 MOUNTING AND WIRING 2 1 Mounting ee eee eee eee eet e cece cece e eee e eee n eee e tense eneeeeeenees 2 1 HM Mounting locations cece e cece cece cece e cree tence eee n ec enees 2 1 M Mounting poSture cece cece cece cece eee eee renee eee nec ences 2 2 M Mounting the Ssubbase eee eee e cece cece reece eee eee e ec eeees 2 2 HM Mounting the Controller e eee ee cece eee cece cence ence se eeeees 2 3 E Dismounting the controller sseee eee cece cece eee e ee eeees 2 3 2 2 WIRINGs ss 54
25. c directly to the output terminals of this device If they are not directly connected com bustion safety cannot be ensured If an auxiliary relay is needed to increase the number of contacts take preventive measures against relay malfunction and contact welding Refer to the laws and standards of the relevant country when design ing equipment Never short circuit the start contact in order to start and stop this device by switching the power on and off This is very important for reli able activation of the self check circuit at device startup Failure to observe this warning could lead to an explosion Do not extend the lead wires of the reset input for more than the allow able length of 10 meters Always input the reset command from beside the combustion equipment not from a remote location Because a safe ty check cannot be made far from the equipment there is an increased risk of explosion Do not allow the pilot or main burner Safety Time ignition trial time to exceed the specifications of the burner or equipment manufacturer If they do fuel may accumulate in the combustion chamber and form an explosive air fuel mixture resulting in a serious explosion hazard Before wiring mounting or removing this device be sure to turn the power off Wiring with the power on can result in an electric shock Make sure the AUD300C 500C does not detect ultraviolet rays other than those of the burner flame If the AU
26. dy pull it out while tilting it as shown in the drawing 6 3 Revision History date CPSP 1264E fist Edition 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 June 2007 W
27. ecker for AUR400C 450C Manual No CP SP 1211E It should be read in advance by those who use the FSP350C to check the operation of the AUR300C 350C and those who use the FSP450A to check the operation of the AUR400C 450C This manual gives important information and precautions for use of the FSP350C and FSP450A FSP136A Analog Flame Meter Manual No CP SP 1212E It should be read in advance by those who use the FSP136A to check the voltage of the AUR300C 350C 400C 450C This manual gives important information and precautions for use of the meter Vii Organization of This User s Manual This manual is organized as follows Chapier 1 Chapter 2 Chapier 3 Chapier 4 Chapter 5 Chapter 6 OVERVIEW An overview of the AUR450C MOUNTING AND WIRING Installation wiring and wiring check methods OPERATION Internal block diagram of the AUR450C and sequence charts showing its opera tion TRIAL RUN ADJUSTMENT Adjustment of the AUR450C and tests that are necessary before operating it MAINTENANCE AND INSPECTION Maintenance and inspection instructions and troubleshooting flowchart SPECIFICATIONS General specifications performance specifications and external dimensions of the AUR450C viii Contents SAFETY PRECAUTIONS The Role of This Manual Organization of This User s Manual Conventions Used in This Manual Chapter1 OVERVIEW E QOVOVIOW 65 oii 6055 odie 8 cess u inns eE a ai
28. emicals or corrosive gas such as ammonia sulfur chlorine ethylene compound acid or others e Where it is exposed to water drops or damp atmosphere e Where it is exposed to high temperatures e Where vibration continues for an extended period of time This device has a protective structure equivalent to IP20 Take measures to protect it from dust In particular if the equipment is designed to comply with CE UL standards be sure to mount this device in an instrument panel with IP54 or equivalent protection Installation wiring inspection adjustment etc should be carried out by a trained and experienced technician who has knowledge and technical skills related to combustion equipment and flame safeguard control devices E Mounting locations For effective heat radiation and convenient dismounting wiring and maintenance be sure to leave work space around the device as shown below Stand alone mounting LLLLLILLLLLLLLLL 50 mm min 100 mm min Close side by side mounting 100 mm min 100 mm min 50 mm min o Handling Precautions e f AUR Series devices are mounted at intervals of less than 100mm on the right and left ensure that the ambient temperature does not exceed 45 C e If ambient temperature is close to the allowable upper limit use a panel cooler or cooling fan to reduce the panel box temperature Allowable ambient temperature upper limits Stand alone mou
