AUD300C2100 Advanced UV Sensor User's Manual
Contents
1. cece eee cece cece eee eee eeenes 3 E Monitoring of burner flame cc cece cece cece cece cece cece ee eeeeeees 3 E Mounting POSITION sessssesssosesssoesssossosesesossesessooeseoe 4 E Mounting posture s ssessssessssesssossssosssoesesossesessooeseoe 5 W Mounting of monitoring pipe ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 6 E Mounting procedure sessssesssosesssossssossooesesossssessooeseoo 8 Chapter 3 WIRING W Wiring diagram sssssssesesesesecooocceceeeceececcoooocceeeeeeeeee 9 M Checking Of wiring ss ssesessssesessesoseesesooesesoooseesecoee 10 Chapter 4 ADJUSTMENT E Before measurement of flame voltage essesessessesessossossees 11 E Measurement of flame voltage essessssssessessscsesesssesses 11 M Pilot turndown test sssssssssssssssosssssossossossossoseooooos 12 M Ignition spark response test eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 13 W Firmly mounting of monitoring pipe sssessssssessesssossesesesses 13 E Final inspection sessessssossssssosossssosessssooesssssooes 13 Chapter 5 TROUBLESHOOTING Chapter 6 MAINTENANCE AND INSPECTION W Periodic INSPECTION ssessssssssssosssssssssssssssoseseeeeeeeee 15 E Replacementofmaintenancekit eeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 16 M Replacement of tube unit eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 16 E Replacement of Shutter unit 6 cece cece2. If the air purging is needed tees are used to supply the air J Handling Precautions e Mount this unit so that its monitoring direction intersects the flame axis at an as small angle as possible This ensures a wide intersection area of the monitoring area between the flame and this unit Thus the detection amount of ultraviolet ray radiation becomes large Chapter 2 MOUNTING Depth of flame is long when the monitoring direction intersects the flame axis at acute angle 7 Burner ge OS Bad 7 Depth of flame is short e Temporary welding for positioning of monitoring pipe 1 Prepare the monitoring pipe and make the mounting hole Make the mounting hole for the monitoring pipe at the selected monitoring NN pipe mounting position Perform the screw threading of one end of the monitoring pipe and cut the monitoring pipe to a desired length so that its length is as short as possible 2 Weld the monitoring pipe temporarily Weld the monitoring pipe temporarily to the plate of the combustion chamber such as boiler At this time do not weld the monitoring pipe completely since the inspection and adjustment are required until the flame is detected properly Weld these parts temporarily Furnace wall Plate Refractory material 3 Carry out the air purging of the monitoring pipe The air purging of the inside of the monitoring pipe is useful to cool the AUD300C and keep the monitoring area clean In pa
3. The service life of the tube unit AUD10C built into the AUD300C is 3 years or Q 25 000 operation hours To ensure the operational safety replace the tube unit with a new one within this service life Do not transport the AUD300C with it mounted on the combustion S equipment The impact or vibration during transportation may cause the AUD300C to malfunction Before starting the transportation remove the AUD300C and put it in the specially designed packing box Replace the shutter unit AUD50A with a new one at a reference replacement Q interval of 3 years ili The Role of This Manual There are nine manuals have been prepared for the AUD300C AUR series Read the manual according to your specific requirements The following lists all the manuals that accompany the AUDS00C AUR series and gives a brief outline of the manual If you do not have the required manual contact Yamatake Corporation or your dealer AUD300C2100 Advanced UV Sensor Manual No CP SP 1170E This manual The manual describes the mounting wiring maintenance and inspection and troubleshooting when the AUD300C is built into the combustion equipment AUR300C Advanced UV Relay Manual No CP SP 1142E The personnel in charge of design mounting operation and maintenance of the combustion equipment using the AURSOOC must read this manual The manual describes the mounting wiring trial run adjustment and maintenance and inspection of the AURSOOC AUR35
4. terminal both are white lead wires 1 Handling Precautions The polarities of the Si terminal and S2 terminal are not specified When measuring the voltage with an analog multi meter set a large voltage range so that the indication needle does not deflect over the negative scale to check the polarities After that measure the shutter voltage gt gt If the indication needle swings in a range of 15Vdc to 24Vdc it is determined that the wiring is connected correctly If the indication needle of the multi meter shows 24Vdc constantly or if it shows OV the wiring may be incorrect If a flame exists the shutter voltage swings within a range of O0Vdc to 24Vdc 6 Mount the tube unit AUD10C 1 min or longer after the power to the AUR300C has been turned OFF 10 Chapter 4 ADJUSTMENT W Before measurement of flame voltage Before measuring the flame voltage check the operation of this unit through the flame voltage output terminals of the AURS3OOC Model No Flame voltage output terminals AUR300C Terminal 9 AUR350C Terminal10 AUR450C Positive terminal Negative terminal 1 Connect a analog flame meter FSP136A100 to the flame voltage output terminals of the AUR300C 2 Light a lighter in front of the ultraviolet ray receiving part of this unit to check that the voltage is output correctly o Handling Precautions e When using an open flame check that there is no flammable gas around this unit W
