Advanced UV Relay AUR300C User's Manual
Contents
1. Ignition transformer Start switch ON Flame detection Start switch OFF Power supply switch toa Flame failure Flame response _ Power switch Start switch Ignition transformer Pilot valve Main valve Combustion lamp j POWER LED SHUTTER LED START CHECK LED K1 FLAME LED K2 FLAME False flame exists before ignition Power switch ON False flame Start switch Start switch OFF 1 ON i Power switch Start switch D Ignition transformer Pilot valve Main valve Combustion lamp POWER LED SHUTTER LED AMI START CHECK LED K1 FLAME LED K2 FLAME ii K1 Start check K2 Flame detection K3 Combustion lamp K3 is operated with it synchronized with K2 For combustion monitor Chapter 2 MOUNTING AND WIRING e Flame signal exists when the shutter is closed 4 Power switch ON Start switch Start switch OFF 1 ON H Power switch i Start switch E Ignition transformer i OoOo Pilot valve C Main valve l i Combustion lamp POWER LED SHUTTER LED l j START CHECK LED Ki FLAME LED K2 FLAME Operation Operation of this unit POWER SHUTTER START FLAME LED LED CHECK LED LED Power ON e Voltage is applied to the terminal 1 S Limit O2. SHUTTER Ly Terminal for connection of Advanced UV Sensor AUD300C NT AUD300C is connected to this terminal p olll 5 M4 screw osv p k Ip a rp UV SENSOR EH Power supply or output devices are connected M4 screw s Input output terminal j Chassis ground connection part Chassis ground connection part commonly used as mounting hole The paint is peeled off to make the electric continuity active Terminal pin assignments Terminal No Electrical rating 14 Flame sensor Shutter white 24Vdc 150mA 3 13 Flame sensor Shutter white 12 Flame sensor G terminal yellow However since the start check is not 1i Flame sensor F terminal blue performed this is not used for the 10 Flame voltage output 0 to 5Vde 2 combustion control but used for the Flame voltage output combustion monitor Combustion lamp output K3 3A 250V cos d 1 1 Always use a measuring instrument 7 Combustion lamp output K3 having an input impedance of 100 kQ Flame output K1 K2 5A 250V cos 6 1 or more Additionally when connecting any Contact output common ae measuring instrument to this terminal K2 relay NC Flame relay NC 5A 250V cos 1 use an IV lead wire with a cross Start input sectional area of 0 75 mm or more Power supply R high voltage side 100 200Vac 50 60Hz and a length of 10 m or less Power supply S ground side The shutter has n
3. Carry out the wiring work in conformity with the specified standards Always connect the power supply finally If any terminal is touched accidentally this may cause an electric shock or damage A load to be connected to each terminal must not exceed the rating shown in the specifications Always supply the electric power having the same voltage and frequency as those stated on the model label of this unit iii CAUTION If timers and auxiliary relays need to be used as additional functions always select those having high reliability to construct a correct circuit This unit must be grounded with the resistance less than 100Q as described in the electric facility technical standards The grounding line must be connected to the burner chassis The power cable and high voltage cable of the ignition transformer must be separated from the power cable of the AUD300C The high voltage cable of the ignition transformer must be individual and kept 10 cm or more away from this unit Connect the high voltage cable of the ignition transformer firmly so that no faulty contacts exist If any faulty contact exists high frequency radio wave is produced causing noise to be produced in the radio or the radio to malfunction Additionally mount the ignition transformer directly on the burner main unit or metallic part electrically connected to the burner main unit After the wiring has been complet
4. 1142E This manual The personnel in charge of design mounting operation and maintenance of the combustion equipment using the AUR300C must read this manual The manual describes the mounting wiring trial run adjustment and maintenance and inspection of the AUR300C Conventions Used in This Manual The following conventions are used in this manual CJ Handling Precaution Handling Precautions indicate items that the user should pay attention to when handling the AUR300C 1 2 3 The numbers with the parenthesis indicate steps in a sequence or indicate corresponding parts in an explanation gt gt Indicates the result of operation or the state of the device after operation Contents SAFETY PRECAUTIONS The Role of This Manual Conventions Used in This Manual Chapter 1 Chapter 2 2 1 2 2 Chapter 3 Chapter 4 Chapter 5 OVERVIEW ME QVOIVICWs 66 ece eels be bie 5 ae ee Ne eRe BE Se TSE EE ed Heke bee Vasa ee eee 1 MM FTW S ass EE E E E EE T Gidon aiandew A E amp Sus atalelae Sune eens 1 MM Part names sess ss seeis oe bike eee ea tawke hat eek Mawsae esas taeaas 2 E Modell NO isi ccecincsciiecnccee die EET weeded a EEEE EEREN sees ee oes 3 M Configuration 6 e cece eee eect eee ene eee e nen eneee 3 MOUNTING AND WIRING MOUNTING cise tees ete eee te cise Ae ied Pepe eae ete ter eh a 4 Wiring ee cs 6 M Wiring diagram se eee eee ene eee ene e ees 7 M Wiring t