29. er Restore all test jumpers and limit interlock regulator settings to their previous states If operation begins without the above steps damage to the equipment gas leak or explosion may result CAUTION rt Only an experienced technician who has knowledge and technical skills related to combustion equipment and combustion safety should carry out the pilot turndown test o Handling Precautions e If a fuel pressure limit switch is used and its contacts are open turn it ON with a jumper cable during this test To carry out the pilot turndown test follow the steps below Preparations for the test 1 Turn OFF the power switch 2 Close the manual valves to stop the gas supply to the pilot burner and main burner 3 Open the manual valve for the pilot burner Check a gas pressure level at which the AUD300C 500C cannot detect the pilot flame 4 Turn ON the power switch and press and hold the start switch gt gt The ignition operation begins the pilot valve opens and the ignition transformer is activated The flame relay turns ON and the combustion lamp lights up 4 3 Chapter 4 TRIAL RUN ADJUSTMENT 5 Close the manual valve for the pilot burner slowly The pilot flame gradually becomes smaller Gradually close the valve until the AUD300C 500C cannot detect the flame 6 FLAME LED goes out and the system is locked out Record the gas pressure just before the lockout Check that the main burner ignites
30. erve this warning could lead to an explosion L R phase Power supply N S phase alg a lE 21 27 8 8 AEREE Start Silale contact Interlock a z input input 9 2 is 3 f i 2 lt 5 ame monitor 2 output O eo 0 ol Subbase for AUR450C _ oe ed eee Lee Cee Re eee nr ene ere ro Note Wiring for input to terminals 15 and 18 through L R phase contacts without using terminals 16 and 17 is also possible l l l l l l l sd L R phase l l l l l l N S phase TY SS Stat Interlock contact input l input 9 ee E E E I E E EE E EE Yellow White 0 Alarm output N N fn N AUD300C 500C 8 Blue White External reset Q 8 8 6 input WOH OH NH Advanced UV sensor o Handling Precautions e If the high voltage side H of the power supply is distinguished from the grounded side G connect the high voltage side H to terminal 13 L1 and the grounded side G to terminal 14 N e Do not use unused terminals as relay terminals e Use an overload prevention device for the power supply as needed e For wiring to the power source use a 0 75mm wire 30 cores 0 18mm dia in keeping with JIS C
31. et as shown in the table below using the loader in this case settings are effective after turning the power off and back on again Description Initial value Data format Data length 8 bit even parity Data length 8 bit even parity stop bit 1 bit stop bit 1 bit Data length 8 bit no parity stop bit 2 bits 19200 9600 4800 2400bps__ 19200bps Chapter 2 MOUNTING AND WIRING E Connection to a 3 wire system 3 wire system AUR450C ODA ODB SG DA FG O E Connection to a 5 wire system 5 wire system SDA SDB RDA RDB W UOU Terminating resistor e Do not connect any terminating resistor to either end of the communica tion path Doing so might cause a communications failure e Even if there are units requiring a terminating resistor in the communica tion path do not connect a terminating resistor o Handling Precautions e Use a twisted shielded pair cable for RS 485 communications e Ground shielded wire to one point on one side of the cable e When a 5 wire system is used wire the connections marked with an DB o T SG O AUR450C a be DA oB O SG AUR450C oO DA eS DB Seem SG AUR450C AUR450C asterisk externally 2 12 Chapter 3 OPERATION o Handling Precautions Do not reset this device while combu
32. etector Does the main burner ignite Does the START LED light up e Check the main valve e Check the burner and wiring The START LED momentarily lights up the ALARM LED lights up and the system is locked out e Check for leakage from the Y main valve e Check the burner N Is there an alarm Check the alarm Replace the AUR450C Normal operation Interlock input is OFF Check the interlock 5 3 Chapter 5 MAINTENANCE AND INSPECTION Use this sheet when checking controller status for inspection or troubleshooting Flame Detector and Protectorelay Status Checklist Fill in the blanks and check the applicable boxes End user name equipment maker name Equipment name production line name or number Controller model No Date code date mfd Date delivered Wiring and mounting Flame current voltage 1 Power supply source instrumentation electric power 1 primary secondary transformer voltage etc Protectorelay power supply voltage Vac Was there a prolonged instantaneous power failure or a voltage drop surge OYes UNo Wiring material diameter distance temperature maker name etc During pilot combustion While ignition transformer is on While ignition transformer is off During main burner combustion During main burner ignition Min Max Normal Length of operation years months and operation frequency Power supply wire