5. receiving part Cover 81446925 002 nm Shutter unit AUD50A2100 Tube unit AUD10C2100 e Shutter Unit AUD50A2100 LL Shutter driving terminal white lead wire Chapter 1 Overview plies Model No AUD300C2100 Advanced UV Sensor AUD300C210D Advanced UV Sensor with inspection certificate AUD300C210DT Advanced UV Sensor with inspection certificate and tropicalization treatment applied Applicable standards UL certificated UL file No MH27717 W Configuration Combined combustion safety controller e AUR300C 350C Model No response supply voltage AR TL aneo O 300C es a ee soc with communication function Contents e AUR450C Basic Safety Standard Flame failure Power Add model No time compliance response time supply processing1 AUR450C tT 4 Add processing2 Description Dynamic self check burner controller ith standard compliance 5 s maximum 2 s maximum s maximum 4 s maximum 00 Vac CE UL standards 00 Vac CE standards 20 Vac CE UL standards 30 Vac CE standards 69 6o gt I I NI 0 09 o additional processing nspection certification provided Tropicalization treatment applied Tropicalization treatment applied and inspection certification provided O Maintenance parts and Optional parts AUD10C2100 UD50A2100 81446925 002 81409780 001 FSP136A100 Chapter 2 MOUNTING 7 WARNING Before removin
6. 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 2004 Yamatake Corporation ALL RIGHTS RESERVED EF SAFETY PRECAUTIONS WW 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 N WA FR N N G product might result in death or serious injury Cautions are indicated when mishandling this N CAUTION product might result in minor injury to the user or only physical damage to the product E Examples Use caution when handling the product The indicated action is prohibited Be sure to follow the indicated instructions WARNING Do not combine the AUD300C with a unit other than Yamatake s flame S safeguard control AUR series S Do not use this unit for detection of ultraviolet rays other that those of the burner flame If this unit responds to other ultraviolet rays the status that the flame failure occurs in the burner is
7. 0C Advanced UV Relay with Communications Manual No CP SP 1175E Personnel in charge of design mounting operation and maintenance of combustion equipment using the AUR350C should read this manual It describes the mounting wiring trial run adjustment maintenance inspection of the AUR350C AUR450C Dynamic Self Check Burner Controller Manual No CP SP 1264E 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 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 AUR3800C 350C 400C 450C This manual describes installation operation and precautions for use of the FSP300C FSP350A Checker for AUR300C 350C Manual No CP SP 1210E FSP450A Checker for AUR450C Manual No CP SP 1211E It should be read in advance by those who use the FSP350A to check the operation of the AUR300C 350C and those who use the FSP450A to check the operation of the AUR450C This manual gives important information and precautions for use of the FSP350A and FSP450A 1
8. Doing so might cause an electric shock CAUTION The AUD300C is specially designed for intermittent burner operation system Q is started and stopped once or more within 24 hours and continuous burner operation system continues the combustion for 24 hours or longer The AUR series having the self check function must be used as an amplifier to be combined equipment and flame safeguard control must carry out the mounting wiring inspection adjustment and maintenance work Q Only authorized personnel who have the technical skill about the combustion If the AUD300C is operated in an atmosphere where any steam smoke oil mist dust and or organic solvent exist that hinder the penetration of ultraviolet rays take appropriate corrective measures When using multiple burners mount the AUDSOOC at a position where it Q detects the flame of only the burner to be monitored Q Carry out the wiring work in conformity with the specified standards Always separate the signal cables of the AUD300C from the high voltage Q cables of the ignition transformer and power cables and then always run the signal cables in a different conduit tube After the wiring work has been completed always check that the wiring is Q 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