5. and monitoring Once a month or more pipe of AUD300C Measurement of flame voltage Once a month or more Plot turndown test o Handling Precautions e Ifthe burner shut off operation may cause a serious accident perform the inspection more frequently e Ifthe burner manufacturer provides specific instructions about the maintenance and inspection always strictly observe them 18 Chapter 4 MAINTENANCE AND INSPECTION Fault inspection flowchart POWER switch ON Is the power Oltage within the allowable range Voltage between terminals 1 and 2 NO YES Set the power voltage within its allowable range e Check the limit switch and stop switch e Check the power supply and power supply wiring NO 4 e Check for light source that may cause the false flame from the flame monitoring pipe e Check the flame voltage level e Check the AUR300C Is FLAME LED off YES Is SHUTTER LED off YES e Check the AUD300C Self discharge of ultraviolet tube warpage of Y shutter blade e Check the flame voltage level START switch ON Check the AUR300C Is the pilot burner ignited NO Are COMBUSTION and FLAME LEDs lit YES Is the flame voltage correct NO y Is the AC voltage p supplied to a point between terminal START sw
6. more in the horizontal direction as shown in the Fig below Vertical mounting It is possible to tightly mount the unit Lom CU w AUR300 power sumer H L IIl surrer 12l 10mm Horizontal mounting 20mm 20mm Chapter 2 MOUNTING AND WIRING 2 According to the mounting dimension drawing make mounting holes in the panel Mounting hole a M4 4 locations Mounting hole ite a M4 4 locations O R tT to X S RS oO O Q 249 0 5 6 oe 3740 5 Vertical mounting Horizontal mounting Mounting dimension drawing 3 Secure this unit to the mounting holes four locations with M4 screws o Handling Precautions e The paint of the lower right mounting hole of this unit is peeled off to make the electric continuity active and then this part is used as the chassis ground connection part Secure this part with the toothed lock washer to perform the electric connection firmly e When mounting this unit horizontally it is not possible to tightly mount the unit Chapter 2 MOUNTING AND WIRING 2 2 Wiring A WARNING Q Before wiring the AUR300C be sure to turn the power OFF Failure to do so might cause electric shock A CAUTION Carefully perform the mounting and or wiring work while referring to this u
7. N and 2 R Voltage is applied to the UV relay Start SW ON As the electric power is applied to the terminal 3 the K1 relay is turned ON through the flame relay contact K2 1 close false flame check As the pilot flame is detected the flame relay K2 is turned ON The output of the pilot valve is kept at the same time when the K1 relay is kept turned ON as the contacts K1 1 and K1 2 are closed As K2 2 and K1 3 are closed the main valve enters the stand by mode As K3 1 is closed the combustion lamp lights up Start SW OFF e As the electric power is applied from the terminal 3 to terminals 5 and 6 to operate the main valve Stop operation e All relays are turned OFF Stop SW OFF Flame shut off e All relays are turned OFF during operation Lit O Off Flash 11 Chapter 3 TRIAL RUN ADJUSTMENT 7 WARNING The pilot and main burner ignition time must not exceed the ignition time specified by the burner or equipment manufacturer Failure to do so may cause the fuel to accumulate in the combustion chamber to form explosive mixing causing a serious explosion trouble Never touch any terminal of this unit during trial run adjustment Doing so may cause an electric shock Before removing or mounting the AUR300C be sure to turn the power OFF Failure to do so might cause electric shock Before starting the pilot turndown test or ignition spark response test always check that all manual fuel valves are
8. PALI ANP ANA No CP SP 1142E Advanced UV Relay AUR300C User s Manual Thank you for purchasing the AUR300C This manual contains information for d ensuring correct use of the AUR300C It also provides necessary information for installation maintenance and trou bleshooting This manual should be read by those who design and maintain devices that use the AUR300C 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 REQUEST Ensure that this User s Manual is handed over to the user 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 User s Manual are sub ject to change without notice Considerable effort has been made to ensure that this User s Manual is free from inaccuracies and omissions I
