FRS100 Multiburner Controller User`s Manual
Contents
1. 5 Terminal 6 e Allowable lead length e Type of signal lead High frequency coaxial cable 5C2V 7C2V e Allowable lead length Approx 30 m 19 Chapter 2 MOUNTING AND WIRING E Wiring the solenoid valve CAUTION S Do not connect a solenoid valve to the high potential 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 Correct connection High potential H FRS100 Power Ground fault Combustion unit Valve closed gt Fuel Ground current will not flow to the solenoid valve if the valve is wired as shown in the figure above even if faulty insulation on the high potential H causes a ground fault Accordingly the valve will not open eliminating the risk of fuel discharge Wrong connection Ground fault High potential H ad mn T7 TN a Rl Power 100 V m 5 l u Cc JE Low potential G I 2 2 7 N L O LL Valve open gt Fuel Ground current will flow to the solenoid valve if the valve is wired as shown in the figure above and if a ground fault occurs Accordingly the solenoid valve will open regardless of the flame relay causing fuel discharge 20 Chapter 2 MOUNTING AND WIRING E Wiring the surge absorber Wire as shown below when using a surge absorber model No 83968019 001 ordered se2. Check burner flame flame detector and flame relay 1K relay is not ON Check power supply at operation input terminal 7 Check flame relay The flame has not Check flame detector burner been detected flame relay valves ignition transformer and flame relay To check if the controller is operating correctly apply a flame signal input to the controller by using a flame simulator Make sure that 2K relay is turned ON and the FLAME LED is lit 29 Chapter 4 MAINTENANCE AND INSPECTION Wiring check of AUD100C 110C Advanced Ultraviolet Flame Detector used with the FRS100C Check that the wiring to the AUD100C 110C Advanced Ultraviolet Flame Detector 1s correct using the steps below e Procedure for the AUD100C AUD15C 1 Remove the AUD15C from the socket 2 Supply power to the FRS100 3 Measure the DC voltage in the socket with a digital voltmeter or tester e Connect the plus probe to the No 1 pin on the socket white lead wire e Connect the minus probe to the No 3 pin on the socket blue lead wire LA _ Digital voltmeter Tester on the market Pin No 3 Pin No 1 prove prove Socket e Reference voltage measured by a Takeda TR6841 digital multimeter Socket Probe Pin No 3 blue lead wire Pin No 1 white lead wire o Handling Precautions f the above measured value is negative the wiring is probably reversed e Before mounting the AUD15C make sure that the wiring is c
3. 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 i 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 powe
4. for operation and so forth by reference to catalogs specifications instruction manual etc in case that you intend to use Azbil Corporation s products for any purposes specified in 1 through 6 below Moreover you are required to provide your Equipment with fool proof design fail safe design anti flame propagation design and other designs of protection safety circuit on your own responsibility to ensure the reliability and safety whereby preventing problems caused by failure or nonconformity 1 For use under such conditions or in such environments as not stated in technical documents including catalogs specification and instruction manuals 2 For use of specific purposes such as Nuclear energy radiation related facilities For use outside nuclear energy controlled areas For use of Azbil Corporation s Limit Switch For Nuclear Energy Machinery or equipment for space sea bottom Transportation equipment Railway aircraft vessels vehicle equipment etc Antidisaster crime prevention equipment Burning appliances Electrothermal equipment Amusement facilities 3 Supply systems such as electricity gas water supply systems large scale communication systems and traffic air traffic control systems requiring high reliability 4 Facilities that are to comply with regulations of governmental public agencies or specific industries 5 Machinery or equipment that may affect human lives human bodies or properties 6 Other ma
5. of 0 3 Nem FRS100 Subbase Push the FRS100 into the subbase Tighten the screw and fix Flame voltage meter terminals 8 If necessary wire the flame voltage meter terminals 9 Mount the cover on the control body Direct panel mounting 1 Drill two M4 mounting holes in the panel so that the arrow on the subbase will 32 UP S M4 2 locations 2 Attach the subbase to the panel using two M4 screws at a maximum torque of 0 7 Nem be facing upward C Handling Precautions e Do not tighten the subbase mounting screws using a torque exceeding the maximum torque Doing so might damage the subbase 3 Wire the subbase terminals as instructed in 2 2 Wiring 4 Pull the bottom of the controller cover downwards to remove 5 Press the controller into the subbase with the display facing upwards 6 Tighten the mounting screw on the center of the body to fix onto the subbase with a maximum torque of 0 3 Nem 7 If necessary wire the flame voltage meter terminals 8 Mount the cover on the control body Chapter 2 MOUNTING AND WIRING 2 2 Wiring WARNING Wire terminals 1 and 2 so that they receive power continuously whenever 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 terminal 1 or 2 Doing so might cause a serious combustion equipment accident Con