9. Measurement of flame voltage If both pilot flame and main flame exist measure each flame voltage Additionally measure the flame voltage in the maximum combustion and minimum combustion states 1 Mount the monitoring pipe on this unit temporarily 2 Start the combustion of the burner 3 To determine an optimal monitoring position measure the flame voltage of the AUR300C with the analog flame meter FSP136A100 meter while moving the monitoring pipe position little by little in order to find a position where as highly stable voltage as possible is shown Recommended flame voltage Inspection item 2 0 to 4 0Vdc flame response 1 5s Check that the flame is monitored 1 5 to 4 0Vdc flame response 3s correctly The flame voltage may fluctuate in a Check that the light receiving lens of range of 0 1 to 0 3V synchronized with this unit is not contaminated the shutter operation of this unit Check that foreign matter such as soot is not caught in the monitoring pipe Lo Handling Precautions e When the flame voltage exceeds 4Vdc provide an orifice sheet into the flange unit to limit the quantity of ultraviolet rays Excess quantity of ultraviolet rays might cause malfunction by the diffused reflection of ultraviolet rays coming into the tube unit even when the shutter is closed 11 Chapter 4 ADJUSTMENT W Pilot turndown test This test is intended to check that the flame is correctly carried over to the main burner wh
10. No CP SP 1170E AUD300C2100 Advanced UV Sensor User s Manual Thank you for purchasing the AUD300C 2100 This manual contains information for ensuring correct use of the AUD300C 2100 It also provides necessary infor mation for installation maintenance and troubleshooting This manual should be read by those who design and maintain devices that use the AUD300C2100 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 the 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 If
11. V 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 AUR3S00C 350C 400C 450C This manual gives important information and precautions for use of the meter AUD60A2100 Maintenance Kit for AUD Manual No CP UM 5441E This manual describes a way of change the maintenance kit for the AUD300C2100 that is composed of the tube unit the shutter unit and the O ring etc as consumables Conventions Used in This Manual The following conventions are used in this manual C Handling Precaution Handling Precautions indicate items that the user should pay attention to when handling the AUD300C gt This indicates the item or page that the user is requested to refer to 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 OVERVIEW MS CR mm E ierimi ee eh oe E ee ee eee EE r c 1 W Featuras eag ard T IO Sh er i idh 546 est berinwosereesteoss eens earwiess 1 Pan hamesas se E ee ee ee ee 0 66 iar ee 1 W RAG ING ae oe ee IG Ara 6 ek es i es es ee is deil dho ah Nan eee 2 W Configuration enn 2 Chapter 2 MOUNTING W Before mounting this UNIt
12. age 2 Trouble checking procedures 1 Check the operating conditions Power voltage e Check that the power switch is turned ON correctly e Check for loose power terminal e Check that the voltage is within the allowable range Wiring e Check that the wiring is correct e Check for faulty wiring e Check the insulation for deterioration or damage e Check that the temperature is 100 C or less Ambient humidity e Check that the ambient humidity is 90 RH or less e Check that no dew condensation occurs inside the unit 2 Check the unit according to the flowchart Zero Check the Insufficient flame voltage e Clean the monitoring window Sus e Clean the inside of the monitoring pipe Remove the AUD10C tuiehthe Na Adjust the monitorin NO Closed flame voltage Is g position and or burner e Shutter of the AUD300 is opened when the power is supplied to he AUR300C OK YES Opened Check the voltage between the NG Check the NG F and G terminals of shutter voltage the AUD300C OK OK Replace the Check the wiring Replace the Check the wiring Pe nil using AUD10C and replace the AUDS50C and replace the s i AUR300C AUR300C 14 Chapter 6 MAINTENANCE AND INSPECTION 7 WARNING Before removing or mounting the AUD300C be sure to turn the power OFF Failure to do so might cause electric shock Do not touch the AUD300C or the F terminal or G terminal of the AUR300C
13. age capacitor Radioactive isotope Other sources producing ultraviolet rays gamma rays and X rays W Firmly mounting of monitoring pipe 1 When the equipment is operated properly with the specified flame voltage output after all adjustments have been completed correctly turn OFF the power to the equipment remove the AUD300C and weld the monitoring pipe firmly 2 Mount the AUD300C on the monitoring pipe firmly and perform the final wiring completely W Final inspection To control the burner properly perform at least one cycle operation of the equipment to check that all control actions correctly 13 Chapter 5 TROUBLESHOOTING 7 WARNING Before removing or mounting the AUD300C be sure to turn the power OFF Failure to do so might cause electric shock Do not touch the AUD300C or the F terminal or G terminal of the AUR series immediately after the power to the AUR series has been turned OFF The F terminal and G terminal are still electrically alive within 1min after the power has been turned OFF causing an electric shock hazard N CAUTION Q 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 Tools and parts to be prepared e Analog flame meter FSP136A100 e For details about replacement parts refer to the section gt Maintenance parts and Optional parts p
