Azbil FRS100 User manual

FRS100

Multiburner Controller

User's Manual

No. CP-SP-1373E

Thank you for purchasing the FRS100

Multiburner Controller.

This manual contains information for

ensuring the correct use of the FRS100.

It also provides necessary information

for installation, maintenance, and trou-

bleshooting.

This manual should be read by those

who design and maintain equipment

that uses the FRS100. Be sure to keep

this manual nearby for handy reference.

NOTICE

Be sure that the user receives this manual before the product is used.

Copying or duplicating this user’s manual in part or in whole is forbid-

den. The information and specifications in this manual are subject to

change without notice.

Considerable effort has been made to ensure that this manual is free

from inaccuracies and omissions. If you should find an error or omis-

sion, please contact Azbil Corporation.

In no event is Azbil Corporation liable to anyone for any indirect, special

or consequential damages as a result of using this product.

■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.

■Examples

Use caution when handling the product.

The indicated action is prohibited.

Be sure to follow the indicated instructions.

SAFETY PRECAUTIONS

WARNING Warnings are indicated when mishandling this

product might result in death or serious injury.

CAUTION Cautions are indicated when mishandling this

product might result in minor injury to the user, or

only physical damage to the product.

WARNING

Use this device for batch operation of the burner (at least one start and

stop in a 24-hour period). Do not use for continuous burner operation

(nonstop combustion for 24 h or longer).

This device does not have the prepurge and ignition sequencing func-

tions required for burner ignition. Use this device as part of a system

whose design gives careful consideration to the prepurge timer and

sequence timing, following established safety guidelines.

Wire terminals 1 and 2 so that they receive power continuously when-

ever the power switch is turned on. This is absolutely necessary to

ensure operation of the self-check circuits at startup.

Therefore, do not wire a thermostat between the power switch and ter-

minal 1 or 2. Doing so might cause a serious combustion equipment

accident.

Connect loads (ignition transformer, solenoid valve, etc.) directly to the

output terminals of this device. If they are not directly connected, com-

bustion safety cannot be ensured.

Do not allow the pilot or main burner "Safety Time" (ignition trial time)

to exceed the specifications of the burner or equipment manufacturer.

If they do, fuel may accumulate in the combustion chamber and form

an explosive air-fuel mixture, resulting in a serious explosion hazard.

Before removing, mounting, or wiring the FRS100, be sure to turn off

the power to the FRS100 and all connected devices. Failure to do so

might cause electric shock.

Do not connect a solenoid valve to the high potential side of the circuit.

If a ground fault occurs, the ground fault current may energize and

open the solenoid valve. This device will not be able to prevent the

valve from opening and fuel from flowing out.

Even after the power to this device is turned off, terminal F continues

to hold an electrical charge. To avoid electrical shock, do not touch ter-

minal F.

Carry out the pilot turndown test carefully. If the flame detector is set

so that it detects a pilot flame that is too small to ignite the main burn-

er, this device will not be able to detect a flame failure in the main burn-

er. In that case, fuel will continue to be supplied, causing a serious

explosion hazard.

Before the pilot turndown test or ignition spark response test, make

sure that all manual fuel valves are closed.

iii

WARNING

If the pilot turndown test must be carried out repeatedly, completely

shut down all equipment each time the test is finished, and completely

discharge unburned gas or fuel that has accumulated in the ducts and

combustion chamber. Failure to discharge unburned gas or fuel may

result in an explosion.

When the pilot turndown test is complete, turn OFF the power switch to

shut down the power. Restore all test jumpers and limit interlock/regu-

lator settings to their previous states. If operation begins without the

above steps, damage to the equipment, gas leak or explosion may

result.

Do not start regular operation of the equipment without first complet-

ing the trial-run adjustments for this device, as well as the tests speci-

fied by the combustion equipment manufacturer.

To prevent electric shock, turn the power off and discharge terminals F

and G before removing this device from the subbase. Use lead wires to

connect terminals F and G of the flame simulator (FSP300C100) to ter-

minals F and G of this device for 10 seconds or more.

CAUTION

Installation, wiring, inspection, adjustment, etc. should be carried out

by a trained and experienced technician who has knowledge and

technical skills related to combustion equipment and flame safeguard

control devices.

Do not install where exposed to any of the following:

• Certain chemicals or corrosive gases (ammonia, sulfur, chlorine,

ethylene compounds, acid, etc.)

• Splashing water or excessive humidity

• High temperatures

• Prolonged vibration

If timers and auxiliary relays are needed for additional functions, select

ones with high reliability, and be sure to design the circuit correctly.

When installing and wiring, be sure to follow the instructions in this

manual and in the user's manual for the combustion equipment.

Make sure the flame detector does not detect ultraviolet rays other

than those of the burner flame. If the flame detector responds to other

ultraviolet rays, it will report that there is a flame even if the burner

flame goes out. As a result, fuel will continue to be discharged,

causing a very serious explosion hazard.