6. on Since relay 1K turns Start check completion on the start check completion output from terminal output ON 8 turns on 3 Flame detection The flame detector detects the flame of the pilot e FLAME LED lights up burner Relay 2K turns on Since relay 2K turns on Flame output ON the flame output from terminal 4 turns on 4 Start contacts OFF The power supplied across terminals 7 and 2 is e Start check LED turns cut off relay 1K turns off and the power to off terminals 4 and 8 is also cut off The start check e Start check completion completion output and flame output turn off output OFF Since the flame detector detects a flame failure e FLAME LED turns off relay 2K turns off The FRS100 returns to standby Flame output OFF status and waits for the next start signal 1 Power ON 2 Start contacts ON 4 Start contacts OFF Start check 2s en detection Start contact term 7 2 Start check completion SIT 7 Flame output POWER LED EO FLAME LED EESE EE Start check LED Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 15 Chapter 2 MOUNTING AND WIRING e Ignition failure Input status FRS100 activity Output activity Power is applied across terminals 1 and 2 POWER LED lights up 2 Start contacts ON When the start contacts are closed power is applied Start check operation across terminals 7 and 2 After completion of the LED l
7. required to renew any Azbil Corporation s products every 5 to 10 years unless otherwise specified in specifications or instruction manuals 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 life due to aged deterioration recommended replacement cycles are prescribed You are required to replace parts based on such recommended replacement cycles 6 Other precautions Prior to your use of Azbil Corporation s products you are required to understand and comply with specifications e g Conditions and environment of use precautions warnings cautions notices as set forth in the technical documents prepared for individual Azbil Corporation s products such as catalogs specifications and instruction manuals to ensure the quality reliability and safety of those products 7 Changes to specifications Please note that the descriptions contained in any documents provided by Azbil Corporation are subject to change without notice for improvement or for any other reason For inquires or information on specifications as you may need to check please contact our branch offices or sales offices or your local sales agents 8 Discontinuance of the supply of products parts Please note that the production of any Azbil Corporation s products may be discontinued without notice For repairable products we wil
8. 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 e Certain chemicals or corrosive gases ammonia sulfur chlorine ethylene compounds acid etc Splashing water or excessive humidity e High temperatures Prolonged vibration If timers and auxiliary relays are needed for
9. the checks listed in Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION E Frequency of maintenance and inspection 28 Determine an inspection cycle taking into consideration the following factors e Type of equipment e Ambient conditions of installation site dust temperature etc e The effect of burner failure on equipment operation 1 Carry out the safety shutoff test described in Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION at least once a month 2 Measure the flame voltage at least once a month 3 Check the viewing window on the AUD100 series advanced ultraviolet flame detector the flame rod etc for dirt and clean as necessary 4 Check the ambient temperature 5 If equipment will be seriously damaged by a burner failure carry out this inspection more frequently Chapter 4 MAINTENANCE AND INSPECTION E Troubleshooting If a problem occurs remove the front cover of the controller Determine the operat ing state of the controller and type of trouble by checking the start check POWER and FLAME LED display states The start check LED is located in the center inside the cover and the POWER and FLAME LEDs are located on the front display O LED out LED lit POWER Start check LED FLAME Results Remedy check items LED LED Before The power is not ON Check panel power switch and startup wiring terminal 7 The flame is being detected normal operation OFF After startup terminal 7 ON False flame
10. 2 The start check is carried out and relay 1K does not turn on because a false flame is detected 3 Start contacts OFF Power across terminals 7 and 2 is cut off The FRS100 returns to standby status and waits for the next start signal If the false flame signal is continuous the FLAME LED is also ON continuously 1 Power ON Flame detection 2 Start contacts ON 3 Start contacts OFF H Start check 2s Start contact erm 7 2 SSSR Start check completion Flame output POWER LED S43 FLAME LED _ EE Start check LED Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 18 Chapter 2 MOUNTING AND WIRING E Wiring the flame detector CAUTION If the FRS100C is used connect the AUD110C detector s signal leads from terminals F and G to terminals 5 F and 6 G of the FRS respectively In the case of the AUD100C connect the detector s blue signal lead to terminal 5 F and the white lead to terminal 6 G Turning on the power when the flame detector is incorrectly wired could damage the AUD15C tube unit Wiring between an AUD100 series sensor and the FRS100C AUD110C AUD15C AUD100C AUD15C FO 5 F Blue 6 G White e Allowable lead length e Type of signal lead 2 mm 600 Vac IV indoor vinyl insulated power lead e Allowable lead length Approx 200 m Wiring between the Flame Rod and the FRS100B Flame rod 2 Terminal
11. 354 220 Vac 50 60Hz 3W max 7W max 1 Discontinuation date Dec 2011 2 Discontinuation date March 2012 3 15 C7007A C7008A when flame voltage is 2 V Flame Rod C7012A 2 C7012C 2 Ultraviolet Flame Detector AUD100C AUD15C AUD110C AUD15C Advanced Ultraviolet Flame Detector C7035A C7027A when flame voltage is 4 2 V Minipeeper Ultraviolet Flame Detector 2s Max when flame voltage is 2 V 32415 when flame voltage is 4 2 V 2s max 3415S when flame voltage is 3 5 V 2 S max when flame voltage is 3 5 V E Names of parts FRS100 body FRS50A100 subbase sold separately POWER O FLAME DIN rail p S BERS 00 FLAME RELAY Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION POWER LED green Indicates power ON OFF FLAME LED red Indicates flame detection 2K relay Indicators Cover removed Body mounting screw Connector for optional flame meter sold separately Start check operation LED green Indicates start check operation 1K relay M3 5 terminal screws 8 TILL ET amp L CT ES LI ES PAST Vas 3 LJ HOH EH LI LJ a a I T ji P U Subbase mounting holes 2 DIN rail mounting plate E Configuration Flame Detector FRS100B Ultraviolet Flame Detector C7012A C 2 Flame Rod C7007A C7008A 2 Discontinuation date March 2012 Optional Parts sold separate