9. and cocks of each fuel system are closed and that the inside of the fuel chamber is exhausted sufficiently 5 After above items 1 to 4 have been checked supply the power and start the trial run adjustment E Measurement of flame signal flame voltage Start the equipment and measure the voltage under several conditions such as start up operation or normal operation 1 Set the multi meter to the 0 to 5Vdc range 2 Connect the positive probe of the multi meter to terminal 9 and the negative probe to terminal 10 3 Check that the voltage is stable at a recommended flame voltage of 1 5V or more 4 If the flame voltage fluctuates largely check the mounting position of the AUD300C and wiring status o Handling Precautions Even during normal operation the flame voltage is synchronized with the shutter operation of the AUD300C and fluctuates in a range of 0 1 to 0 3V 13 Chapter 3 TRIAL RUN ADJUSTMENT E Pilot turndown test This test is intended to check that the flame is carried over to the main burner correctly when the AUD300C detects the pilot flame if the gas pressure and air pressure are changed to their worst conditions 7 WARNING If the AUD300C detects a small pilot flame which cannot ignite the main burner this unit does not recognize the flame failure even though the flame failure occurs in the main burner Therefore the fuel flows out continuously causing a serious explosion trouble To p
10. cket on a metallic part such as burner chassis to connect the grounding line E Wiring to AUD300C Make the wiring to the AUD300C as shown below Advanced UV Sensor AUD300C Advanced UV Relay AUR300C o Handling Precautions e The signal lines of the AUD300C blue and yellow have specific polarities Connect the blue line to the terminal 11 F of the AUR300C and the yellow line to the terminal 12 G If the signal lines are connected reversely this may cause the tube unit to break or malfunction e To extend the wiring use a 600V vinyl insulated IV cable having a cross sectional area of 2 mm and a length of 200 m or less Chapter 2 MOUNTING AND WIRING E Wiring to solenoid valve 7 WARNING Do not connect the solenoid valve to the high voltage side S If a ground fault occurs the ground fault current may flow into the solenoid valve Regardless of this unit the valve is opened causing the fuel to flow out Correct connection High voltage side H Power supply Grounding side G AUR300C Ground fault Valve Close juawidinba uonsnqwog gt Fuel When the valve wiring is connected correctly as shown in the Fig the ground fault current does not flow through the solenoid valve even though a ground fault occurs due to faulty insulation of the high electrical potential side Therefore the valve is not opened and the fuel does not flow out Inc
11. closed Do not start the actual operation unless the trial run adjustment tests and tests specified by the equipment manufacturer are completed The terminal 11 F is electrically alive within 1 min after the power to this unit has been turned OFF Never touch the terminal 11 F immediately after the power has been turned OFF Doing so may cause an electric shock E Outline of adjustment The following shows the test adjustment items described in this chapter e Measurement of flame voltage e Pilot turndown test Ignition spark response test e Safety shut off test o Handling Precautions After the above items have been adjusted check again that each adjustment item is satisfied It is absolutely necessary to satisfy all adjustment items at the final mounting position of the flame detector Tools and parts to be prepared e Multi meter Input impedance 100KQ or more AC range 0 to 300V DC range 0 to 10V e Jumper cable with alligator clip 2 cables 12 Chapter 3 TRIAL RUN ADJUSTMENT E Pre operational inspection 1 Inspect all wiring parts 2 Check that the unit is mounted in a place where the ambient temperature is within its allowable range 3 Check that the AUD300C is mounted correctly In particular the blue lead wire to terminal 11 and yellow lead wire to terminal 12 of the AUD300C are connected correctly For details refer to the user s manual for AUD300C CP SP 1141E 4 Check that the valves
12. ed always check that the wiring is correct Incorrect wiring may cause damage or malfunction Only authorized personnel who have the technical skill about the combustion equipment and flame safeguard control must carry out the pilot turndown test Only authorized personnel who have the technical skill about the combustion equipment and flame safeguard control must carry out the mounting wiring inspection adjustment and maintenance work If the safety shut off is activated and the equipment is restarted carry out all the inspection items stated in Chapter 3 TRIAL RUN ADJUSTMENT When performing the maintenance and inspection of the burner always carry out the pilot turndown test Additionally this inspection must be carried out once a year or more frequently When cleaning the burner clean also the AUD300C The Role of This Manual In all two manuals have been prepared for the AUR300C and AUD300C Read the manual according to your specific requirements The following lists all the manuals that accompany the AUR300C and AUD300C and gives a brief outline of the manual If you do not have the required manual contact Yamatake Corporation or your dealer Advanced UV Sensor AUD300C Manual No CP SP 1141E The manual describes the mounting wiring maintenance and inspection and troubleshooting when the AUD300C is built into the combustion equipment Advanced UV Relay AUR300C Manual No CP SP