14. ain flame does not mistakenly detect the pilot flame If the sensor for the main flame detects the pilot flame the fuel supply will not be shut down if the main burner fails since the flame failure will not be detectable Multiple burners existing in one combustion chamber Mount the AUD300C on each burner and carry out the mounting work so that the unit does not detect the flame of other burner incorrectly Additionally the tube unit AUD10C of the AUD300C may produce the electrical discharge phenomenon inside the tube This electrical discharge may emit the ultraviolet rays from the tube Therefore when using multiple units adjust their positions so that the ultraviolet ray radiation from other tube unit is not detected Redundant system Duplicate monitoring To increase the reliability of the system and avoid unnecessary shut off as much as possible the AUD300C is combined with the AUR series and the redundant system is constructed so that two sets monitor the flame of one burner If two AUR series units detect the flame failure at the same time the system must be shut off If either flame detector does not output the flame signal or if any dummy signal exists the alarm is given but the system continues the combustion This avoids any unnecessary shut off of the system caused by this unit combustion safety control unit or oscillating flame The highly reliable flame monitor can be achieved W Mounting position Determine an opti
15. determined as flame presence Thus the fuel flows out continuously causing an explosion Before removing or mounting the AUD300C be sure to turn the power OFF Q Failure to do so might cause electric shock Before wiring the AUD300C be sure to turn the power OFF Failure to do so might cause electric shock To prevent an explosion trouble carry out the pilot turndown test firmly If the Q AUD300C detects a small pilot flame which cannot ignite the main burner it is determined that flame failure does not occur in the flame safeguard control even though the flame failure occurs in the main burner Thus the fuel is supplied continuously causing an exposition accident resulting in a serious hazard 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 might cause an explosion accident Do not touch terminals F or G on the AUD300C or on the AUR immediately QD after the power to the AUR has been turned OFF The F terminal and G terminal are still electrically alive within 1min after the power has been turned OFF causing an electric shock hazard When measuring the voltage between the F terminal and G terminal of the Q AUD300C in the wiring check do not touch any terminal by bare hand
16. e 19 Chapter 7 SPECIFICATION W Dimensions 20 5 co Seon rap im p wy Al Amb Temp 20 100C DATECODE XXXX S N XXXX Lo INIT UII L N MADEN JAPAN t O iii A Parallel qo ma pipethread G1 cm i 13 3 Thread F length 20 7 Conduit tube connection port 1 2NPSM N pen T y Boo 93 10 659 my 4 20 Revision History Date CP SP 1170E ist Edition iii May 2007 Cover etc The Model No changed AUD300C2000 to AUD300C2100 2 16 Maintenance kit added Monitoring of pilot flame and main flame individually added Yamatake Corporation Advanced Automation Company 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan URL http www azbil com Printed on recycled paper 07 azbil Specifications are subject to change without notice Printed in Japan 1st Edition Issued in Aug 2004 E 2nd Edition Issued in May 2007 M
17. eee eee e cece cee eecenns 17 Chapter 7 SPECIFICATION E Specification ssssssssssssesessssooosossssessssssooooeeeeeen 19 W DIMERS IONS 6 oro eso H Se ee oS KEENE NERES B Ae as a ee EE ORR 20 vi Chapter 1 OVERVIEW W Overview This advanced ultraviolet sensor AUD300C2100 hereafter referred to as the AUD300C is a flame detector designed to sense the ultraviolet ray radiation of the oil or gas burner flame This unit is used in combination with the dedicated Advanced Ultraviolet Relay hereafter referred to as AUR series Any malfunction that has occurred in the AUD300C or AUR series can be detected by the accurate dynamic continuous self check function of the built in shutter driven by the AUR series ensuring highly reliable combustion safety control W Features e Maintenance parts such as the tube unit AUD10C and shutter unit AUD50A can be handled as a single unit This ensures easy replacement and maintenance work e As for a flame sensor for the self check the AUD300C is compact and lightweight This ensures free burner mounting e The operating ambient temperature is 100 C and the protection structure is IP66 This ensures excellent environment proof performance e The vertical mounting is possible and the maximum wiring distance is 200 m This ensures flexible construction work E Part names e Main unit e Tube unit AUD10C2100 Mounting nut Fia unit Ultraviolet ray E Lead wires