12. No CP SP 1074E FRS100 Multiburner Controller User s Manual 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 Azbil Corporation 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 1999 2012 Azbil Corporation All Rights Reserved NU SAFETY PRECAUTIONS 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
13. Start check operation LED turns off Flame Pa ina 7 Blower stop Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on Chapter 2 MOUNTING AND WIRING False flame detection during startup Input status FRS100 activity Output activity Receives power across terminals 1 and 2 POWER LED lights up Blower operation If the limit switch and interlock status is normal the blower starts After completion of the prepurge the prepurge completion signal is transmitted to allow execution of the next operation Flame detection Relay 2K is turned on by a false flame signal FLAME LED lights up not turn on because a false flame is detected Ignition switch ON Even though the ignition switch contacts are closed no voltage is applied to terminal 8 and so the ignition transformer and the pilot valve do not operate 5 Ignition switch OFF No voltage is supplied from terminal 4 and the load is not energized 6 Blower stop The power across terminals 7 and 2 is cut off and the FRS100 returns to standby status and waits for the next start signal If the false flame signal is continuous the FLAME LED is also ON continuously 3 4 Burner start If the limit switch status is normal limit switch contacts ON contacts closed when the start contacts are closed power is applied across terminals 7 and 2 The start check is carried out and relay 1K does 3 Burner start contact
14. base 99 1 Unit mm DIN rail Subbase FRS50A100 sold separately FRS100 E5100 FLAME REMY POWER 1 Space required to mount and remove the body 2 Space required to mount and remove the body from DIN rail 33 M3 5 terminal screws 8 41 Chapter 5 SPECIFICATIONS FRS50A100 subbase Subbase mounting holes 2 DIN rail mounting plate el BR CRE el RE Ael RE EF Er i n SS a LAN Ep and Lay Se fn Te A be Pint A 34 Revision History date Oct 1999 CP SP HO7AE fret Edition Dec 2007 14th Edition ovale June 2009 RESTRICTIONS ON USE deleted Precautions for facility instrumentation section description added Contents changed Information on signal lead for C7012C added Flame signal output details corrected End of a book Terms and Conditions added 16th Edition li Electric shock warning item 6 changed 9 14 20 21 High voltage side changed to High potential Ground side changed to Low potential 10 to 13 15 to 18 Note added 13 Table No 3 5 and 6 changed fig changed 14 Start check circuit 2K changed to 1K 18 Description in the table added fig changed Nov 2011 17th Edition Model selection guide was changed Tables in Configuration section were changed An explanation was added to the diagram 10 to 12 The table and diagram were changed 19 CAUTION was changed Sect
15. chinery or equipment equivalent to those set forth in items 1 to 5 above which require high reliability and safety 4 Precautions against long term use Use of Azbil Corporation s products including switches which contain electronic components over a prolonged period may degrade insulation or increase contact resistance and may result in heat generation or any other similar problem causing such product or switch to develop safety hazards such as smoking ignition and electrification Although acceleration of the above situation varies depending on the conditions or environment of use of the products you are required not to use any Azbil Corporation s products for a period exceeding ten 10 years unless otherwise stated in specifications or instruction manuals 5 Recommendation for renewal Mechanical components such as relays and switches used for Azbil Corporation s products will reach the end of their life due to wear by repetitious open close operations In addition electronic components such as electrolytic capacitors will reach the end of their life due to aged deterioration based on the conditions or environment in which such electronic components are used Although acceleration of the above situation varies depending on the conditions or environment of use the number of open close operations of relays etc as prescribed in specifications or instruction manuals or depending on the design margin of your machine or equipment you are
16. d equipment 100 KQ min Ambient temperature Stand alone mounting 20 to 60 C Gang mounting 2 units or more 20 to 45 C Ambient humidity 90 RH 40 C without condensation Vibration resistance 4 9 m s max 10 to 60 Hz for 2 h each in X Y and Z directions when directly mounted on panel Insulation resistance 50 MQ min between terminals and ground terminal by 500 Vdc megger Dielectric strength No failure after applying 1500 Vac for 1min or 1800 Vac for 1 s between terminals and ground terminal excluding flame detector input of terminals 5 and 6 Lightning induced surge 10 kV 1 2 x 50 us JEC 187 surge impedance 75 Q or more when the following surge absorber is attached to a power supply contact terminal 2 and the ground terminal e Recommended surge absorber 83968019 001 100 000 operations at ordinary temperature and humidity and rated voltage Mounted on DIN rail or screw mounted when using the FRS50A100 subbase FRS100B Approx 270 g FRS100C Approx 270 g FRS50A subbase Approx 70g Optional parts Subbase Model No FRS50A100 sold separately Flame Meter Model No FRS60A Lightning induced surge absorber Model No 83968019 001 Flame Simulator for Flame Rod Model No 123514A Flame Simulator for AUD100C 110C Model No FSP300C100 C7035A C7027A Discontinuation date Dec 2011 32 Chapter 5 SPECIFICATIONS E External dimensions External dimensions when attached to the sub