33. g e Insulation resistance tester 5 00Vdc megger 4 1 Chapter 4 TRIAL RUN ADJUSTMENT E Preliminary inspection 1 Inspect all wiring parts 2 Check that the AUR450C is mounted in a place where the ambient temperature is within its allowable range 3 Check that the AUD300C 500C is mounted correctly In particular be sure the blue lead wire to terminal 1 and yellow lead wire to terminal 2 of the AUD300C 500C are connected correctly For details refer to gt AUD300C user s manuals No CP SP 1141E and CP SP 1170E AUDS500C user s manual No CP SP 1181E 4 Check that the valves and cocks of each fuel system are closed and that the inside of the fuel chamber is vented sufficiently 5 After items 1 to 4 above have been checked supply the power and start the trial run adjustment E Measurement of flame voltage flame signal Start the equipment and measure the voltage under several conditions such as start up operation and normal operation 1 Set the multimeter to the 0 to 10Vdc range 2 Connect the positive probe of the multimeter to terminal and the negative probe to terminal of flame voltage terminals 3 Check that the voltage is stable and is between 1 5 to 4 0V 4 If the flame voltage fluctuates widely check the AUD300C 500C s mounting position and wiring condition o Handling Precautions e Always use IV wire with a cross sectional area of 0 75mm or more for signal lines The wiring le
34. gh reliability and be sure to design the circuit correctly When installing and wiring be sure to follow the instructions in this manual and in the user s manual for the combustion equipment Run the high voltage ignition transformer cable separately and keep it at least 10 cm away from this device Keep power lines and ignition transformer high voltage cables separate from the AUD300C 500C cables and from the external reset input cable Make sure that ignition transformer high voltage cables are properly connected to prevent faulty contact Faulty contact might generate high frequency radio waves which can cause malfunction Always connect the power supply last Otherwise touching a terminal accidentally could result in electric shock or damage Always supply electric power at the voltage and frequency stated on the model label of this device In keeping with technical standards for electrical equipment the burner body must have an earth ground connection with a resistance of less than 100 Q After the wiring is complete be sure to check that it is correct Incorrect wiring may cause damage or faulty operation Q Q Q Q Q Q Q Q Q Q Chapter 2 MOUNTING AND WIRING E Wiring diagram 7 WARNING Never short circuit the start contact in order to start and stop this device by switching the power on and off This is very important for reliable activation of the self check circuit at device startup Failure to obs
35. he AUR450C Dynamic Self Check Burner Controller Manual No CP SP 1187E This manual is supplied with the SLP AOO Smart Loader Package The manual describes the software used to make various settings for smart loader package using a personal computer Personnel in charge of design or setup of a system using the AUR450C must thoroughly read this manual The manual describes installation of the software into a personal computer operation of the personal computer various functions and setup procedures AUD300C1000 Advanced UV Sensor Manual No CP SP 1141E The manual describes the mounting wiring maintenance and inspection and troubleshooting when the AUD300C1000 when it is used in a safeguard control system vi AUD300C2000 Advanced UV Sensor Manual No CP SP 1170E The manual describes the mounting wiring maintenance and inspection and troubleshooting the AUD300C2000 when it is used in a safeguard control system AUD500 Explosion Proof Advanced UV Sensor Manual No CP SP 1181E It describes the mounting wiring maintenance inspection and troubleshoot ing of the AUD500C when it is used with combustion equipment FSP300C Flame Simulator Manual No CP SP 1209E It should be read in advance by those who use the FSP300C to check the operation of the AUD300C 500C and the AUR300C 350C 400C 450C This manual describes installation operation and precautions for use of the FSP300C FSP450A Ch
36. he power Restore all test jumpers and limit interlock regu lator settings to their previous states If operation begins without the above steps damage to the equipment gas leak or explosion may result Do not start regular operation of the equipment without first completing the trial run adjustments for this device as well as the tests specified by the equipment manufacturer If lockout occurs be sure to do a prepurge before restarting the sys tem If the combustion chamber and gas flue are not ventilated to remove any unburned gas the ignition process may cause an explo sion Q Q Q Q 9 Q Q If a check is performed using a flame simulator without dismounting this device be sure to close the fuel valve When a flame simulator is used during normal operation the flame detector reports that a flame is present even if the pilot burner and main burner are not ignited with the result that fuel is supplied continuously This could cause an explo sion iii A CAUTION Do not install where exposed to any of the following e Certain chemicals or corrosive gases ammonia sulfur chlorine ethylene compounds acid etc e Splashing water or excessive humidity e High temperatures e Prolonged vibration This device has a protective structure equivalent to IP20 Take measures to protect it from dust In particular if the equipment is designed to comply with CE UL standards be sure to mount this