18. en the AUD300C detects the pilot flame if the gas pressure and air pressure are changed to their worst conditions A WARNING To prevent an explosion trouble carry out the pilot turndown test firmly If the AUD300C detects a small pilot flame which cannot ignite the main burner it is determined that flame failure does not occur in the flame safeguard control even though the flame failure occurs in the main burner Thus the fuel is supplied continuously causing an exposition accident resulting in a serious hazard 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 might cause an explosion accident N CAUTION 12 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 Only authorized personnel who have the technical skill about the combustion equipment and flame safeguard control must carry out the pilot turndown test For details about how to carry out the pilot turndown test refer to the user s manual for AUR series combined with the AUD300C as well as the instruction manuals published by equipment manufacturers Chapter 4 ADJUSTMENT W Igni
19. ening torque of 0 7N m W Replacement of shutter unit CAUTION Q Replace the shutter unit AUD50A with a new one at a reference replacement interval of 3 years 1 Turn OFF the power 2 Remove 4 cover mounting screws to detach the cover 3 Remove 4 terminal screws white lead wire x 2 blue lead wire x 1 yellow lead wire x 1 to disconnect the lead wires from the shutter unit 4 Remove 2 shutter unit fixing screws 5 Separate the flange unit from the shutter unit with they opened upward to remove it At this time pay special attention so that the lead wires are not disconnected from the cable guide of the flange unit 6 Remove the orifice sheet from the flange unit 7 Remove the tube unit from the shutter unit For details refer to CF previous section W Replacement of tube unit 8 Provide a new orifice sheet and push it to the lens in the flange unit 9 Secure a new shutter unit to the flange unit 17 Chapter 6 MAINTENANCE AND INSPECTION Shutter unit fixing screw 2 pcs lt N hutter unit j Orifice sheet Q Blue lead wire c F terminal Blue lead wire G terminal Yellow lead wire H armen ll Tee ad I rr TIT F terminal Blue lead wire Running of lead wires Bottom view o Handling Precautions e f the lead wires are disengaged from the grooves on the cable guide of the flange unit put lead wires in relevant slits on the shut
20. g or mounting the AUD300C be sure to turn the power OFF Failure to do so might cause electric shock Do not use the AUD300C for detection of ultraviolet rays other that those of the burner flame 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 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 AUD300C is operated in an atmosphere where any steam smoke oil mist dust and or organic solvent exist that hinder the penetration of ultraviolet rays take appropriate corrective measures When using multiple burners mount the AUD300C at a position where it detects the flame of only the burner to be monitored W Before mounting this unit To mount the AUD300C correctly thoroughly read the instruction manuals published by burner boiler and or other equipment manufacturers Make the proper mounting plan while referring to such instruction manuals e Itis necessary that the AUD300C actually monitors the flame As long as the overall layout and temperature around the burner and other limitations permit mount the AUD300C as close to the flame as possible As the AUD300C is mounted closer to the burner nozzle the detection amount of the ultravi
21. immediately after the power to the AUR300C has been turned OFF The F terminal and G terminal are still electrically alive within 1min after the power has been turned OFF causing an electric shock hazard 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 The service life of the tube unit AUD10C built into the AUD300C is 3 years or 25 000 operation hours To ensure the operational safety replace the tube unit with a new one within this service life W Periodic inspection 1 Turn OFF the power to the AUR series 2 Clean the monitoring window and monitoring pipe periodically Remove the AUD300C from the monitoring pipe and clean the inside of the monitoring pipe and or the lens with a cloth rag 3 To check the function of the tube unit AUD10C perform the safety shut off test periodically For details about safety shut off test refer to gt user s manual for AUR300C CP SP 1142E user s manual for AUR350C CP SP 1175E user s manual for AUR450C CP SP 1264E 4 Adjust the burner so that it is operated at its optimal operating level recommended by the burner manufacturer Frequency of maintenance and inspection Inspection contents Inspection frequency Contamination of monitoring window and monitoring pipe or loose screw Once a month or more Safety shutoff tesi Meas