17. e and ignition transformer The ignition transformer turns on the pilot valve opens and the combustion lamp lights up The flame detector detects the pilot burner flame and relay 2K turns on allowing power to be supplied through terminal 4 Since the ignition switch contacts are open power to the ignition transformer is cut and ignition transformer operation stops Because power is supplied through relays 1K and 2K power through terminal 4 continues to maintain the operation of the pilot valve When the ignition switch is turned off its N C contacts close supply ing power to the main valve which opens Relay 2K turns off after the flame response period the voltage that was supplied from terminal 4 is cut off the pilot valve and the main valve close and the combustion lamp turns off Power across terminals 7 and 2 is cut and relay 1K turns off The FRS100 returns to standby status and waits for the next start signal 3 Burner start contacts ON aan check 2s 4 ignition switch ONF 6 Flame failure cee detection 5 Ignition switch OFF mn 10s 2 Blower operation 1 Power Start check operation LED lights up e Ignition transformer ON Pilot valve opens e Combustion lamp lights up e FLAME LED lights up Ignition transformer OFF e Pilot valve continues open e Main valve opens e FLAME LED turns off Pilot valve closes e Main valve closes e Combustion lamp turns off
18. ed Refer to its instruction manual e Disconnect the loads and flame detector wiring Measure the insulation resis tance across the terminals and panel ground and make sure that the resistance is 50 MQ or more using an insulation tester or megger of 500 Vdc or more e Check that all fuel valves and cocks are closed and the combustion chamber has been completely vented E How to measure the flame signal L Handling Precautions e When using the high sensitivity model limit the flame voltage to 4 5 V or less 1 Start the controller and measure the flame voltage for each burner under vari ous conditions at startup normal operation etc 2 When measuring the flame voltage insert the tester probes into the holes to con nect to terminals A and B at the bottom front of the controller as shown below Terminal A Terminal B Tester Input impedance 100 KQ or more 0 to 5 Vdc range 3 Refer to the following table for voltage values Recommended flame voltage Checklist Make sure that flame monitoring is correct The viewing window of the flame detector Stable 2 0 Vdc or more must be free of dirt The monitoring tube must not be blocked with soot 4 If the flame signal fluctuates check the flame detector mounting position and wiring again 23 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION E Pilot turndown test WARNING Do not allow the pilot or main burner Safety Time ignition trial
19. erminals 7 and 2 Relay 1K turns on after completion of the start check 5 Ignition switch ON When the ignition switch is pushed contacts closed Ignition transformer ON power is applied from terminal 8 to the pilot valve Pilot valve opens and ignition transformer The ignition transformer Combustion lamp lights turns on the pilot valve opens and the combustion up lamp lights up If the pilot burner fails to ignite the flame detector cannot detect the pilot burner flame and relay 2K does not turn on Ignition switch OFF Since the ignition switch contacts are open power Ignition transformer OFF to the ignition transformer pilot valve and e Pilot valve closes combustion lamp is cut off Accordingly ignition e Combustion lamp turns transformer operation stops the pilot valve closes off and the combustion lamp turns off Also because relay 2K is not ON the voltage from terminal 4 by way of relays 1K and 2K is zero Therefore no voltage is supplied to the main valve which does not open Blower stop Power across terminals 7 and 2 is cut and relay Start check operation 1K turns off LED turns off The FRS100 returns to standby status and waits for the next start signal 3 Burner start contacts ON Start check 2s 6 Blower stop 2 Blower operation 4 lgnition switch ON No flame detection 5 lgnition switch 1 Power ON OFF 5 10s Limit Interlock contacts Blower operation Prepurge Pre
20. etween the minimum and maximum levels igniting the main burner five or six times Make sure that the main burner ignites smoothly every time 9 If the main burner does not ignite properly the reason is probably that the pilot flame is too small Increase the size of the pilot flame and carry out the follow ing adjustment e Either slightly take the monitor line of the flame detector away from the axis of the pilot flame or stop the iris down to correct the visible flame size Set the flame size so that the main pilot ignites smoothly at the minimum flame sensitivity 10 After making this adjustment repeat steps 5 to 8 and make sure that main burner ignition is reliable 11 When this test is completed return the manual valve for the main burner to its fully open position Check that the flame signal is appropriate 12 If any limit switch has jumper cables attached disconnect them to return the limit switch to its previous state 25 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION MH Ignition spark response test CAUTION 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 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 bu
21. f the power to the FRS100 and all connected devices Failure to do so might cause electric shock 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 terminal F 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 terminals 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 Conduct periodic inspections in accordance with the user s manual of the equipment manufacturer lf the safety shutoff has been activated check all of the items on the check lists in Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION before restarting the equipment 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 When cleaning the burner clean the flame detector as well 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