37. ice as well as the tests specified by the equipment manufacturer If lockout occurs be sure to do a prepurge before restarting the system If the combustion chamber and gas flue are not ventilated to remove any unburned gas the ignition process may cause an explosion Installation wiring inspection adjustment etc should be carried out by a trained and experienced technician who has knowledge and technical skills related to combustion equipment and flame safeguard control devices Only an experienced technician who has knowledge and technical skills related to combustion equipment and combustion safety should carry out the pilot turndown test E Outline of adjustment The following test adjustment items are described in this chapter e Measurement of flame voltage e Pilot turndown test e Ignition spark response test e Safety shutoff test o Handling Precautions e After the above items have been adjusted check again that each adjustment is satisfactory It is absolutely necessary for all adjust ments to be correct before the final positioning of the flame detector e Do not repeatedly turn the power supply switch ON and OFF Doing so may cause incorrect operation After turning the power OFF wait at least 3 seconds before turning it ON Tools and parts needed e Multimeter or FSP136A Input impedance 100k or more AC range 0 to 300V DC range 0 to 10V e Jumper cables with clips Two AWG14 2mm min approx 30cm lon
38. ion 15 Check that the flame voltage is correct 16 If any limit switch has jumper cables attached disconnect them to return the limit switch to its previous state 4 4 Chapter 4 TRIAL RUN ADJUSTMENT E Ignition spark response test 7 WARNING Make sure the AUD300C 500C does not detect ultraviolet rays other than those of the burner flame If the AUD300C 500C responds to other ultraviolet rays flame failure in the burner will not be detected As a result fuel will continue to be discharged causing a serious explosion hazard 1 Close the manual fuel valves of the pilot and main burners 2 Begin operation and measure the flame voltage in the pilot ignition sequence to check whether or not the flame voltage is influenced 3 If the FLAME LED is lit make adjustments using the following procedures while referring to the instruction manual for the equipment e Move the AUD300C 500C or ignition spark rod so that there is no influence e Puta shielding plate in the optical path of the AUD300C 500C so that the effect of the spark is a flame signal of 0 4Vdc or less o Handling Precautions e Be sure the AUD300C 500C does not detect ultraviolet rays other that those of the burner flame e The following shows various ultraviolet ray sources other than the burner flame that may activate the AUD300C 500C Ultraviolet ray source Red hot furnace wall within 50cm of furnace wall Ignition transformer and welding arc
39. ion and shutdown of combustion equipment e Operates each value ignition transformer in a predetermined order with preset timing 3 Fixed ignition timing To ensure safety the ignition circuit is so designed that ignition cannot continue in excess of the specified time even if part of the ignition circuit fails 4 Safe startup e Checks flame detector and flame circuit for internal failure before every startup e If failure is detected prevents burner startup Checks for false flame detection or false discharge of the tube unit failure of the ignition circuit and failure of the alarm circuit 5 Flame safeguard control in compliance with safety standards This controller s design is based on North American and European safety stan dards and it is certified to meet them This device can be used with combustion safety equipment in Europe and North America 6 Dynamic self checking Checks continuously for sensor failure of the AUD300C 500C and for failure of the flame detection circuit even during the RUN stage of operation If failure is detected fuel supply shutdown and lockout are immediately carried out 7 Protection against part failure Failure Mode Effect Analysis FMEA has been done for all parts Even if a part failure occurs safety will be maintained and dangerous conditions such as the following will not occur e Out of order ignition sequence e Dangerous sequence timing longer ignition time 1 2 Chapter 1 OVERVIEW
40. lock during stand by state The system is not locked out though the lockout interlock contact is disconnected or changed to OFF during standby and then a start signal is input the system is locked out and an alarm is output On the AUR450C E1 interlock and P1 are displayed alternately Standby Pre purge Start Lockout check Power supply PB j SPB 5 TOOT Purge timmer 101X During the purge 102X Purge end Input Power supply __ tu _ y yiy 7i__ Flame signal _ Relay output K1 K2 K3 K4 K5 K6 K7 Load output Ignition transformer Interrupted pilot valve Intermittent pilot valve Main valve ss Flame monitor output _ Alarm output__ LED display Sequence display mr Ba Chapter 4 TRIAL RUN ADJUSTMENT 7 WARNING Do not allow the pilot or main burner Safety time ignition trial time to exceed the specifications of the burner or equipment manufacturer If they do fuel may accumulate in the combustion chamber and form an explosive air fuel mixture resulting in a serious explosion hazard Even after the power to this device is turned off terminal F continues to hold an electrical charge To avoid electrical shock do not touch terminal F Do not start regular operation of the equipment without first completing the trial run adjustments for this dev
