Azbil AUR455 User Manual Download

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Thank you for purchasing an Azbil

Corporation product.
This manual contains information for

ensuring the correct use of this 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.

No. CP-SP-1439E

Dynamic Self-Checking

Burner Controller

Model AUR455

User’s Manual

Summary of Contents for AUR455

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 No CP SP 1439E Dynamic Self Checking Burner Controller Model AUR455 User s Manual ...

Page 2: ...ecifications in this manual are subject to change without notice Considerable effort has been made to ensure that this manual is complete and accurate but if you should find an omission or error please contact us Please understand that we cannot in some cases accept responsibility for the results of the use of this equipment by the customer 2019 2021 Corporation All Rights Reserved ...

Page 3: ...minor injury or property damage only In describing the product this manual uses the icons and wording listed below Indicates that caution is required in handling The indicated action is prohibited Be sure to follow the indicated instructions Handling Precautions Information to be aware of when handling Note Indicates information that may be useful Indicates an item or page to which the user may re...

Page 4: ...If this device is misused a serious combustion equipment accident may occur Do not reset this device from a remote location Because it is difficult to make a safety check when far from the equipment there is an increased risk of explosion Do not use the event output or alarm output as safety output This device has a limited product life Beyond the product life the risk of device failure becomes hi...

Page 5: ... the details with our sales representatives Installation wiring maintenance inspection and adjustment must be carried out by a professional with technical training in combustion equipment and flame safeguard system Use this product correctly within the range of the rated specifications stated in the user s manual Not doing so may cause device failure or malfunction Do not install where exposed to ...

Page 6: ...gh frequency radio waves causing malfunction Always supply electricity at the voltage and frequency stated on the model label of this device Make sure the burner frame is properly grounded in compliance with applicable local electrical codes ordinances and regulations The pilot turn down test should be carried out only by an experienced specialist possessing knowledge and skills pertaining to comb...

Page 7: ...nication maintenance and inspection and specifications Dynamic Self Checking Burner Controller Model AUR455 User s Manual for Installation Document No CP UM 5955JE This manual is supplied with the AUR455 Personnel who design or maintain equipment that uses the AUR455 should read this manual thoroughly This manual describes installation of this device Installation and Usage Guide for Smart Loader P...

Page 8: ...Check of wiring between this device and model AUD300C or AUD500C 15 Connections to solenoid valve 16 Chapter 3 Operation 17 Part names 17 Operation 17 Turn down test and communication setting modes 20 Host communication setting using the Smart Loader Package model SLP A55 23 Chapter 4 Explanation of Operation 25 Instrumentation example of model AUR455 for an interrupted pilot 25 Notes about the in...

Page 9: ...Inspection procedure 39 Chapter 6 Maintenance and Inspection 45 General maintenance and inspection 45 Maintenance and inspection cycle 45 Alarm codes and details 46 What to do if E951 occurs 48 Failure inspection flowchart 49 Chapter 7 Specification 51 External dimensions 53 ...

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Page 11: ...n mode that is convenient for trial operation and adjustment and other features Additionally the device is equipped with host communications RS 485 and a smart loader package function allowing more detailed observation of status and troubleshooting The combustion sequence alarm codes and flame voltage are shown on the 7 segment display LED indicators show whether there is a flame signal and indica...

Page 12: ...Part 1 Gas Burners JIS B 8407 1 Forced Draught Burners Part 2 Oil Burners JIS B 8407 2 Index of Safety Technology of Industrial Gas Combustion Equipment by Japan Gas Association Index of Safety Technology of Gas Boiler Combustion Facilities by Japan Gas Association Most important points for ensuring safety Design the equipment observing the following points to ensure safety Connect loads directly ...

Page 13: ...max AUR455C only 3 4 s max 1 100 V AC 2 200 V AC 3 120 V AC 5 230 V AC 0 Interrupted pilot 0 Without inspection data D With inspection data If the ignition method is an intermittent pilot select a direct ignition model z Direct ignition type Example AUR455C433110 Basic model No Flame detector Ignition trial Notused Flame failure response Power Pilot sequence Other Description Note AUR455 B Flame r...

Page 14: ... YT With traceability certificate and tropicalization z Optional parts sold separately Model No Name BC R05A100 Dedicated sub base a requirement for the AUR455 81447514 001 Connector for front wiring Weidmüller model number BL3 5 11F Compatible wire 0 2 1 5 mm2 28 14 AWG 81447514 002 Connector for front wiring for right side wiring Weidmüller model number BL3 5 11 270F Compatible wire 0 2 1 5 mm2 ...