22. g Allowable ambient temperature upper limits 45 C Stand alone mounting Allowable ambient temperature upper limits 60 C L Handling Precautions If there is room leave as much space as possible between the FRS and other FRS units to allow for heat radiation If ambient temperature is close to the allowable upper limit reduce the internal temperature of the control panel by mounting a panel cooler or a cooling fan Allowable ambient temperature upper limits e Gang mounting 45 C e Stand alone mounting 60 C Chapter 2 MOUNTING AND WIRING Mounting direction DIN rail mounting e Mount in a vertical plane so that the arrow on the subbase is facing upwards n kd Ets LR r 4 WE FAN FAN FAN SB SISY TEER ii CG all i UP LS Indicator _ _ gt 1 Pull the DIN rail mounting plate downwards 2 Place the subbase on the DIN rail so that the arrow on the subbase is facing upwards 3 Lock the subbase to the DIN rail by pushing the mounting plate upward Push the DIN rail mounting plate upward Pull down Mount the subbase Chapter 2 MOUNTING AND WIRING 4 Wire the subbase terminals as instructed in 2 2 Wiring 5 Pull the bottom of the controller cover downwards to remove 6 Press the controller into the subbase with the display facing upwards 7 Tighten the mounting screw on the center of the body to fix onto the subbase with a maximum torque
23. he next operation Burner start If the limit switch and interlock status is normal Start check operation LED contacts ON limit switch contacts closed when the burner lights up start contacts are closed power is applied across terminals 7 and 2 Relay 1K turns on after completion of the start check 4 Ignition switch ON When the ignition switch is pushed contacts closed Ignition transformer ON power is applied from terminal 8 to the pilot valve Pilot valve opens and ignition transformer The ignition transformer Combustion lamp lights turns on the pilot valve opens and the combustion up lamp lights up The flame detector detects the pilot burner flame FLAME LED lights up and relay 2K turns on allowing power to be supplied through terminal 4 Ignition switch OFF Since the ignition switch contacts are open power Ignition transformer OFF to the ignition transformer is cut and ignition Pilot valve continues transformer operation stops open Because power is supplied through relays 1K and Main valve opens 2K power through terminal 4 continues to maintain the operation of the pilot valve When the ignition switch is turned off its N C contacts close supply ing power to the main valve which opens Blower stop Since the prepurge completion signal has been Pilot valve closes discontinued the power across terminals 7 and 2 Main valve closes is cut relay 1K turns off and the power to ter
24. hout first completing the trial run adjustments for this device as well as the tests specified by the equipment manufacturer 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 Check the flame current at least once per month Doing so can prevent shutdowns caused by a weak flame current signal HM Outline The following table shows the test adjustment items described in this chapter Applicable Unit Flame signal measurement method All units Pilot turndown test Units using the pilot burner Ignition spark response test All units Safety shutdown test All units o Handling Precautions e After adjusting the above items make sure that all of the adjustment requirements are satisfied All of the adjustment requirements must be satisfied by the final mounting position of the flame detector Required equipment e Tester input impedance 100 kQ or more Range 0 to 300 Vac 0 to 5 Vdc e Two jumper leads with crocodile clips AWG14 2 mm or more approximate ly 30 cm long e Insulation tester 500 Vdc megger Preliminary inspection e Check all connections e Make sure that the controller is mounted at a location within the allowable ambi ent temperature 22 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION e Make sure that the flame detector is properly mount
25. ights up start check relay 1K turns on Since relay 1K turns Start check completion on the start check completion output from terminal output ON 8 turns on 3 Ignition failure If the burner does not ignite the flame detector does not detect a burner flame and relay 2K does not turn on 4 Start contacts OFF The power supplied across terminals 7 and 2 is e Start check LED turns cut off relay 1K turns off power to terminals 4 off and 8 is cut off and the start check completion Start check completion output turns off output OFF The FRS100 returns to standby status and waits for the next start signal 1 Power ON 2 Start contacts ON 4 Start contacts OFF Start check 2s Start contact term 7 2 Start check completion BE Flame output POWER LED Ss FLAME LED RE Start check LED i RE Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 16 Chapter 2 MOUNTING AND WIRING Flame failure during combustion O Input status FRS100 activity Output activity 1 Power is applied across terminals 1 and 2 POWER LED lights up Start contacts ON When the start contacts are closed power is applied Start check operation across terminals 7 and 2 After completion of the LED lights up start check relay 1K turns on Since relay 1K turns Start check completion on the start check completion output from terminal output ON 8 turns on 3 Flame detection The flame de