41. method 1 N 15 units max Terminating resistor Use prohibited resistor already built in Signal level RS 485 compliant Environment specifications Description Allowable ambient temperature Stand alone mounting 20 to 55 C Side by side mounting of multiple units and intervals of less than 100 mm 20 to 45 C Storage temperature 20 to 70 C Ambient humidity 90 RH at 40 C Vibration resistance During operation amplitude 0 6 mm p p frequency 10 to 55 Hz for 2h each in X Y and Z directions During transportation storage amplitude 0 75 mm p p frequency 10 to 55 Hz for 2 h each in X Y and Z directions Impact resistance During operation 0 to 49 m s During transportation storage 0 to 300 m s E External dimensions 103 a gt i7 S azbil Yamatake Corporation DYNAMIC SELF CHECK OPOWER BURNER CONTROLLER OEVENT AUR450 OSHUTTER ise OFLAME 0O EA OALARM OSTART REME gt OIG Ori a moors C OmV LOADER y J AC xxxV 50 60Hz XXXXX_XXXXXX UUUUVUU U AUR450C 000 UU INU UU OM Yamatake Corporation MADE IN JAPAN at Chapter 6 SPECIFICATIONS Unit mm 163 Space required for dismounting the main body z 7 6 31 Note When dismounting the main bo
42. ngth must be 10m or less e A measuring instrument connected to this device should have an input impedance of 100k or more Note e Even during normal operation the flame voltage is synchronized with the shut ter operation of the AUD300C S500C and fluctuates between 0 1 to 0 3V e On the AUR450C the average flame voltage can be checked on the 7 segment display 4 2 Chapter 4 TRIAL RUN ADJUSTMENT E Pilot turndown test This test is intended to check that the flame is reliably transferred to the main burner when the AUD300C 500C detects a pilot flame if the gas pressure and air pressure change to their worst conditions A WARNING Carry out the pilot turndown test carefully If the flame detector is set so that it detects a pilot flame that is too small to ignite the main burner this device will not be able to detect a flame failure in the main burner In that case fuel will continue to be supplied causing a serious explosion hazard Before the pilot turndown test or ignition spark response test make sure that all manual fuel valves are closed 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 ducts and combustion chamber Failure to discharge unburned gas or fuel may result in an explosion When the pilot turndown test is complete turn OFF the power switch to shut down the pow
43. nt code display For details how to event setup refer to gt Smart loader package for the AUR450C CP SP 1187E 1 7 Chapter 1 OVERVIEW E Terminal block signals Subbase terminal block The table below describes the terminals on the subbase N 2 AUD300C terminal F blue AUD300C terminal G yellow Power supply L1 100 120 200 230Vac 50 60Hz Power supply N Start contact input 100 120 200 230Vac 50 60Hz Start contact input Contact resistance 1002 max 17 Interlock 100 120 200 230Vac 50 60Hz 19 Ignition transformer 300VA max 200Vac 1 5A PF 0 5 7 AUD300C shutter white 24Vdc 150mA AUD300C shutter white 200VA max 200Vac 1A PF 0 5 200VA max 200Vac 1A PF 0 5 9 External reset input Alarm output contact 75VA max Flame monitor output 75VA max 200Vac 0 375A PF 0 5 a a Flame voltage terminals The table below describes the flame voltage terminals on the front panel Terminal Description No oO 13 14 15 16 17 18 19 20 21 2 23 24 p Flame voltage output 0 to 5Vdc P Flame voltage output The flame voltage may reach approx 7V during self discharge 1 8 Chapter 2 MOUNTING AND WIRING 2 1 Mounting 7 WARNING Before wiring mounting or removing this device be sure to turn the power Q off Wiring with the power on can result in an electric shock CAUTION Do not mount the AUR450C in the following places e Inthe presence of ch
44. nting 55 C Close side by side mounting 45 C 2 1 Chapter 2 MOUNTING AND WIRING E Mounting posture Mount the controller so that the display control panel is vertical not horizontal and its writing is correctly oriented GOOD Panel WRONG Panel WRONG Panel WRONG Panel Mount the controller as shown on the left below WRONG Panel GOOD WRONG Panel Wiring diagram Front of controller Panel Front of controller E Mounting the subbase Mount the subbase on a vertical surface The threaded hole for the body subbase screw should be in the lower portion of the vertically oriented subbase 1 Open knockout holes on the subbase as required by the wiring situation 2 Connect the wiring conduit s 3 Mount the subbase in the desired location with M4 screws using the 4 mount ing holes unit mm M4 mounting hole 4 locations o K N oO Q 00 800 2 o Handling Precautions e Although there are 5 holes use the 4 holes at the corners as shown in the above drawing e Tighten the screws with a torque of 1 5N m min Failure to do so may break the subbase 4 Connect the wiring in accordance with the description of Item 2 2 Wiring 2 2 Chapter 2 MOUNTING AND WIRING E Mounting the controller The method of mounting the controller on the subbase is described below 1