Page 15: ... could lead to an explosion Do not extend the lead wires of the contact reset for more than the allowable length of 10 meters If the device is reset from a location where it is difficult to check the safety of combustion there is a risk of explosion CAUTION For mounting and wiring follow the instructions in this user s manual or in manuals provided by the combustion equipment manufacturer All wiri...

Page 16: ...lightning Do not configure a circuit that turns off the interlock input terminals 22 19 or 22 20 using the alarm output contacts terminals 9 10 With such a circuit if a false flame UV alarm ignition failure or flame failure occurs the interlock alarm E1 may be displayed When the control load wiring is grounded an alarm occurs Use the contact reset terminal 24 input in isolation Do not share the te...

Page 17: ...following Certain chemicals or corrosive gases ammonia sulfur chlorine ethylene compounds acid etc Splashing water or excessive humidity High temperatures Prolonged vibration Do not connect a load that exceeds the rating stated in the specifications to the control load terminals 6 7 8 and do not short circuit the load Doing so will burn out the internal fuse making this device unusable When using ...

Page 18: ...pull on the wiring while it is attached to the device Doing so can cause failure of the connectors or this device itself If there is room leave as much space as possible between them for heat dissipation If the ambient temperature is close to the allowable upper limit install a panel air conditioner or a fan to lower the temperature inside the panel Upper limit of allowable ambient temperature for...

Page 19: ...ase is not upside down 3 Push up the DIN rail clamp to fasten the sub base to the DIN rail Pull down the DIN rail clamps Push the DIN rail clamps upward to fix in place Attachsub basetoDINrail Mounting in a panel 1 Cut two M4 threaded holes in the panel Unit mm 62 5 M4 2 locations 2 Use screws to mount the sub base in the panel Maximum tightening torque 1 2 N m ...

Page 20: ... push the device toward the sub base 3 Tighten the device s retaining screws to secure it in the sub base Maximum tightening torque 0 5 N m z Removing 1 Remove the mounting screws 2 Pull the device out toward you while holding down the sub base Terminal numbers front panel item names Sub base sold separately Terminal block 2 RESET switch DISP switch Display Loader jack 1 Front connector Front DIN ...

Page 21: ...ot used 7 PV Pilot valve or Lo solenoid valve 19 COM1 Input common 1 8 MV Main valve or Hi solenoid valve 20 COM2 Input common 2 9 AL NO Alarm output 21 START Start input 10 AL COM Alarm output 22 IL Interlock input 11 FL NO Flame monitor output 23 Not used 12 FL COM Flame monitor output 24 RESET Contact reset input z Front connector terminals No Function 25 FV Flame voltage output 26 FV Flame vol...

Page 22: ...ont wiring model 81447514 001 terminal layout 25 35 Mounting screw Wiring Screws for wiring Mounting screw z Connector for front wiring for right side wiring model 81447514 002 terminal layout 25 35 Screws for wiring Mounting screw Mounting screw Wiring ...

Page 23: ...ital K7 K8 K6 Load 30 V DC max Loader jack 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 33 34 35 8 8 25 35 Terminallayoutofconnector forfrontwiring The names used for the loads in the above diagram are for interrupted pilot systems only In the case of direct ignition the pilot valve is the Lo solenoid valve and the main valve is the Hi solenoid valve Handl...

Page 24: ... 31 32 1 2 3 4 5 6 7 8 9 10 11 12 33 34 35 8 8 25 35 Terminallayoutofconnector forfrontwiring Flame rod Pilot valve Main valve The names used for the loads in the above diagram are for interrupted pilot systems only In the case of direct ignition the pilot valve is the Lo solenoid valve and the main valve is the Hi solenoid valve Handling Precautions After mounting the connector for front wiring s...

Page 25: ... m Check of wiring between this device and model AUD300C or AUD500C Necessary tools tester Input impedance of 100 kΩ or more To check that wiring to this device is correct remove the tube unit from the AUD300C or AUD500C 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 termi...

Page 26: ...ageside L1 Low voltageside L2 N Linesurge absorber Linesurge absorber Fastonterminalside 187series Fastonterminalside 187series Mountingbracketside groundside Mountingbracketside groundside Burner controller Burner controller Connections to solenoid valve CAUTION Connect the load ignition transformer solenoid valve etc directly to the output terminals of this device If it is not directly connected...