26. ion Wiring between the C7035 C7027 Minipeeper Ultraviolet Flame Detector and the FRS100C was changed to Wiring between an AUD100 Series Sensor and the FRS100C Text and diagram were changed Diagram of the 121708 was deleted Optional parts details were changed Nov 2012 18th Edition Company name changed 1 3 4 23 27 29 Descriptions were changed due to the discontinuation of the C7012 End of a book Terms and Conditions was changed 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 terms and conditions for your purchase of Azbil Corporation s products field instruments control valves and control products unless otherwise stated in any separate document including without limitation estimation sheets written agreements catalogs specifications and instruction manuals 1 Warranty period and warranty scope 1 1 Warranty period Azbil Corporation s products shall be warranted for one 1 year from the date of your purchase of the said products or the delivery of the said products to a place designated by you 1 2 Warranty scope In the event that Azbil Corporation s products has any failure attributable to azbil during the aforementioned warranty period azbil shall without charge deliver a replacement for the said product to the place where you purchased or repair the said product a
27. l in principle undertake repairs for five 5 years after the discontinuance of those products In some cases however we cannot undertake such repairs for reasons such as the absence of repair parts For field instruments we may not be able to undertake parts replacement for similar reasons Azbil Corporation Advanced Automation Company 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan URL http www azbil com azbil Specifications are subject to change without notice 09 1st edition Oct 1999 18th edition Nov 2012 M
28. ly FRS100C Name Model No AUD100C AUD15C AUD110C AUD15C Advanced Ultraviolet Flame Detector Minipeeper Ultraviolet Flame C7035A C7027A Detector 1 Discontinuation date Dec 2011 FRS50A100 Flame Meter RS60A Flame simulator for AUD100C 110C AUD15C C7035A C7027A Flame Simulator for 123514A Flame Rod FSP300C100 Lightning surge absorber 83968019 001 1 Discontinuation date Dec 2011 Chapter 2 MOUNTING AND WIRING 2 1 Mounting and Wiring the Subbase CAUTION Do not install where exposed to any of the following e Certain chemicals or corrosive gases ammonia sulfur chlorine ethylene compounds acid etc e Splashing water or excessive humidity e High temperatures e Prolonged vibration 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 When installing and wiring be sure to follow the instructions in this manual and in the user s manual for the combustion equipment Mounting location Maintain space around the control as shown below for heat radiation and to facili tate mounting removal wiring and maintenance Above 50 mm min Above 50 mm min ERSEUI FLAME RELAY POWER RESHU FLAME RELAY POWER RRSHUI FLAME RELAY POWER FLAME Below 20 mm min Below 20 mm min Gang mountin
29. mentation Model selection guide Names Of palis 2 ee he metre Configuration 4203 ee sement pet cmd enis MOUNTING AND WIRING Burner flame monitoring only Wiring the flame detector Wiring the solenoid valve Wiring the surge absorber ADJUSTMENTS FOR TRIAL OPERATION S 6442 ch qereeesst coca neeaeent How to measure the flame signal Pilot turndown 1eSt 5224 te dose dre tas mr ese Ignition spark response test Safety shutoff lesb 54060 es essor one MAINTENANCE AND INSPECTION Frequency of maintenance and inspection E Troubleshooting SPECIFICATIONS Specifications Eee ed ee ee do ee craie External dimensions Vil Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION E Overview The FRS100 Multiburner Controller is a combustion safety control with a safe start circuit for use with manually ignited combustion equipment To ensure safe ty the FRS100 prevents ignition if anything abnormal is detected at start up and shuts off the fuel valve if a flame failure occurs during operation It is used in con junction with the AUD100 series advanced ultraviolet flame detector or flame
30. minal FLAME LED turns off 4 is also cut The pilot and main valves close and Combustion lamp turns the combustion lamp turns off off All loads are de energized and when the flame e Start check operation detector detects the flame failure relay 2K turns off LED turns off The FRS100 returns to standby status and waits for the next start signal 3 Burner start contacts ON 3 Bu Start check 2s 6 Blower stop 2 Blower operation 4 lgnition switch ON Flame detection 5 lgnition switch 1 Power ON OFF 5 10s Limit Interlock contacts Blower operation Prepurge Prepurge completion signal Burner start contacts term 7 2 Ignition transformer Pilot valve Main valve Combustion lamp POWER LED FLAME LED Start check LED Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 10 Chapter 2 MOUNTING AND WIRING e Ignition failure Input status FRS100 activity Output activity Receives power across terminals 1 and 2 POWER LED lights up Blower operation If the limit switch and interlock status is normal the blower starts After completion of the prepurge the prepurge completion signal is transmitted to allow execution of the next operation 3 Burner start If the limit switch and interlock status is normal Start check operation LED contacts ON limit switch contacts closed when the burner lights up start contacts are closed power is applied across t
31. nd deliver it to the aforementioned place Notwithstanding the foregoing any failure falling under one of the following shall not be covered under this warranty 1 Failure caused by your improper use of Azbil Corporation s products noncompliance with conditions environment of use precautions etc set forth in catalogs specifications instruction manuals etc 2 Failure caused for other reasons than Azbil Corporation s products 3 Failure caused by any modification or repair made by any person other than azbil or azbil s subcontractors 4 Failure caused by your use of Azbil Corporation s products in a manner not conforming to the intended usage of that product 5 Failure that the state of the art at the time of Azbil Corporation s shipment did not allow us to predict or 6 Failure that arose from any reason not attributable to Azbil Corporation including without limitation acts of God disasters and actions taken by a third party Please note that the term warranty as used herein refers to equipment only warranty and Azbil Corporation shall not be liable for any damages including direct indirect special incidental or consequential damages in connection with or arising out of Azbil Corporation s products 2 Ascertainment of suitability You are required to ascertain the suitability of Azbil Corporation s products in case of your use of the same with your machinery equipment etc hereinafter referred to as Equipment on you