13. evious statuses If the operation is started without above restoration this may cause damage to the equipment or gas leak or explosion Do not use the AUD300C for detection of ultraviolet rays other than those of the burner If the AUD300C responds to other ultraviolet rays the status that the flame failure occurs in the burner is determined as flame presence Thus the fuel flows out continuously causing an explosion CAUTION This unit is specially designed for intermittent burner operation system is started and stopped once or more within 24 hrs and 24 hour continuous burner operation system continues the combustion for 24 hrs or longer The AUD300C having the self check function must be used as a flame detector to be combined with This unit is equipped with important functions necessary to safely operate the equipment Always operate this unit according to the user s manual J Do not mount this unit in the following places e Place where special chemical or corrosive gas exists such as ammonia sulfur chlorine ethylene compound acid or others e Place where it is exposed to water drops or damp atmosphere e Place where it is exposed to the high temperature e Place where vibration continues for an extended period of time Carefully perform the mounting and or wiring work while referring to this user s manual as well as the instruction manuals published by the equipment or set manufacturers
14. f you should find any inaccuracies or omissions 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 2002 Yamatake Corporation ALL RIGHTS RESERVED IF SAFETY PRECAUTIONS J E About Icons Safety precautions are for ensuring safe and correct use of this product and for preventing injury to the operator and other people or damage to property You must observe these safety precautions The safety precautions described in this manual are indicated by various icons As the following describes the icons and their meanings be sure to read and understand the descriptions before reading this manual WA R N N G Warnings are indicated when mishandling this product might result in death or serious injury to the user A CA U TI O N Cautions are indicated when mishandling this product might result in minor injury to the user or only physical damage to this product E Examples wrongful operation or misuse of this product These icons graphically represent the actual danger The example on the left warns the user of the danger of electric shock i Triangles warn the user of a possible danger that may be caused by 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
15. ghtly away from the pilot flame Throttle the monitoring pipe to decrease the incoming light amount from the pilot flame 13 Slowly open the manual valve of the pilot passage to make the pilot flame larger than the previous flame After the adjustment has been completed check again that the main burner can be ignited with the minimum flame 14 Perform the steps stated in Check that the main burner can be ignited with the minimum pilot flame again Measures to be taken after completion of the test 15 After the test has been completed return the manual valve of the main passage to its fully opened position 16 Check that the flame voltage is proper 17 If any limit is connected with jumper cables disconnect them to return the limit to its previous state 15 Chapter 3 TRIAL RUN ADJUSTMENT E Ignition spark response test 7 WARNING Do not use the AUD300C for detection of ultraviolet rays other than those of the burner If the AUD300C responds to other ultraviolet rays the status that the flame failure occurs in the burner is determined as flame presence Thus the fuel flows out continuously causing an explosion 1 Close the manual fuel valves of the pilot and main burners 2 Start the 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 the adjustment using the following procedures w