Page 27: ...hey turn off and the display of the sequence code begins If lockout occurs an alarm code is displayed automatically If an alarm occurs the alarm code and the code for the sequence step where the lockout occurred are displayed alternately Identifying information Item Notation Product number AUR455_ _ _ _ _ _ _ Voltage AC _ _ _ V Timing Ignition trial pilot or main burner ignition time IGT _ _ s Fla...

Page 28: ...k error K1 E9 04 Relay answerback error K2 E9 05 Relay answerback error PV E9 06 Relay answerback error MV E9 07 Relay answerback error IG E9 08 Alarm at power on E9 50 Device error Sample display when an error occurs alarm code without a sub code The item displayed changes every 0 8 s Sample display when an error occurs alarm code with a sub code The item displayed changes every 0 8 s Sub code z ...

Page 29: ...ent occurs Configure event settings using Smart Loader Package model SLP A55 SLP A55J91 z RESET switch Lockout can be canceled by pressing the RESET switch for 1 second After lockout is canceled start input is not accepted for about 5 seconds z Contact reset input terminal 24 Lockout can be canceled by shorting the contact reset input for 1 second After lockout is canceled start input is not accep...

Page 30: ...nication setting mode The central dot of the 7 segment display starts blinking a 1 s cycle 2 When the DISP switch is pressed the display changes in the following order C 1 H 1 H2 H3 CL Select the turn down test or communication setting type using the DISP switch Display Description C 1 Continuous pilot burner combustion mode H 1 Communication address setting H2 Baud rate setting H3 Communications ...

Page 31: ...2 _ _ _ _ represents 1 2 or 3 Default setting 3 1 4800 bps 2 9600 bps 3 19200 bps 2 When the DISP switch is pressed in this situation the display cycles through H2 1 H2 2 H2 3 Select the baud rate 3 After making a selection press the RESET switch H2 blinks and when the blinking stops configuration is complete At this time H2 is displayed Communications format setting H3 Use the DISP switch to sele...

Page 32: ...for 5 s or more to end the turn down test or communication setting mode Turn down test and communication setting modes also end in the following cases When the power goes OFF When a warning is issued during the turn down test or communication setting mode in continuous pilot burner combustion mode z Operation when the dot at the lower right of the 7 segment LED is blinking If the communication set...

Page 33: ...n setting mode can also be set using the Smart Loader Package 1 Turn off the power to the burner controller 2 Remove the RS 485 wires Insert one end of the USB loader cable into the loader jack on the product and insert the other end into a USB port on the PC 3 Turn on the power to the burner controller 4 Start the SLP A55 and set up host communication 5 Turn off the power to the burner controller...

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Page 35: ...it configuration of the AUR455 for an interrupted pilot note the following For safety control and operation circuitry implement inherent safety design measures based on risk assessment Directly connect the interlock including limit contacts to the interlock input terminal 19 or 20 with terminal 22 of the burner controller or configure the contacts to directly turn off the load such as the ignition...

Page 36: ...cts Prepurge complete External reset input Emergencystopcircuit Blower on off circuit prepurge circuit Gas pressure high limit interlock Gas pressure low limit interlock Seismic limit Overheating limit Air pressure low limit interlock Input circuit 10 A DC24 V Air pressure switch install the following verification circuit When the blower is about to start and there is no air flow the circuit shoul...

Page 37: ...low limit interlock Seismic limit Overheating limit Air pressure low limit interlock Input circuit 10 A DC24 V Flame detection circuit Self diagnostic function Diagnostic circuit F G Flame rod Air pressure switch install the following verification circuit When the blower is about to start and there is no air flow the circuit should verify that no pressure is detected If pressure is detected under ...

Page 38: ... OFF this device goes into standby mode P6 P8 Power supply Burner start contacts Interlock Flame signal Ignition transformer Pilot valve Main valve Flamemonitoroutput Alarm output SHUT 2 FL AL Input Load output LED indication Sequence display Standby Start check Ignition trial Pilot only Main trial Run Standby Prepurge 1 1 ON in the case of a direct ignition model OFF in the case of an interrupted...

Page 39: ... Pilot valve Main valve Flamemonitoroutput Alarm output SHUT FL AL Sequence display Prepurge 5 s z Operation during start check error self discharge If self discharge is detected during the start check and the error is not cleared after 5 seconds lockout occurs At this time the flame monitor does not output anything and the flame LED does not light up E2 UV alarm and P 1 are displayed alternately ...