22. ing nut Excessive torque by a tool could damage the packing and compromise the seal e Do not adjust the mounting pose by forcibly holding the unit or wiring pipe Failure to do so may damage the packing and compromise the seal Chapter 3 WIRING 7 WARNING Before wiring the AUDSOOC be sure to turn the power OFF Failure to do so might cause electric shock When measuring the voltage between the F terminal and G terminal of the AUD300C in the wiring check do not touch any terminal by bare hand Doing so might cause an electric shock 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 Always separate the signal cables of the AUD300C from the high voltage cables of the ignition transformer and power cables and then always run the signal cables in a different conduit tube W Wiring diagram Advanced UV Sensor AUD300C White White Shutter output terminal Yellow Blue When performing the wiring work put all lead wires used for the connection with the AUR series in the conduit tube or conduit box Additionally set these lead wires separated from other power cables n Handling Precautions e Never set the lead wires to the AUD300C in the same conduit tube containing the high voltage cables such as power cables or ignition transformer cables e Put the high voltage cab
23. les of the ignition transformer and the grounding cables in the same conduit tube At the same time ground one end of this conduit tube firmly In particular this caution must be observed strictly when using an automotive spark plug e f the surge of the ignition transformer adversely affects the AUD300C ground both ends of the conduit tube between the AUD300C and combustion safety control unit or change the cable wiring route Chapter 3 WIRING W Checking of wiring Before applying the voltage to this unit check that the wiring is correct Procedures 1 Remove the cover of this unit and take out the tube unit AUD10C For details about how to take out the tube unit gt refer to the section Replacement of tube unit in Chapter 6 2 Turn ON the power to the AURSOOC 3 Measure the DC voltage between the F terminal and G terminal with a multi meter or digital voltmeter 4 Connect the positive probe to the G terminal yellow lead wire and the negative probe to the F terminal blue lead wire Positive probe Negative probe ocet 220v G terminal yellow lead wire blue lead wire gt gt If a voltage of 160Vdc to 220Vdc is output it is determined that the wiring work has been performed correctly If the measured DC voltage is a negative value the wiring to the F terminal and G terminal is connected reversely 5 Next measure the DC voltage between the shutter voltage S1 terminal and S2
24. mal mounting position of the AUD300C while carefully observing the following items Temperature Mount this unit in a place where the operating temperature range 1s 20 C to 100 C n Handling Precautions e f the above temperature range is not observed this may cause the tube unit AUD10C or shutter unit AUD50A assembled to the AUD300C to malfunction or unnecessary shut off e f the actual temperature may exceed the operating temperature range put an appropriate thermal insulation plate between the combustion chamber and the AUD300C or carry out the air purging to put the temperature within the operating temperature range e Vibration Outdoor W Mounting posture Chapter 2 MOUNTING Mount the AUD300C in a place where the acceleration is 4 9 m s or less 1 Handling Precautions e The vibration may cause the service life of the tube unit AUD10C or shutter unit AUD50A to be shortened improper operation or malfunction Mount appropriate roofs or eaves to avoid rain water 1 Handling Precautions e There might be a case that the body color of the AUD300C is changed by the influence of sunlight or other causes But there is no problem for the product functions or operations The allowable range of the mounting posture is that the upper limit is 90 conduit tube port becomes horizontal and the lower limit is 45 Upper limit 90 Horizontal plane Vertical plane Side 1 Handling Precautio
25. ng nut and G terminal or yellow lead wire between flange unit mounting nut and S1 terminal or white lead wire between flange unit mounting nut and S2 terminal or white lead wire 1500Vac for 1min or 1800Vac for 1s at the above each location The AUD10 tube unit must be dismounted 20 10 100 C 20 t0 70 C Ambient storage humidity 90 RH at 40 C max no condensation allowed 4 9m s2 max 10 to 55Hz for 2 hours each in X Y and Z directions Impact resistance 300m s2 in vertical and horizontal directions Pressure resistance for flange 350kPa Protection IP66 except a conduit tube connection port 45 to 90 in vertical direction Mounting G1 at the mounting section for monitoring pipe Lead wires AWG18 heat resistant silicone cables with 2 4m color lead wires 4 pcs Electric wire pipe mounting conduit 1 2 14NPSM Flame signal wire requirements and Requirements 600V vinyl insulation wires IV wires with 2 0mm2 Materials Main body Heat resistant resin PPE l Mounting nut Aluminum Main body color Purple equivalent to DIC257 Approx 6309 Tube unit effective service life Tube unit to be replaced after 25 000 hours of use or the specified lifespan 3 years marked on Tube unit Applicable standards UL certificated UL file No MH27717 Ultraviolet ray quantity differs according to the type of fuel Also the combustion quantity of burner type of equipment or installation conditions will give influenc