45. pter 4 TRIAL RUN ADJUSTMENT Contamination of monitoring window and sighting Once a month or more pipe of AUD300C 500C foresters Measurement of flame voltage Pilot turndown test o Handling Precautions e f unintended burner shutoff may cause a serious problem perform the inspection more frequently e Ifthe burner manufacturer provides specific instructions about maintenance and inspection always strictly observe them e Always use IV wire with a cross sectional area of 0 75mm or more for flame voltage output The wire length must be 10m or less A measuring instrument connected to this device should have an input impedance of 100k or more 5 1 Chapter 5 MAINTENANCE AND INSPECTION E Alarm code and description When lockout occurs an alarm code is automatically displayed When the alarm is activated the lockout sequence code and the alarm code are displayed alternately Start check alarm The start check was not completed for some reason such as momentary power failure or part malfunction Interlock alarm Interlock occurred E2 False flame A false flame such as a remaining flame was detected 5 UV alarm A flame was detected even though the shutter output was off Ignition failure No flame was detected at the completion of the ignition trial E Flame failure A flame failure occurred in the following sequence e Pilot Stabilization e Main Trial e RUN o Handling Precautions e When the DISP switch is pressed
46. put Ignition transformer i m aaa Interrupted pilot valve i E Intermittent pilot valve tt ___ mmm a S OOOO Main vale WT Fiame monitor apati ___ _ nm Alarm output _ i f f LED display d b x TPE xd X xd Sequence display i When the voltage output to the shutter is ON opening the shutter LED goes off When the voltage output to the shutter is OFF closing the shutter LED lights up 3 2 Chapter 3 OPERATION Start check error due to false flame If an error false flame is detected during the start check and normal operation Power supply PB __ Standby does not resume for 10 seconds the system is locked out While the false flame is detected the K6 flame monitor output is ON On the AUR450C E2 false flame and P1 are displayed alternately Pre purge Start check Lockout at alarm detection Stop PB iz D O N Q 3 v 100T Purge timmer 101X During the purge 102X Purge end Input Power supply ____ Start contact input Flame signal__ Relay output K1_ K2 K3 K4 K5 K6 K7 Load output Ignition transformer Interrupted pilot valve Intermittent pilot valve _ Main valve Flame monitor output Alarm output __ LED display POWER N E EN a De ee
47. rde darent naaa nanes 4 3 E Ignition spark response test sssssessssesesseresoseeceseserecees 4 5 M Safety shutoff test sssssssssesesuesuessssesssesseseseseseeee 4 6 Chapter 5 MAINTENANCE AND INSPECTION E Frequency of maintenance and inspection sseeeeeeeee 5 1 E Alarm code and description eee ee cece cece ence cence eeeees 5 2 E Fault inspection flowchart eeee cece e eee e eee e eee eeeeeees 5 3 Chapter 6 SPECIFICATIONS E Specifications cece cece eee cece cece cece e eee e nent eee eeeeeees 6 1 E External cimenSilons esos siscsccwsieses cass ne caweds cecieca vars ews wise e6 6 3 Conventions Used in This Manual The following conventions are used in this manual CJ Handling Precautions Handling Precautions indicate items that the user should pay attention to when handling the AUR450C Note Notes indicate information that might benefit the user CF This indicates the item or page that the user is requested to refer to 1 2 3 Numbers within parentheses indicate steps in a sequence or parts of an explanation xi Chapter 1 E Overview E Features OVERVIEW The AUR450C Dynamic Self Check Burner Controller hereafter the this device is a flame safeguard controller that safely and automatically ignites and control a gas oil burner using the correct sequence of steps It operates in combination with the AUD300C Advanced UV Sensor
48. rom the subbase and pack it in its original box It might be damaged if transported while mounted on a panel or the like The Role of This Manual A total of 9 different manuals are available for the AUR450C Read them as necessary for your specific require ments If a manual you require is not available contact Yamatake Corporation or its dealer AUR450C Dynamic Self Check Bunner Controller Manual No CP SP 1264E This Manual This manual should be read by personnel using the AUR450C for the first time those in charge of designing combustion equipment that uses the AUR450C or designing the hardware for mounting the device in a control panel and personnel performing maintenance The manual gives an overview of the product its mounting and wiring for connection to other equipment its operation trial run adjustment mainte nance and inspection and specifications AUR450C Dynamic Self Check Bunner Controller Communications Manual No CP SP 1176E Those using the communications functions of the AUR450C should read this manual It is necessary for making the program of the device that uses AUR450C An operation status and various data of AUR450C can be read by using the communication This manual describes a details of display outline of CPL communications communications procedures a list of communications data how to remedy trouble and communications specifications Smart Loader Package for t
