Azbil AUR450C User Manual Download Page 1

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Dynamic Self-Checking

Burner Controller

Model AUR450C

User’s Manual

No. CP-SP-1264E

Summary of Contents for AUR450C

Page 1: ...product It also provides necessary information for installation maintenance and troubleshooting This manual should be read by those who design and maintain equipment that uses this product Be sure to keep this manual nearby for handy reference Dynamic Self Checking Burner Controller Model AUR450C User s Manual No CP SP 1264E ...

Page 2: ...manual are subject to change without notice Considerable effort has been made to ensure that this manual is free from inaccuracies and omissions If you should find an error or omission please contact the azbil Group In no event is Azbil Corporation liable to anyone for any indirect special or consequential damages as a result of using this product 2007 2019 Azbil Corporation All Rights Reserved ...

Page 3: ...r or physical damage to the product In describing the product this manual uses the icons and notations listed below Use caution when handling the product The indicated action is prohibited Be sure to follow the indicated instructions Handling Precautions Handling Precautions indicate items that the user should pay attention to when handling this device Note Notes indicate information that might be...

Page 4: ...ounting or removing this device be sure to turn the power off Wiring with the power on can result in an electric shock Make sure that the AUD300C 500C does not detect ultraviolet rays other than those of the burner 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 hazar...

Page 5: ...lem has been eliminated If lockout occurs reset it only after removing the cause Also do not enter reset input repeatedly Operating this product improperly could result in a serious combustion equipment accident Do not use the alarm output as safety output CAUTION Be sure to use this device correctly within the ranges specified in this user s manual Otherwise device failure or malfunction could re...

Page 6: ...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 Ω 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 detect...

Page 7: ...bbase and pack it in its original box It might be damaged if transported while mounted on a panel or the like Do not short the control load terminals 18 19 18 20 18 21 or 18 22 or the shutter terminals 7 8 Internal fuses between these terminals will burn out if these terminals are shorted If a fuse burns out replace the entire product ...

Page 8: ...ould read this manual thoroughly This manual de scribes installation of this device Dynamic Self Checking Burner Controller Model AUR450C User s Manual for Communication 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 opera tion status and various data of AUR450C can be r...

Page 9: ...th combustion equipment User s Manual for Subbase Model Q241A104 for Dynamic Self Checking Burner Controller Model AUR450C Manual No CP UM 5942JE This manual is supplied with the subbase Those who design or manufacture equip ment that uses the AUR450C should read this manual thoroughly The subbase is necessary when installing the AUR450C in a panel etc This manual describes in stallation and wirin...

Page 10: ...ATION Internal block diagram of the AUR450C and sequence charts showing its operation Chapter 4 TRIAL RUN ADJUSTMENT Adjustment of the AUR450C and tests that are necessary before operating it Chapter 5 MAINTENANCE AND INSPECTION Maintenance and inspection instructions and troubleshooting flowchart Chapter 6 SPECIFICATIONS General specifications performance specifications and external dimensions of...

Page 11: ... the subbase 2 2 Mounting the controller 2 3 Dismounting the controller 2 3 2 2 Wiring 2 4 Wiring diagram 2 5 Connection to the Model AUD300C 500C 2 7 Checking the connection between the controller and the Model AUD300C 500C 2 7 Wiring to a solenoid valve 2 8 Wiring for continuous measurement of flame voltage 2 9 2 3 Communications Connections 2 11 Smart Loader connection 2 11 Connection of RS 485...

Page 12: ...1 Outline of adjustment 4 1 Preliminary inspection 4 2 Measurement of flame voltage flame signal 4 2 Pilot turndown test 4 3 Ignition spark response test 4 5 Safety shutoff test 4 6 Chapter 5 MAINTENANCE AND INSPECTION 5 1 Frequency of maintenance and inspection 5 1 Alarm code and description 5 2 Fault inspection flowchart 5 3 Chapter 6 SPECIFICATIONS 6 1 Specifications 6 1 External dimensions 6 3...

Page 13: ...o standards is not permitted for combustion safety equipment This product is certified to meet standards as noted below UL File No MH27717 CE Gas Appliance Directive 0063BS1427 FM File No 0003059531 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 se lectable by output terminal 3...

Page 14: ...xed 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 Safe startup Checks flame detector and flame circuit for internal failure before every startup If failure is detected prevents burner startup Checks for false flame detection or false discharge of the tube unit failure of ...

Page 15: ...ct the load to this device Structure the interlock so that power to the load can be directly turned off Use the start check circuit during startup do not short out the start contact input Do not make a manual operation circuit or other bypass circuit for any load Use a redundant shutdown system for both main valve and pilot valve z z Precautions for system design Use external equipment to make a p...