Page 40: ...ected during RUN lockout occurs and an alarm is issued E7 flame failure and P8 are alternately displayed Power supply Burner start contacts Interlock Flame signal Ignition transformer Pilot valve Main valve Flamemonitoroutput Alarm output SHUT FL AL Input Load output LED indication Standby Pilot only Main trial Run Flame failure Lockout Flame failure response Start check Ignition trial Sequence di...

Page 41: ... the case of an interrupted pilot model This is because the AUR455 has one output with different operation depending on the type of model while the AUR450 has two outputs for the pilot valve one for the intermittent and one for the interrupted type z Operation during interlock interlock activation between standby and start signal Even if the interlock contacts turn OFF before the start contact inp...

Page 42: ...measures based on risk assessment Individually install flame monitoring equipment flame detector and burner controller for the pilot burner and the main burner Install the flame detector for the main burner at a position where it does not detect the pilot burner flame Connect the limit contacts and the interlock contacts to the interlock input terminals of the burner controller for the pilot burne...

Page 43: ...imit Airpressure lowlimitinterlock 1 Input circuit 10 A DC24 V Powercircuit K6 K7 Flame output K5 K1 K2 K3 K4 AUD300C 500C Flame detector Shutter drive circuit Flame circuit Main valve 2 Main valve 1 AUR455 for main burner Input circuit 10 A DC24 V K8 Alarm output External reset input 3 1 Air pressure switch Install the following verification circuit When the blower is about to start and there is ...

Page 44: ...cuit 10 A DC24 V K8 Alarm output External reset input 3 Flame detection circuit Self diagnostic function Diagnosticcircuit F G Flame rod Flame detection circuit Self diagnostic function Diagnosticcircuit F G Flame rod 1 Air pressure switch install the following verification circuit When the blower is about to start and there is no air flow the circuit should verify that no pressure is detected If ...

Page 45: ...ector Shutter drive circuit Flame circuit Interrupted pilot Ignitiontransformer Intermittent pilot Main valve for load monitor Alarm relay Blue Yellow White White Start contacts External reset input 103X Emergencystopcircuit Blower on off circuit prepurge circuit Gaspressure highlimitinterlock Gaspressure lowlimitinterlock Seismic limit Overheating limit Air pressure low limit interlock Start inpu...

Page 46: ...ir pressure switch install the following verification circuit When the blower is about to start and there is no air flow the circuit should verify that no pressure is detected If pressure is detected under these conditions the blower should not be started 2 The interlock that was connected in series with the load to terminal 18 of the AUR450 can be connected to terminal 1 of the AUR455 If this int...

Page 47: ...ng operation If an instantaneous power failure or instantaneous voltage drop occurs during operation this device operates as described below Instantaneous power failure Shorter than 50 ms Operation continues 50 ms or longer Operation continues or restarts from stop or restarts after power OFF Instantaneous voltage drop drop in power of 50 Shorter than 100 ms Operation continues 100 ms or more Oper...

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Page 49: ...nce inspection and adjustment must be carried out by a professional with technical training in combustion equipment and flame safeguard system The pilot turn down test should be carried out only by an experienced specialist possessing knowledge and skills pertaining to combustion equipment and combustion safety This device does not start operation until about 8 seconds after power on Preliminary i...

Page 50: ...tor Adjust so that the spark s effect on the flame signal is no more than 0 4 V DC If an S7200A_ _ _GH_ or S720A_ _ _GH_ igniter is used swap the polarity of the power to the igniter When this device is used in combination with an igniter changing the polarity of the power can prevent the AUD flame detector from detecting the spark Handling Precautions Ensure that the ultraviolet detector does not...

Page 51: ...is not correctly wired Open circuit Short circuit High resistance short circuit of the lead wires due to humidity or dirt Incorrect flame detector mounting angle AUR455C Dirty flame detector sensing surface AUR455C Tube unit deterioration AUR455C Incorrect flame rod installation AUR455B Area in contact with flame is insufficient Position of flame rod in flame is incorrect The flame rod insulator i...

Page 52: ...ge and confirm that it is 2 0 V or more This device has turn down test and communication setting modes If Continuous pilot burner combustion mode is selected in the turn down test or communication setting mode pilot burner combustion will continue instead of progressing to main burner combustion When the turn down test or communication setting mode is used the pilot turn down test can be executed ...