49. rs Indicates current status of the system RS 485 communications connector Communications connector Loader jack Connects to a personal computer using a dedicated cable when using the PC Smart Loader program CF For the use of the loader refer to Smart loader package for the AUR450C RST switch Resets the alarm lockout Controller subbase screw CP SP 1187E After the controller is placed on the subbase Flame voltage terminals itis Secured with this screw Used for monitoring the flame voltage M3 5 screws Note e There are covers on the RS 485 communications connector loader jack and flame voltage terminals For purposes of explanation covers are not shown in the above drawing 1 4 LED display details Chapter 1 OVERVIEW Description Lights up when the power is turned on Lights up when an event occurs AUR450C Lights up when the shutter is closed Lights up when a flame is detected ALARM Rea Lights up when there is an alarm START Green Lights up when the start contact circuit is closed and goes off when an alarm is detected Lights up when the ignition transformer output is on PV Green Lights up when the interrupted pilot valve opening output is on Lights up when the main valve opening output is on On the AUR450C the color changes to green orange or red as determined dur ing setup The factory settings are green for a flame voltage of more than 2 5 V orange for 1 6 to 2 4 V
50. splayed code and the concurrent stage in the sequence Standby Standby when the start contact input is off Start check Start check of this device and of the AUD300C Ignition of the pilot burner Check to conform reliable pilot burner ignition Ignition of main burner Flame monitoring after main burner ignition Alarm code display When lockout occurs the display automatically changes to alarm code display and the lockout sequence code and alarm code are alternately displayed Start check alarm The start check was not completed for some reason such as momentary power failure or part malfunction EO Ei Interlock occurred E2 E3 E4 5 UV alarm A flame was detected even though the shutter output was off Ignition failure No flame was detected at the completion of the ignition trial E Flame failure A flame failure occurred in the following sequence e Pilot Stabilization e Main Trial e RUN o Handling Precautions elf the DISP switch is pressed while an alarm code is displayed the flame voltage is displayed rather than the alarm code When DISP is pressed again the sequence code and the alarm code are alternately displayed False flame A false flame such as a remaining flame was detected e If the system is locked out and then reset the display prior to lockout resumes For example if lockout occurs while flame voltage is dis played the display changes to alarm display in which the alarm code
51. stion equipment is running If it is reset combustion will stop and restart as determined by the start contact input E Wiring diagram and internal block diagram The internal block diagram below shows an example of wiring with external devices L R phase N S phase pula Stop PB eb Operation PB Purge start a During the purge Purge end AUR450C 102X Start contact 102X Flame amplifying White COH Shutter Ignition transformer wne a arving ij White arai circuit ja pilot Interrupted pilot valve D circuit Main valve D K3 Alarm output O K6 Flame monitor output AUD300C 500C Flame detector External reset Chapter 3 OPERATION E Sequence charts Operation sequences for this device are shown below Normal operation When the start contact is turned ON with the power supply and interlock also ON the operation progresses to RUN following the sequence shown below When the start contact is turned OFF the sequence goes to standby Standby Pre purge Start Safety Pilot l Main Trial l RUN l Standby check Time Stabilization nterlock or _ ja Power supply PB i a T T ENE AE E EN Se Stop PB___ 100T Purge imme 101X During the purge _ 102X Purge end i Input Power supply ___ Start contact input Interlock eae i Se a IT ee ee eee Relay output Ki K2 K3 K4 K5 K6 K7 Load out