Page 16: ...ltage LED indicators Indicates current status of the system Controller subbase screw After the controller is placed on the subbase it is secured with this screw DISP switch Switches between sequence code and flame voltage display RST switch Resets the alarm lockout ADDRESS switch Sets the device s communications address RS 485 communications connector Communications connector Loader jack Connects ...

Page 17: ...K6 is off z z Subbase Q241A104 sold separately 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 2 2 2 2 Q241A104 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 ...

Page 18: ...ure or part malfunction E1 Interlock alarm Interlock occurred E2 False flame A false flame such as a remaining flame was detected E3 UV alarm A flame was detected even though the shutter output was off E4 Ignition failure No flame was detected at the completion of the ignition trial E5 Flame failure A flame failure occurred in the following sequence Pilot Stabilization Main Trial RUN EE Other When...

Page 19: ...e 1 minute ON when the shutter cycle count drops below the lower preset value A4 Operation time for event ON when the time since startup exceeds the preset value A5 Combustion time for event ON when the RUN time exceeds the preset value A6 Combustion count for event ON when the combustion count exceeds the preset value A7 Flame voltage upper value ON when the flame voltage exceeds the preset value...

Page 20: ...ding on model No 14 Power supply G 15 Start contact input Contact resistance 100 Ω max 16 Start contact input 17 Interlock 100 120 200 230 V AC 50 60 Hz Contact resistance 100 Ω max 18 Interlock 19 Ignition transformer 300 VA max cos φ 0 5 20 Main valve 200 VA max cos φ 0 5 21 Intermittent pilot 200 VA max cos φ 0 5 22 Interrupted pilot 200 VA max cos φ 0 5 23 Flame monitor output 75 VA max cos φ ...

Page 21: ...ures such as keeping power lines away from the input lines between the control panel and the burner controller After wiring check that the equipment is operating properly Mounting locations For effective heat radiation and convenient dismounting wiring and maintenance be sure to leave work space around the device as shown below 50 mm min 100 mm min 100 mm min 50 mm min 100 mm min 100 mm min 50 mm ...

Page 22: ...Correct Incorrect Incorrect Incorrect Front of controller Panel MADE IN JAPAN AC xxxV 50 60Hz XXXXX XXXXXX Panel Front of controller MADE IN JAPAN AC xxxV 50 60Hz XXXXX XXXXXX AUR450C 000 Panel Wiring diagram Front of controller Correct Incorrect Incorrect 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...

Page 23: ... Push the controller against the subbase so that the terminals make contact 2 Tighten the main unit subbase screw to secure the controller to the subbase The maximum tightening torque of the screw is 0 5 N m 3 Attach the code 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 Dismounting the controller Remove the ma...

Page 24: ...ns 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 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 ...

Page 25: ...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 observe this warning could lead to an explosion Note Wiring for input to terminals 15 and 18 through H contacts without using terminals 16 and 17 is also possible H G F G AUD300C 500C H G Subbase for AUR450C Advanced Ultravio...

Page 26: ...et input of another device cannot be shared Although terminals with a ground mark are provided on the subbase this de vice is not grounded z z 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 H G AUR450C AUR450C Power supply Power supply Surge absorber 83968019 001 Flat te...

Page 27: ...the connection between the controller and the Model AUD300C 500C Required equipment Tester Input impedance 100 kΩ min To check if the connection to the controller is correct remove the tube unit of the AUD300C 500C and measure the DC voltage between terminals F and G with the tester as shown below Connect the tester probe red to terminal G yellow lead wire and the tester probe black to terminal F ...

Page 28: ... Fuel N L AUR450C When the 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 H Therefore the valve does not open and fuel does not flow out z z Incorrect connection Ground fault Burner Valve open Fuel N L High potential side H Power supply Combustion equip...

Page 29: ... The wiring length must be 10 m or less Connect a measuring instrument to the device having an input impedance of 100 kΩ or more and connect a pen recorder having an input impedance of 1 MΩ or more z z Removing the terminal cover Handling Precautions Do not remove the cover with your fingers The cover may break Required tool a screwdriver 1 Insert the screwdriver between the terminal cover and ter...

Page 30: ...WIRING z z Mounting the 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 ...

Page 31: ...485 communications Signal name Description DA Transmission and reception terminal DB Transmission and reception terminal SG Signal GND terminal Compatible connectors Phoenix Contact model No MSTB2 5 3 STF 5 08 Azbil Corporation model No 81446848 001 1 connector Handling Precautions Use shielded twisted pair cable for RS 485 communication wiring z z Communication setting Station address is set by t...

Page 32: ...resistor Do not connect any terminating resistor to either end of the communication path Doing so might cause a communications failure Even if there are devices requiring a terminating resistor in the communication path do not connect a terminating resistor Handling Precautions Use a twisted shielded pair cable for RS 485 communications Ground shielded wire to one point on one side of the cable Wh...