16. hile referring to the instruction manual for the equipment e Move the position of the AUD300C or ignition spark rod so that they do not affect adversely e Puta shield plate in the optical path of the AUD300C so that the effect of the spark is a flame signal value of 0 4Vdc or less o Handling Precautions Do not use this unit to detect ultraviolet rays other that those of the flame The following shows various ultraviolet ray sources other than flame that may activate the AUD300C Examples Uiraviolet ray soures Disinfecting lamp ultraviolet radiation lamp fluorescent lamp Strong flash light toward UV sensor Gamma ray and X ray source Other sources producing ultraviolet rays gamma rays and X rays 16 Chapter 3 TRIAL RUN ADJUSTMENT E Safety shut off test After all operational adjustments have been completed carry out the safety shut off test Pilot ignition failure Ignition failure 1 Close the pilot and main manual fuel valves 2 Press the START switch gt gt The operation is then started 3 Normally as the pilot burner is ignited the pilot valve is opened Check that the FLAME LED does not light up and the main valve is not opened if the flame fails Flame failure during normal combustion 1 Open the pilot and main manual fuel valves 2 Press the START switch to start the operation 3 When the sequence advances correctly and it enters the normal combustion main valve is
17. itch OFF YES 18 6 and 1 when the NO eration is started e Check the ignition transformer e Check the AUR300C pilot burner and wiring YES e Check the flame monitoring position e Check the AUD300C Is the START CHECK Is the main burner ignited NO Se NED it No e Check the burner carry over YES Pilot turn down test YES e Check the wiring e Check the shut off valve w T e Check the ignition transformer e Check the AUR300C e Check the wiring pilot burner and wiring 19 Chapter 5 SPECIFICATION E Specification Nominal 3s Max 4s at 3V flame voltage e When ignited 1 2 to 4 0Vdc at room temperature humidity and rated voltage When flame fails 0 0 to 0 6Vdc at room temperature humidity and rated voltage Allowable voltage range 85 to 110 of rated power supply voltage OW max with AUD3OOC Contact rating Flame output K1 K2 5A 250V cos 6 1 Flame output K2 5A 250V cos 1 Dielectric strength Insulation resistance Induced thunderbolt surge Service life Ambient temperature Storage temperature Ambient humidity Vibration resistance Terminal screw tightening torque Mounting posture Color Mass 20 Combustion Lamp output K3 3A 250V cos 1 1500Vac 50 60Hz 1 min or 1800Vac 50 60Hz 1s Application points Between ground and primary terminals 1 to 8 units except 9 to 14 100MQ min by 500Vdc megger Measurement points Between ground and primary
18. o AUD300C eee eee eee ence teen e ees 8 M Wiring to solenoid valve eee cece e eee eee e ete ees 9 m Cautions for continuous measurement of flame voltage 9 Operational Description 6 cece cece ence cece n ees 10 TRIAL RUN ADJUSTMENT E Outline of adjustment 6 eee e eee eee eee ce eee eeeen ees 12 E Pre operational inspection eee eee eect tenet eens 13 E Measurement of flame signal flame voltage 13 E Pilot turndown test cc ccc ccc cee cece ee eee eee cence ee enee 14 E Ignition spark response test 0 eee e cece eee eee teen eee 16 E Safety shut off test 6c cece eeee ence eee n eens 17 MAINTENANCE AND INSPECTION E Frequency of maintenance and inspection ee eee 18 SPECIFICATION M Specification 6 cece eect eee nee eee n eens 20 E Dimensi ns isrrreriirinirossake ni inniy EN ENEE ENEO bee Rie ete KEETE NRKS 21 vi Chapter 1 E Overview E Features OVERVIEW This Advanced UV Relay AUR300C hereafter referred to as AUR300C is a relay with a dynamic self checking function and is used in combination with the Advanced UV Sensor AUD300C hereafter referred to as AUD300C As the shutter of the AUD300C is driven the AUR300C drives the flame relay while checking the AUD300C or AUR300C for faulty part If a fault occurs in the flame de
19. o polarities Functions in the same manner as the K2 relay Terminal No oo i e 2 oon ie o ead Le e Chapter 1 OVERVIEW E Model No AUR300C13100 Advanced UV relay 100Vac 50 60Hz AUR300C13200 Advanced UV relay 200Vac 50 60Hz AUR300C131D0 Advanced UV relay 100Vac 50 60Hz with inspection certificate AUR300C132D0 Advanced UV relay 200Vac 50 60Hz with inspection certificate E Configuration Combined flame detector Model No Advanced UV sensor AUD300C Optional parts Flame simulator 123514B Surge absorber 83968019 001 Chapter 2 MOUNTING AND WIRING 2 1 Mounting 7 CAUTION Do not mount this unit in the following places S e Place where special chemical or corrosive gas exists such as ammonia sulfur chlorine ethylene compound acid or others e Place where it is exposed to water drops or damp atmosphere e Place where it is exposed to the high temperature e Place where vibration continues for an extended period of time Only authorized personnel who have the technical skill about the combustion equipment and flame safeguard control must carry out the pilot turn down test Mounting posture Mount this unit on a wall When mounting this unit vertically it is possible to tightly mount the unit Mounting procedures 1 To allow easy removal heat radiation wiring and maintenance work keep a work space that is 20 mm or more in the vertical direction and 10 mm or