32. nect loads ignition transformer solenoid valve etc directly to the output terminals of this device If they are not directly connected combustion safety cannot be ensured CAUTION If timers and auxiliary relays are needed for additional functions select ones with high reliability and be sure to design the circuit correctly Make sure the load connected to each terminal does not exceed the rating indicated in the specifications When installing and wiring be sure to follow the instructions in this manual and in the user s manual for the combustion equipment Follow all applicable regulations when doing the wiring work 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 f
33. nected 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 A WARNING If the pilot turndown test must be carried out repeatedly completely shut down all equipment each time the
34. or electrical equipment the burner body must have an earth ground connection with a resistance of less than 100 Q After the wiring is complete be sure to check that it is correct Incorrect wiring may cause damage or faulty operation Chapter 2 MOUNTING AND WIRING E Manual ignition intermittent pilot High potential Low potential Blower on off circuit Prepurge circuit Limit Interlock circuit limit switch interlock switch mm lamp l M LStart check circuit Ignition transformer Cet Prepurge Input circuit Pilot valve 1 completion Burner start 3 Pilot valve 2 0 0 oC 3 _o 0 4 Main valve 2 2K Z Combustion F m Te Flame A e Flame voltage Flame detector G amplifier circuit O TGS Ve The combustion lamp lights up when the ignition switch is turned on 1 Handling Precautions If the power supply high potential and low potential are differentiated connect the high potential to terminal 1 and the low potential to terminal 2 Chapter 2 MOUNTING AND WIRING Explanation of operation Normal operation and shutdown Input status FRS100 activity Output activity Receives power across terminals 1 and 2 POWER LED lights up Blower operation If the limit switch and interlock status is normal the blower starts After completion of the prepurge the prepurge completion signal is transmitted to allow execution of t
35. orrect 30 Chapter 4 MAINTENANCE AND INSPECTION Connecting a flame simulator o Handling Precautions e Do the operation check in one sitting and afterwards remove all test wiring at once e Do not touch terminals F and G during the operation check Doing so might cause electric shock FSP300C 1 Wire terminals F to F and G to G as shown below 2 Turn the FLAME MODE switch of the FSP300C on FRS100C S FLAME RELAY OTOS Terminal 6 G Flame mode gt switch ON 123514A FRS100B Terminal 5 ntl 6 F terminal wire G terminal wire erminal G plug Terminal F prove 123514A Connect terminal 5 to the terminal F probe and terminal 6 to the terminal G plug 31 Chapter 5 SPECIFICATIONS E Specifications Rated power supply 100 Vac 50 60 Hz 200 Vac 50 60 Hz Allowable voltage 15 to 10 of rated voltage FRS100B 3W max FRS100C 7W max Contact ratings 250VA terminal 3 4 for flame output 250 VA 1K and 2K terminal 3 8 for start check output 250 VA 1K Flame sensitivity Ignition detection level Flame voltage 1 V or less Flame out detection level FRS100B series flame voltage 0 2 V or more FRS100C series flame voltage 0 4 V or more Recommended flame Stable 2 0 Vdc or more voltage Flame signal output Use at least 0 75 mm wire a max of 10 m long with IV indoor vinyl insulation Output terminals A and B on body Required input impedance of externally connecte
36. others and to prevent damage to proper ty Be sure to observe these safety precautions Warnings are indicated when mishandling this A WARN NG product might result in death or serious injury Cautions are indicated when mishandling this A 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 0 0e A 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 con
37. parately for protection from lightning surge High potential H Low potential G Surge absorber 83968019 001 Inter lead surge absorber 187 series receptacle made by TE bS Connectivity LA z Metal mounting bracket ground side o Handling Precautions Use a JIS C 3306 0 75 mm power lead lead diameter 0 18 30 strand or higher for wiring to the power supply Attach a straight terminal equivalent to a 187 series receptacle made by TE Connectivity to one end of the power lead and keep the wire as short as possible e Since the surge absorber mounting bracket is crimped internally to make contact with the low potential side electricity can flow between them To ground the bracket attach it to a grounded metal part such as the burner housing 21 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION 7 WARNING 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 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 terminal F Before the pilot turndown test or ignition spark response test make sure that all manual fuel valves are closed Do not start regular operation of the equipment wit