Page 33: ...valve note the following For safety control and operation circuits devise a safety plan based on risk assessment Configure the interlock including limit contacts so as to directly disconnect loads ignition transformer pilot safety shutoff valve main safety shutoff valve etc Design a circuit that shuts down all the burners when a ignition failure or a flame failure of the pilot or main burner occur...

Page 34: ...arm relay 7 Main valve 2 K1 Input circuit Interlock input circuit 15 Burner start contacts Prepurge end Emergency stop circuit Blower on off circuit and prepurge circuit Gas pressure upper limit interlock Gas pressure lower limit interlock Interlock Limit contacts Vibration detection limit Overtemperature limit Air pressure lower limit interlock 103X Fuse Air pressure switch Configure a verificati...

Page 35: ...o ON the operation progresses to RUN following the sequence shown below When the start contact is turned OFF the sequence goes to standby P1 P2 P3 P4 P5 POWER SHUTTER FLAME ALARM START IG PV MV Pre purge Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monitor output Alarm output Load o...

Page 36: ...ame monitor output is ON On the device E2 false flame and P1 are displayed alternately P1 E2 P1 K1 K2 K3 K4 K5 K6 POWER SHUTTER FLAME ALARM START IG PV MV K7 Sequence display Lockout Pre purge Standby Start check at alarm detection Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monito...

Page 37: ... FLAME LED does not light up On the device E3 UV alarm and P1 are displayed alternately P1 E3 P1 POWER SHUTTER FLAME ALARM START IG PV MV K1 K2 K3 K4 K5 K6 K7 Sequence display Lockout Pre purge Standby Start check at alarm detection Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monit...

Page 38: ...e and P2 are displayed alternately P2 E4 P2 K7 K1 K2 K3 K4 K5 K6 POWER SHUTTER FLAME ALARM START IG PV MV Pre purge Standby Start check Ignition trial Lockout Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monitor output Alarm output Load output Sequence display LED display P1 ...

Page 39: ... K1 K2 K3 K4 K5 K6 POWER SHUTTER FLAME ALARM START IG PV MV Flame Failure Response Time Pre purge Standby Start check Ignition trial Pilot Stabilization Main trial RUN Flame failure Lockout Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monitor output Alarm output Load output Sequence...

Page 40: ...E1 P5 P4 P5 P2 P3 K7 K1 K2 K3 K4 K5 K6 POWER SHUTTER FLAME ALARM START IG PV MV Pre purge Standby Start check Ignition trial Pilot Stabilization Main trial RUN Lockout Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monitor output Alarm output Load output Sequence display LED display F...

Page 41: ...ocked out and an alarm is output On the device E1 interlock and P1 are displayed alternately E1 P1 K1 K2 K3 K4 K5 K6 POWER SHUTTER FLAME ALARM START IG PV MV K7 Pre purge Standby Lockout Power supply Burner start contacts Interlock Flame signal Input Relay output Ignition transformer Interrupted pilot valve Intermittentpilotvalve Main valve Flame monitor output Alarm output Load output Sequence di...

Page 42: ...for the main burner and pilot burner Install the flame detector for the main burner in a location where it does not de tect the pilot burner flame Be sure to connect the limit contacts and interlock contacts to the interlock input terminals of the burner controllers for both the pilot and main burners in such a way that the circuit can directly disconnect loads ignition transformer pilot safety sh...

Page 43: ...tacts Prepurge end Emergency stop circuit Blower on off circuit and prepurge circuit Gas pressure upper limit interlock Gas pressure lower limit interlock Interlock Limit contacts Vibration detection limit Overtemperature limit Air pressure lower limit interlock 1 113X 14 1 10 12 11 24 23 K6 Flameoutput K5 Alarmoutput AUD300C 500C flame detector 2 K6 K2 K2 K7 K3 K4 Shutter driving circuit External...

Page 44: ...ns the blower should not be started 2 When configuring the circuit use the pilot ignition signal output as the condition for starting the burner controller for the main burner and for activating the interlock 3 Be sure to set up a separate external reset input for each AUR450C The external reset input of another AUR450C cannot be shared Note JIS B8415 defines ignition times as follows Pilot burner...

Page 45: ...stment 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 Outline of adjustment The following test adjustment ite...

Page 46: ...t and measure the voltage under several conditions such as start up operation and normal operation 1 Set the FSP136A range to 7 5 V 2 Connect the positive probe of the FSP136A to the FLAME VOLTAGE termi nal on this device and the negative probe to the FLAME VOLTAGE terminal 3 Check that the voltage is stable and 2 0 V DC or more Recommended flame voltage Stable 2 0 V DC or more 4 If the flame volt...