26. ns e Mount this unit at an appropriate angle so that it monitors the burner from the upper slanted position If this unit is mounted so that it monitors the burner from the lower slanted position or horizontal position dust or soot may accumulate on the monitoring window or in the monitoring pipe This may block the ultraviolet rays causing the flame not to be detected Chapter 2 MOUNTING W Mounting of monitoring pipe e Materials of monitoring pipe Use a monitoring pipe with the black inside wall If a pipe with the stainless steel or galvanized inside wall is used the diffused reflection of the ultraviolet rays occurs inside the pipe causing a malfunction Size of monitoring pipe Mounting space To detect the ultraviolet rays radiation of the flame at its optimal level it is necessary to widen the light receiving area of the AUDSOOC If a recommended flame voltage of 1 5V or more cannot be kept make the monitoring pipe thicker to receive a sufficient amount of ultraviolet rays e Use the monitoring pipe as thick as possible and connect the pipe to this unit with the reducing socket e Make the length of the monitoring pipe as short as possible However always keep the operating ambient temperature within 100 C Keep a sufficient space to allow easy maintenance and inspection and service work Monitoring pipe 25A or more Use 2B to 3B pipe Reducing socket Furnace wall Connection nipple 1B
27. olet ray radiation will increase e Mount the AUDSOOC at a position far from the ignition transformer Additionally mount the ignition transformer as close to the burner as possible and then ground it firmly W Monitoring of burner flame Monitoring of only pilot flame Continuous pilot intermittent pilot The main burner must be ignited firmly with the minimum pilot flame that the AUD300C can detect Therefore throttle the pilot fuel manual valve until the main burner is ignited barely Mount the AUD300C under these conditions so that the unit monitors only the top of the pilot flame Put the monitoring area as close to the top of the flame as possible so that the unit monitors the pilot flame along with the axis of the pilot flame Monitoring of both pilot flame and main flame Continuous pilot intermittent pilot Mount the AUD300C so that the unit monitors an area where the pilot flame intersects the main flame Chapter 2 MOUNTING Monitoring of only main flame Interrupted pilot Mount the AUD300C so that the unit monitors any status of the main flame most stable part of the flame in both the low combustion and high combustion In the special combustion it is recommended to use two units in order to monitor the main flame of each of the high combustion and low combustion Monitoring of pilot flame and main flame individually continuous pilot or intermittent pilot Mount the AUD300C so that the sensor for monitoring the m
28. rticular if the ambient temperature of the AUD300C exceeds 100 C the cooling such as air purging is needed e If the inside of the furnace is a type of induced draft make an air purging hole in the monitoring pipe e If the forced type furnace is used connect an air purging supply pipe Chapter 2 MOUNTING W Mounting procedure When mounting the AUD300C on a monitoring pipe proceed as follows Check item File the monitoring pipe in advance to eliminate burrs and protrusions Mounting 1 Hold the unit securely with one hand to prevent it from rotating 2 Tighten the mounting nut approximately 4 turns with the other hand until the unit is held securely in place 3 Make sure the unit is properly aligned in the vertical plane when viewed from the front Mounting pipe x Do not tilt 7 Ne plane mounting X Front side Do not mount Vertical _ horizontally Mounting nut Do not mount upside down o Handling Precautions e Be sure the AUD300C is properly aligned vertically when seen from the front If not the shutter in the AUD50A shutter unit may be damaged or malfunction If this unit is not mounted correctly this may cause the shutter of the shutter unit AUD50A to be damaged or malfunction e File any burrs or protrusions from the monitoring pipe If the packing in the mounting nut is damaged any chance of leakage may be caused e Do not use a tool such as pipe wrench when tightening the mount