Page 53: ...s and flues Before starting the pilot turn down test in turn down test or communication setting mode shut off the gas to the main burner by closing the manual cock or disconnecting the wiring z Safety shutoff check Interlock check During burner combustion simulate the operation of each type of interlock and check if this device is locked out or stops Then restart the burners and check for proper i...

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Page 55: ...least once a year Inspect the combustion equipment periodically in accordance with the instructions given in the manual provided by the equipment manufacturer When cleaning the burner clean the flame detector also General maintenance and inspection When replacing this device observe the cautions Page 1 and carry out all the inspections and adjustments of this device and the combustion equipment th...

Page 56: ... Reset E9 04 Relay answerback error K2 Terminals 4 and 5 were connected to terminal 3 through the ground or load Or K2 relay contact welding due to output short circuit etc occurred Reset E9 05 Relay answerback error PV Terminal 7 was connected to terminal 2 through the load Or K3 relay contact welding due to output short circuit etc occurred Reset E9 06 Relay answerback error MV Terminal 8 was co...

Page 57: ...do a reset E9 64 Internal error flame circuit Error in the circuit for diagnosing the flame detection circuit Reset E9 65 Internal error flame circuit Error in the interactive diagnosis of the flame detection circuit Reset E9 66 Internal error K1 circuit Internal fuse burn out or internal feedback signal error Reset E9 67 Internal error K2 circuit Internal feedback signal error Reset E9 68 Interna...

Page 58: ...rs reset it 5 Wait for 5 seconds after the reset If there is no error message turn off the power of the burner controller 6 Turn the power back on Wait for 5 seconds after is displayed on the 7 segment LED If there is no error message the settings have been properly stored in the EEPROM If E951 occurs again repeat the operation from step 1 E951 occurs when data was not properly saved to the burner...

Page 59: ...nspect burner Inspectflamedetector Inspect panel power switch and fuse Inspect wiring Inspect burner false flame Inspect flame detector Inspect main valve Inspectburnerandwiring Checkforleakfrommainvalve Inspect burner Check airflow switch air and check for disconnection Inspect alarm function Inspect this device Close manual valve for main burner Normal Is there voltage betw terminals 4 5 and bet...

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Page 61: ...clamp except for flame detector connection terminals terminals 14 15 and 16 17 Insulation resistance 50 MΩ min with a 500 V DC megger Between each terminal and ground the DIN rail clamp except for flame detector connection terminals terminals 14 15 and 16 17 Contact rating Ignition transformer 300 VA Pilot valve Lo solenoid valve 1 200 VA Main valve Hi solenoid valve 1 200 VA Alarm 75 VA Event out...

Page 62: ...mensions W95 x H105 x D110 mm Weight Approximately 600 g incl sub base Wiring types and max wiring length Start interlock Copper 600 V PVC insulated cable IEC 60227 3 1 25 mm2 Recommended length 20 m or less maximum length 100 m Contact reset Copper 600 V PVC insulated cable IEC 60227 3 1 25 mm2 maximum length 10 m AUD300C 500C F G S1 S2 Copper 600 V PVC insulated cable IEC 60227 3 1 25 mm2 maximu...

Page 63: ... unit Unit mm 95 105 27 17 Main unit mounting screw Main unit mounting screw 61 110 Sub base sold separately Sub base sold separately Connector for front wiring A DIN rail clamp Model No of connector for front wiring A 81447514 001 10 6 81447514 002 14 6 ...

Page 64: ... 27 17 61 64 62 5 φ12 knockout hole φ12 knockout hole Sub base mounting hole Sub base mounting hole M3 5 terminal screw Knockout hole Knockout hole 16 z Sideboard model 81447515 001 sold separately Sub base 46 6 73 5 Sideboard Sideboard Sideboard φ19 knockout hole φ19 knockout hole Sub base 30 7 23 9 ...

Page 65: ...Revision History of CP SP 1439E Date Rev New Page No Description Feb 2021 1 ...

Page 66: ...to your use 3 Measures to be taken to secure the required level of the reliability and safety of your Equipment in your use Although azbil is constantly making efforts to improve the quality and reliability of Azbil Corporation s products there exists a possibility that parts and machinery may break down You are required to provide your Equipment with safety design such as fool proof design 1 and ...

Page 67: ...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 68: ... 11 Specifications are subject to change without notice 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan https www azbil com 1st edition Feb 2021 F ...

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