CAUTION

Follow all applicable regulations when doing the wiring work.

Connect the blue signal lead from the AUD100 series Advanced

Ultraviolet Flame Detector to terminal 5 and the white lead to terminal

6. Turning on the power when the flame detector is incorrectly wired

could damage the AUD15C tube unit.

Run the high-voltage ignition transformer cable separately and keep it

at least 10 cm away from this device.

Make sure that ignition transformer high-voltage cables are properly

connected to prevent faulty contact. Faulty contact might generate

high-frequency radio waves which can cause malfunction.

The ignition transformer ground lead should be connected directly to

the burner body or to a metallic part electrically connected to the

burner body.

Keep power lines and ignition transformer high-voltage cables

separate from the flame detector wires.

Always supply electric power at the voltage and frequency stated on

the model label of this device.

Always connect the power supply last. Otherwise, touching a terminal

accidentally could result in electric shock or damage.

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 detector does not detect the ignition spark. If

the flame detector can detect the spark, change the detector's line of

sight or change the ignition electrode's position.

Only an experienced technician who has knowledge and technical

skills related to combustion equipment and combustion safety should

carry out the pilot turndown test.

This product is equipped with functions that are extremely important

for the safe operation of combustion equipment. Carefully follow the

instructions for its use that are given in this user's manual.

CAUTION

If the safety shutoff has been activated, check all of the items on the

checklists in Chapter 3, ADJUSTMENTS FOR TRIAL OPERATION

before restarting the equipment.

Check the flame current at least once per month. Doing so can prevent

shutdowns caused by a weak flame current signal.

This device has an operating life. Assuming that the operating life of

the combustion equipment used with this device is longer, be sure to

do periodic maintenance and replacement of this device.

In the event that this device is replaced, do all of the checks listed in

Chapter 3, ADJUSTMENTS FOR TRIAL OPERATION.

When doing a maintenance inspection of the burner, be sure to do the

pilot turndown test. Inspection must be done at least once a year.

Conduct periodic inspections in accordance with the user's manual of

the equipment manufacturer.

When cleaning the burner, clean the flame detector as well.

Do not transport this device while it is mounted on a DIN rail. Remove

it from the subbase and pack it in its original box. If it is transported

while on a DIN rail, it might fall off and be damaged.

Conventions Used in This Manual

The following conventions are used in this manual:

Handling Precautions:

Handling Precautions indicate items that the user should pay attention to

when handling the FRS100.

Note: Notes indicate information that might benefit the user.

(1), (2), (3): Numbers within parentheses indicate steps in a sequence or parts of an

explanation.

Contents

vii

SAFETY PRECAUTIONS

Conventions Used in This Manual

Chapter 1. OVERVIEW AND PRODUCT CONFIGURATION

■Overview •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••1

■Features •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••1

■System configuration ••••••••••••••••••••••••••••••••••••••••••••••••••••1

■Security function•••••••••••••••••••••••••••••••••••••••••••••••••••••••••2

■Precautions for facility instrumentation••••••••••••••••••••••••••••••••••2

■Model selection guide••••••••••••••••••••••••••••••••••••••••••••••••••••3

■Names of parts•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••4

■Configuration ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••4

Chapter 2. MOUNTING AND WIRING

2-1 Mounting and Wiring the Subbase•••••••••••••••••••••••••••••••••••••••••••5

2-2 Wiring••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••8

■Manual ignition (intermittent pilot) •••••••••••••••••••••••••••••••••••••••9

■Burner flame monitoring only ••••••••••••••••••••••••••••••••••••••••••14

■Wiring the flame detector •••••••••••••••••••••••••••••••••••••••••••••••19

■Wiring the solenoid valve •••••••••••••••••••••••••••••••••••••••••••••••20

■Wiring the surge absorber ••••••••••••••••••••••••••••••••••••••••••••••21

Chapter 3. ADJUSTMENTS FOR TRIAL OPERATION

■Outline ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••22

■How to measure the flame signal •••••••••••••••••••••••••••••••••••••••23

■Pilot turndown test •••••••••••••••••••••••••••••••••••••••••••••••••••••24

■Ignition spark response test ••••••••••••••••••••••••••••••••••••••••••••26

■Safety shutoff test ••••••••••••••••••••••••••••••••••••••••••••••••••••••27

Chapter 4. MAINTENANCE AND INSPECTION

■Frequency of maintenance and inspection •••••••••••••••••••••••••••••28

■Troubleshooting ••••••••••••••••••••••••••••••••••••••••••••••••••••••••29

Chapter 5. SPECIFICATIONS

■Specifications ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••32

■External dimensions ••••••••••••••••••••••••••••••••••••••••••••••••••••33

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