20. og K1 Start check K2 Flame detection K3 Combustion lamp o Handling Precautions e Ifthe high voltagel side H of the power supply is distinguished from the grounding side G the high electrical potential side H is connected to the terminal 2 R and the grounding side G to the terminal 1 S e When necessary an overload prevention device is used for the power supply Wiring to surge absorber When using the surge absorber model 83968019 001 optional unit as protective measures against lightning connect it as shown below AUR300C AUR300C Voltage side H Voltage side H Oo a 3 ae Power supply Z a Q Power supply 2 R 7 AE Grounding side G 1 8 Grounding side G 18 Surge absorber Surge absorber between lines 83968019 001 Flat terminal FS4 8 series terminal side NL Mounting bracket side Grounding side P Chapter 2 MOUNTING AND WIRING o Handling Precautions e For wiring of the power supply use an electric cable JIS C 3306 having an cross sectional area of 0 75 mm or more wire diameter 00 18 number of strand wires 30 e Connect the flat connector FS4 8 series AMP s 187 series receptacle or equivalent to one end of the electric cable and make the wiring as short as possible e The grounding side of the metallic bracket for mounting of the surge absorber is crimped internally to make the electric continuity active Mount this bra
21. on the left notifies the user that disassembly is prohibited Black filled in 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 This unit is not equipped with the pre purge timer and sequence functions necessary for the burner ignition The overall equipment must be designed carefully by taking the timer and sequence functions into consideration Never touch any terminal of this unit while the power is being supplied Doing so may cause an electric shock Before wiring the AUR300C be sure to turn the power OFF Failure to do so might cause electric shock Do not connect the solenoid valve to the high electric potential side If a ground fault occurs the ground fault current may flow into the solenoid valve Regardless of this unit the valve is opened causing the fuel to flow out The pilot and main burner ignition time must not exceed the ignition time specified by the burner or equipment manufacturer Failure to do so may cause the fuel to accumulate in the combustion chamber to form explosive mixing causing a serious explosion trouble Never touch any terminal of this unit during trial run adjustment Doing so may cause an electric shock Before removing or mounting the AUR300C be sure
22. opened close the pilot and main manual fuel valves to put off the burner flame At this time check that the flame failure is detected and the safety shut off is activated correctly 17 Chapter 4 MAINTENANCE AND INSPECTION N WARNING Q Before removing or mounting the AUR300C be sure to turn the power OFF Failure to do so might cause electric shock Z CAUTION Only authorized personnel who have the technical skill about the combustion equipment and flame safeguard control must carry out the mounting wiring inspection adjustment and maintenance work If the safety shut off is activated and the equipment is restarted carry out all the inspection items stated in Chapter 3 TRIAL RUN ADJUSTMENT When performing the maintenance and inspection of the burner always carry out the pilot turndown test Additionally this inspection must be carried out once a year or more frequently When cleaning the burner clean also the AUD300C E Frequency of maintenance and inspection Determine an appropriate frequency of the maintenance and inspection work by considering the equipment type ambient conditions dust or ambient temperature of the mounting place and damage or influence if the burner is shut off for some reason during operation of the equipment Inspection contents Inspection frequency Safety shut off test For details refer to Chapter 3 Once a month or more TRIAL RUN ADJUSTMENT Contamination of monitoring window
23. orrect connection Ground fault High voltage side H Power supply Grounding side G juawdinba uoysnqwog gt Fuel When the valve wiring is connected to the high electrical potential side the ground fault current flows through the solenoid valve if a ground fault occurs as shown in the Fig Therefore the valve is opened regardless of this unit and the fuel flows out E Cautions for continuous measurement of flame voltage e Connect a measuring instrument having an input impedance of 100kQ or more and a pen recorder having an input impedance of 1MQ to this unit Always use an IV cable with a cross sectional area of 0 75 mm or more for signal lines The wiring length must be 10 m or less Chapter 2 MOUNTING AND WIRING 2 3 Operational Description 10 Manual ignition meth a EA FLAME LED o wW ir wW E 5 w K2 driving circuit od Intermittent pilot AUR300C Shutter driving Flame amplify circuit ing circuit Flame voltage output circuit CHECK LED M gt START POWER LED AUD300C Advanced UV sensor e Operation is changed from normal operation to flame shut off operation Power switch ON 0 to 5Vde Measuring instrument Combustion lamp Main valve ole Limit Stop switch o o Pilot valve