Page 47: ...sult in an explosion When the pilot turndown test is complete turn OFF the power switch to shut down the power 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 Only an experienced technician who has knowledge and technical skills related to combustion...

Page 48: ... 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 in coming light so that the AUD300C 500C cannot detect a pilot flame that can not ignite the main burner There are two kinds of adjustment procedures Move the monitoring area of the sighting pipe slightly away from the pilot flame Narrow the sighting pipe to decrea...

Page 49: ...C 500C or ignition spark rod so that there is no influence Put a shielding plate in the optical path of the AUD300C 500C so that the ef fect of the spark is a flame signal of 0 4 V DC or less Handling Precautions Be sure the AUD300C 500C does not detect ultraviolet rays other that those of the burner flame The following shows various ultraviolet ray sources other than the burner flame that may act...

Page 50: ...if the flame fails z z 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 RUN 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 cor rectly activated z z Interl...

Page 51: ...nual of the equipment manufacturer When cleaning the burner clean the flame detector as well Frequency of maintenance and inspection Determine an appropriate frequency for maintenance and inspection work by considering the equipment type ambient conditions dust or temperature of the location damage or negative effects if the burner is shut off for some reason during operation of the equipment Insp...

Page 52: ... was detected E3 UV alarm A flame was detected even though the shutter output was off E4 Ignition failure No flame was detected at the completion of the ignition trial E5 Flame failure A flame failure occurred in the following sequence Pilot Stabilization Main trial RUN EE Other When the cause of lockout cannot be identified In cases where power was turned off before CPU error determination In cas...

Page 53: ... Replace the device Does the pilot burner ignite Is there voltage between terminal 14 and each of terminals 19 21 and 22 Is the flame voltage more than 1 5 V Does FSP300BC100 signal make FLAME LED light up Is there voltage between terminals 20 and 14 Does the FLAME LED of this device light up Does the flame go out Is there an alarm Does the main burner ignite Normal operation Turn on the start con...

Page 54: ...stantaneous power failure or a voltage drop surge Yes No 2 Wiring material diameter distance temperature maker name etc Power supply wire Signal wire Ground wire 3 Mounting Indoors Equipment room Outdoors Device cover Yes No 4 Dirt or dust on UV ray detector glass 5 UV sensor signal line F G wiring check OK Reversed connection Flame current voltage 1 During pilot combustion While ignition transfor...

Page 55: ...0 to 0 6 V DC Flame establishment 1 5 to 4 0 V DC Recommended flame voltage Stable 2 0 V DC or more Service life 7 years or 100 000 operation cycles max at room temperature and humidity and rated voltage and load Max tightening torque Subbase mounting screws 1 5 N m or less Body subbase screw 0 5 N m or less M3 5 terminal screws 1 0 N m or less Mounting method Mounted on subbase Subbase Q241A104 E...

Page 56: ...onization 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 method 1 N 15 units max Terminating resistor Use prohibited resistor already built in Signal level RS 485 compliant z z Environment specifications Item Description Allowable ambient temperature Stand alone mounti...

Page 57: ... ALARM START IG PV MV RST DISP FLAME VOLTAGE ADDRESS LOADER RS 485 DYNAMIC SELF CHECK BURNER CONTROLLER AUR450 MADE IN JAPAN AC xxxV 50 60Hz XXXXX XXXXXX AUR450C 000 163 Space required for dismounting the main unit Note When dismounting the main unit pull it out while tilting it as shown in the drawing China RoHS ...

Page 58: ...Memo ...

Page 59: ...ling Precautions Explanation about ultraviolet ray source changed Alarm code display EE added to the table Environment specifications Allowable ambient temperature changed EC DECLATRATION OF CONFORMITY changed Terms and Conditions was changed Feb 2013 5 1 1 1 4 6 1 The table was deleted Certificates were added Approvals was changed to Certificates Standards compliance section was deleted from Spec...

Page 60: ...on design fault avoidance fault tolerance and other kinds of protection safety circuit design on your own responsibility to ensure reliability and safety whereby preventing problems caused by failure or nonconformity Terms and Conditions We would like to express our appreciation for your purchase and use of Azbil Corporation s products You are required to acknowledge and agree upon the following t...

Page 61: ...margin of your machine or equipment you are required to renew any Azbil Corporation s products every 5 to 10 years unless otherwise specified in specifications or instruction manuals System products field instruments sensors such as pressure flow level sensors regulating valves etc will reach the end of their life due to aged deterioration of parts For those parts that will reach the end of their ...

Page 62: ... 11 Specifications are subject to change without notice 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan https www azbil com 1st edition June 2007 W 8th edition Sep 2019 V ...

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