29. ter unit and mount the tube unit on the flange unit with the lower white lead wires fit into the grooves on the cable guide 10 Connect the lead wires to the terminals on the shutter unit correctly L Handling Precautions e Connect the blue lead wire to the F terminal and yellow lead wire to the G terminal Connect the signal wires so that they are matched with the polarity indication label F G on the shutter unit 11 Mount the tube unit 12 Subsequent procedures are the same as those after step 6 stated in the previous section W Replacement of tube unit J Handling Precautions e Tighten the terminal screws and mounting screws with a tightening torque of 0 7N m 18 Chapter 7 SPECIFICATION W Specification Description City gas Natural gas Propane gas Kerosene Heavy oil Coke oven gas Hydrogen Chlorine Ammonia Naphtha Ethylene etc Approx 24Vdc supplied from AUR series Approx 1 to 2 times s Insulation resistance Between flange unit mounting nut and F terminal or blue lead wire between flange unit mounting nut and G terminal or yellow lead wire between flange unit mounting nut and S1 terminal or white lead wire between flange unit mounting nut and S2 terminal or white lead wire 50MQ min by 500Vdc megger at the above each location The AUD10 tube unit must be dismounted Dielectric strength Between flange unit mounting nut and F terminal or blue lead wire between flange unit mounti
30. tion of the shutter unit and push down the rear to mount it 6 Tighten 2 tube unit fixing screws 7 Make sure that the O ring is not disengaged from the flange unit 8 Secure the cover with 4 cover mounting screws Mounting part Tube unit iii a n Li Flange unit sid Cable guide Tube unit fixing screw 2 pcs Cover mounting screw 4 pcs o Handling Precautions e The tube unit has specific polarities Make these polarities matched with the polarity indication label F G at the upper portion of the shutter unit and mount it correctly e When transporting or storing the tube unit always put it in the specially designed packing box 16 Chapter 6 MAINTENANCE AND INSPECTION e The tube unit is made of glass Handle it carefully so as not to give an impact to the unit e f the thermo label provided on the AUD10C has turned black no longer white there is the possibility that its temperature has exceeded the allowable operating temperature range When the ambient temperature around the advanced UV sensor in operation is highly excessive cool the unit using the air purging The thermo label should be regarded as a reference only Always confirm the correct ambient temperature with a thermometer e When mounting the cover mount the O ring of the flange unit firmly Failure to do so may cause the sealing ability to lower e Tighten the terminal screws and mounting screws with a tight
31. tion spark response test 7 WARNING Do not use the AUD300C for detection of ultraviolet rays other that those of the burner flame If the AUDSOOC 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 Procedures 1 Close the manual shut off valves of the pilot burner and main burner 2 Operate the burner to perform the ignition operation The ignition spark is then started At this time check that the flame relay K2 of the AURSOOC is not excited K2 is the flame relay for the AUR300 350 and K6 is the flame relay for the AUR450 3 If the flame relay is excited adjust the monitoring point of this unit again to avoid the influence of the ignition spark and its reflection L Handling Precautions e The table below shows various sources other than flame that may activate the AUD300C Check that the AUD300C control action is not influenced under all operating conditions Examples Ultraviolet ray Scorching furnace wall with a temperature of 1370 C or more sources within 50 cm of furnace wall Ignition transformer and welding arc spark lightning Gas laser Sunlamp Disinfecting lamp ultraviolet ray radiation lamp fluorescent lamp Strong flash light toward UV sensor Gamma ray and Diffraction analyzer X ray sources Electron microscope X ray camera High voltage vacuum switch High volt
32. urement of flame voltage Once a month or more Pilot turn down test Once a year or more J Handling Precautions e lf the burner shut off operation may cause a serious accident perform the inspection more frequently e lf the burner manufacturer provides specific instructions about the maintenance and inspection always strictly observe them 15 Chapter 6 MAINTENANCE AND INSPECTION W Replacement of maintenance kit N CAUTION Q The service life of the tube unit is a maximum of 3 years or 25 000 hours of operation Similarly the recommended life of the shutter unit is 3 years To ensure operational safety replace the maintenance kit within this service life The maintenance kit is composed of the AUD10C tube unit and the AUDSOA shutter unit and attached the O ring etc as consumables For details about replacement of maintenance kit refer to gt user s manual for the AUD60A2100 2110 CP UM 5441E W Replacement of tube unit CAUTION Q The service life of the tube unit is a maximum of 3 years or 25 000 hours of operation To ensure safety replace it with a new one within this service life 1 Turn OFF the power 2 After 1min has elapsed remove 4 cover mounting screws to detach the cover 3 Remove 2 tube unit fixing screws on the rear of the tube unit 4 Hold the rear of the tube unit and gently raise it upward to remove it 5 Insert the top of a new tube unit into the round hole in the upper por
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