24. revent such troubles always perform the pilot turndown test firmly When performing the pilot turndown test repeatedly stop the equipment completely every time the pilot turndown test is completed in order to completely discharge the unburnt gas or oil accumulated in the combustion chamber or flue If the unburnt gas or oil is not discharged completely this may cause an explosion accident After the pilot turndown test has been completed turn OFF the POWER switch to shut down the power Always restore all the test jumpers and limit regulator settings to their previous statuses If the operation is started without above restoration this may cause damage to the equipment or gas leak or explosion CAUTION Q Only authorized personnel who have the technical skill about the combustion equipment and flame safeguard control must carry out the pilot turndown test o Handling Precautions If the limit of the fuel pressure if used is opened make it turned ON with a jumper cable during this test To carry out the pilot turndown test follow the steps below Preparations before starting test 1 Turn OFF the POWER switch 2 Close the manual valves of the pilot passage and main passage to stop the gas 3 Open the manual valve of the pilot passage Check a gas pressure level at which the AUD300C cannot detect the pilot flame 4 Turn ON the POWER switch and START switch gt gt The ignition operation is then started
25. ser s manual as well as the instruction manuals published by the equipment or set manufacturers Check the insulation of each wiring If any insulation is faulty this may cause a ground fault or an electric shock Carry out the wiring work in conformity with the specified standards Always connect the power supply finally If any terminal is touched accidentally this may cause an electric shock or damage A load to be connected to each terminal must not exceed the rating shown in the specifications Always supply the electric power having the same voltage and frequency as those stated on the model label of this unit If timers and auxiliary relays need to be used as additional functions always select those having high reliability to construct a correct circuit This unit must be grounded with the resistance less than 100Q as described in the electric facility technical standards The grounding line must be connected to the burner chassis The power cable and high voltage cable of the ignition transformer must be separated from the power cable of the AUD300C The high voltage cable of the ignition transformer must be individual and kept 10 cm or more away from this unit Connect the high voltage cable of the ignition transformer firmly so that no faulty contacts exist If any faulty contact exists high frequency radio wave is produced causing noise to be produced in the radio or the radio to malfunction Additionally mount
26. tection circuit of the AUD300C or AUR300C the AUR300C turns OFF the relay firmly to ensure the operational safety The AUR300C can monitor each burner The dynamic self checking function continuously performs the self checking of the flame detection circuits of the AUD300C and AUR300C to ensure the operational safety e If a fault occurs in the circuit of the AUD300C or AUR300C before starting the operation the main valve is not opened to ensure the safety even though the start operation is performed e If a fault occurs in the flame amplifier of the AUD300C or AUR300C during combustion the main valve and pilot valve are shut off Ifa fault is found during start up operation the check relay is not turned ON and the output flame output to the main valve is not performed The operation status can be checked using various LED indicators POWER SHUTTER START CHECK and FLAME A flame signal output 0 to 5Vdc is provided as a standard function This is useful for burner adjustment and flame status control Chapter 1 OVERVIEW E Part names Mounting hole 4 locations To be secured with M4 screws Details of indicators POWER Green Lights up when the power is turned ON Qsuurren starrcuticx ed Indicators SHUTTER Green Lights up when the shutter is closed START CHECK Green Synchronized with the K1 relay start check J FLAME Green Green Synchronized with the K2 relay flame detection