52. terminal cover When wiring is done reattach the flame voltage terminal cover 1 Insert the left part of the cover into the square hole on the controller 2 Push the right side of the cover into place by hand 2 10 Chapter 2 MOUNTING AND WIRING 2 3 Communications Connections E Smart Loader connection To use the Smart Loader Package SLP remove the terminal cover the same one used for the flame voltage terminal and connect the dedicated cable from the loader jack to a PC gt Removing the terminal cover page 2 9 Note e For details operations of SLP refer to gt Smart Loader Package for the AUR450C user s manual No CP SP 1187E E Connection of RS 485 communications For RS 485 communications remove the cover from the RS 485 communications connector and attach a compatible connector The controller uses 3 wire RS 485 communications RS 485 communication connectors DA ransmission and reception terminal DB Transmission and reception terminal Signal GND terminal Compatible connectors Phoenix Contact model No MSTB2 5 3 STF 5 08 Yamatake model No 81446848 001 one unit Q Handling Precautions e Do not reset this device while combustion equipment is running If it is reset combustion will stop and restart as determined by the start contact input Communication setting Station address is set by the address switch Data format and transmission speed can be s
53. the controller Remove the body subbase screw first and then while holding the subbase lift off the controller bottom first Chapter 2 MOUNTING AND WIRING 2 2 Wiring 7 WARNING Connect loads ignition transformer solenoid valve etc directly to the output terminals of this device If they are not directly connected combustion safety cannot be ensured If an auxiliary relay is needed to increase the number of contacts take preventive measures against relay malfunction and contact welding Refer to the laws and standards of the relevant country when designing equipment Do not extend the lead wires of the reset input for more than the allowable length of 10 meters Always input the reset command from beside the combustion equipment not from a remote location Because a safety check cannot be made far from the equipment there is an increased risk of explosion Before wiring mounting or removing this device be sure to turn the power off Wiring with the power on can result in an electric shock CAUTION Installation wiring inspection adjustment etc should be carried out by a trained and experienced technician who has knowledge and technical skills related to combustion equipment and flame safeguard control devices Make sure the load connected to each terminal does not exceed the rating indicated in the specifications If timers and auxiliary relays are needed for additional functions select ones with hi
54. with the minimum pilot flame 7 Open the manual valve for the pilot slowly to adjust the pressure to a level immediately before the combustion lamp goes off 8 Reset this device and turn ON the start contact again to ignite the pilot 9 Check that the main burner ignites smoothly within 1 second after the manual valve for the main burner has opened 10 Change the gas pressure level between the minimum and maximum levels and ignite the main burner five or six times Be sure that the main burner ignites smoothly every time If the main burner does not ignite with the minimum pilot flame 11 Adjust the mounting position of the AUD300C 500C and the amount of incoming light so that the AUD300C 500C cannot detect a pilot flame that cannot ignite the main burner There are two kinds of adjustment procedures e Move the monitoring area of the sighting pipe slightly away from the pilot flame e Narrow the sighting pipe to decrease the incoming light amount from the pilot flame 12 Open the manual valve for the pilot burner slowly to make the pilot flame larger than the previous flame After adjustment check again that the main burner ignites with the minimum pilot flame 13 Perform steps 7 to 10 to be sure that the main burner still ignites with the minimum pilot flame Measures to be taken after completion of the test 14 After the test has been completed return the manual valve of the main burner to its fully open posit
55. y processing1 aurasoco TCT CTT CS ee Fo F a 25 00 Vac CE UL standards 20 Vac CE UL standards 30 Vac CE standards Add processing2 g D k n wWj gt 5 N N o additional processing nspection certification provided Tropicalization treatment applied Tropicalization treatment applied and inspection certification provided TO T is 1 3 Chapter 1 OVERVIEW E Optional devices The table below shows the devices that can be used with this device Compatible flame detector Advanced UV sensor AUD300C 20 to 100 C IV wire 2 0 mm AUD500C 20 to 60 C 0 75 mm cable explosion proof with silicone rubber insulation Compatible base Subbase Q241A104 20 to 60 C AWG14 to 18 Optional parts FSP300C100 E Approvals European directives e Gas Appliance Directive 90 396 EEC e Electromagnetic Compatibility Directive 89 336 EEC revised by 92 31 EEC and 93 68 EEC e Low Voltage Directive 73 23 EEC revised by 93 68 EEC e GASTEC CE 0063BS 1427 Underwriters Laboratories Inc File No MH27717 E Names and functions of parts Controller DISP switch Changes the contents of the 7 segment display 7 segment display Displays sequence codes alarm codes event codes and flame voltage Yamatake Corporation DYNAMIC SELF CHECK BURNER CONTROLLER OEVENT AUR450 OSHUTTER ADDRESS switch Sets the device s communications address LED indicato

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