27. terminals 1 to 8 units except 9 to 14 10kV 1 2 50us JEC 187 75Q min surge impedance The surge absorber listed hereunder must be connected between the power supply terminal No 1 terminal and the ground Recommended surge absorber Part No 83968019 001 7 years or 100 000 cycles operation cycles of each relay 20 to 60 C 20 to 70 C 90 RH at 40 C max 4 9m s2 max 10 to 55Hz for 2 h each in X Y and Z directions 1 4N m max all mounting vertical or horizontal mounting hite Approx 1 2kg Chapter 5 SPECIFICATION E Dimensions Unit mm rower Osum start cack Orme Free terminal screw M4 I sures Gr UV SENSOR EEEE azez e HEE a Chassis ground commonly used as mounting screw Revision History Date 02 12 oPSP 11A2E ist Edmon ___ _ 08 OSCR SE S ON USE changed Duplicate pilot changed to Intermittent pilot WAMATAKE Specifications are subject to change without notice Yamatake Corporation Advanced Automation Company Totate International Building 2 12 19 Shibuya Shibuya ku Tokyo 150 8316 Japan URL http www yamatake com This has been printed on recycled paper 02 Printed in Japan 1st Edition Issued in Dec 2002 2nd Edition Issued in Aug 2004 B
28. the ignition transformer directly on the burner main unit or metallic part electrically connected to the burner main unit Q Q Q Q Q Q Q Q Q Q After the wiring has been completed always check that the wiring is correct Incorrect wiring may cause damage or malfunction E Wiring diagram Monitoring of burner flame AUR300C SHUTTER LED FLAME LED Chapter 2 MOUNTING AND WIRING Manual ignition Intermittent pilot AUR300C SHUTTER LED gt FLAME LED N Bulaup saynys UNO Bulaup anys K2 K2 So00eanv Qooeany No419 Gurup ZJ ynowo urup ZJ Josuas AN peoueapy Josus AN pavueapy n3119 Bul pydwe awe 4 nouo Bul Ayyjdue wej4 0 to 5Vde 0 to 5Vde juewnujsul Buunseayy quewnujsul Buunseayy NUP yndjno abeyon awe 4 unap yndyno abeyon awe 4 Combustion lamp output Combustion lamp output Start switch Main valve Flame output Contact output common K2 NC Start check circuit Start check circuit Ignition transformer START Start contact CHECK LED oo CHECK LED Pilot valve 1 r START 1 1 1 1 1 POWER LED POWER LED Limit Stop switch oo ACG nono Ajddns 1amog unono Ajddns sam
29. the pilot valve is opened and the ignition transformer is operated The flame relay is turned ON and combustion lamp lights up 14 Chapter 3 TRIAL RUN ADJUSTMENT 5 Slowly close the manual valve of the pilot passage The pilot flame becomes small gradually Gradually throttle the valve until the AUD300C cannot detect the flame 6 Record the gas pressure immediately before the flame relay is turned OFF and the combustion lamp goes off Check that the main burner can be ignited with the minimum pilot flame 7 Press the START switch again 8 Slowly open the manual valve of the pilot passage to adjust the pressure to a level immediately before the combustion lamp goes off At this time check that the flame relay is turned ON and the combustion lamp lights up 9 Release the IGNITION switch 10 Check that the main burner is ignited smoothly within 1 sec after the manual valve of the main passage has been opened 11 Change the gas pressure level between the minimum and maximum levels and ignite the main burner five or six times At this time check that the main burner is ignited smoothly every time Main burner is not ignited with the minimum pilot flame 12 Adjust the mounting position of the AUD300C and the incoming light amount so that the AUD300C cannot detect the ignition of the main burner There are two kinds of adjustment procedures as shown below Keep the monitoring wire of the monitoring pipe sli
30. to turn the power OFF Failure to do so might cause electric shock Before starting the pilot turndown test or ignition spark response test always check that all manual fuel valves are closed Do not start the actual operation unless the trial run adjustment tests and tests specified by the equipment manufacturer are completed The terminal 11 F is electrically alive within 1 min after the power to this unit has been turned OFF Never touch the terminal 11 F immediately after the power has been turned OFF Doing so may cause an electric shock If the AUD300C detects a small pilot flame which cannot ignite the main burner this unit does not recognize the flame failure even though the flame failure occurs in the main burner Therefore the fuel flows out continuously causing a serious explosion trouble To prevent such troubles always perform the pilot turndown test firmly 00000 SF 90900 When performing the pilot turndown test repeatedly stop the equipment completely every time the pilot turndown test is completed in order to completely discharge the unburnt gas or oil accumulated in the combustion chamber or flue If the unburnt gas or oil is not discharged completely this may cause an explosion accident WARNING After the pilot turndown test has been completed turn OFF the POWER switch to shut down the power Always restore all the test jumpers and limit regulator settings to their pr
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