38. purge completion signal Burner start contacts term 7 2 Ignition transformer Pilot valve Main valve Combustion lamp POWER LED FLAME LED Start check LED Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 11 Chapter 2 MOUNTING AND WIRING 12 Blower operation Burner start contacts ON Ignition switch ON Ignition switch OFF Flame failure occurs Blower stop Limit Interlock contacts Blower operation Prepurge Prepurge completion signal Burner start contacts term 7 2 Ignition transformer Pilot valve Main valve Combustion lamp POWER LED FLAME LED Start check LED Flame failure during combustion Input status FRS100 activity Output activity POWER LED lights up If the limit switch and interlock status is normal the blower starts After completion of the prepurge the prepurge completion signal is transmitted to allow execution of the next operation If the limit switch and interlock status is normal the blower starts The prepurge completion signal is transmitted to allow execution of the next operation If the limit switch and interlock status is normal limit switch contacts closed when the burner start contacts are closed power is applied across terminals 7 and 2 Relay 1K turns on after completion of the start check When the ignition switch is pushed contacts closed power is applied from terminal 8 to the pilot valv
39. r 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 Q 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 Q Q Q Q Q Q 6 S 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 wi
40. r own responsibility taking the following matters into consideration 1 Regulations and standards or laws that your Equipment is to comply with 2 Examples of application described in any documents provided by Azbil Corporation are for your reference purpose only and you are required to check the functions and safety of your Equipment prior 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 Corporation 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 fool proof design fail safe design anti flame propagation design safety design or the like so that the said Equipment may satisfy the level of the reliability and safety required in your use whereby preventing any occurrence of physical injuries fires significant damage and so forth 3 Precautions and restrictions on application Azbil Corporation s products other than those explicitly specified as applicable e g azbil Limit Switch For Nuclear Energy shall not be used in a nuclear energy controlled area radiation controlled area Any Azbil Corporation s products shall not be used for with medical equipment In addition you are required to conduct a consultation with our sales representative and understand detail specifications cautions
41. re to give careful consideration to the safety guidelines listed below For safety standards for industrial facilities using combustion equipment see the technical guidelines published by the Ministry of Health Labour and Welfare For general safety rules for industrial combustion furnaces see JIS B 8415 For technical safety guidelines for gas combustion furnaces in industrial use see publications by the Japan Gas Association For technical safety guidelines for gas boiler combustion equipment see publica tions by the Japan Gas Association Important points for ensuring safety L Connect the load directly to the FRS100 2 Design the interlock so that it can directly cut off power to the load 3 Be sure to use a safe startup circuit upon startup 4 Do not set up a bypass such as manual operation for any load 5 Have a redundant main valve and pilot valve Precautions for system design Since the FRS100 does not have purge or ignition functions they must be provid ed externally Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION E Model selection guide Power FI failur Standard model High sensitivity model FRS100C200 200 Vac 50 60Hz FRS100C3800 220 Vac 50 60Hz FRS100C104 100 Vac 50 60Hz FRS100C204 200 Vac 50 60Hz FRS100C304 220 Vac 50 60Hz FRS100C150 100 Vac 50 60Hz FRS100C250 200 Vac 50 60Hz FRS100C350 220 Vac 50 60Hz FRS100C154 100 Vac 50 60Hz FRS100C254 200 Vac 50 60Hz FRS100C
42. rner flame goes out As a result fuel will continue to be discharged causing a very serious explosion hazard This test should be carried out on any equipment that uses an ultraviolet flame detector The test is to check that the ultraviolet flame detector does not respond to UV rays emitted from the ignition spark AUD100 series advanced ultraviolet flame detector Carry out the following test to check that the AUD100 series advanced ultraviolet flame detector or flame rod does not respond to the UV rays emitted from the igni tion spark so that the FLAME LED does not light up 1 Close the manual fuel valves to the pilot and main burners 2 Start the combustion equipment and measure the flame voltage in the pilot igni tion sequence to check whether or not there is an effect on the flame voltage 3 If the FLAME LED is lit make adjustments using the following procedure while referring to the equipment user s manual e Move of the AUD100 series or flame rod so that there is no effect e Put a shielding plate in the optical path of the AUD100 series so that the effect of the spark on the flame voltage is 0 4 Vdc or less 26 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION Cautions regarding UV sources other than flames The table below shows various radiation sources other than the burner flame that may activate the flame detector Make sure that the flame voltage is not affected under any conditions of the flame response tes
43. rod for batch operation of a burner For continuous burner operation nonstop combus tion for 24 h or longer instead of the FRS100 use the AUR350C which has a continuous self checking function Because the FRS100 does not have an ignition function it is used for systems in which an operator ignites the burner manually This device should be used in com bination with external instrumentation that supplies a purge function Key Characteristics of the FRS100 Compatible Purge Ignition Flame Behavior if Compatible burner function function monitoring flame failure flame operation type occurs detectors Does not recycle E Features e Upon equipment startup the FRS100 checks both itself and the flame detector If anything abnormal is detected the FRS100 prevents ignition to ensure safety The FRS100 is designed to be compact and can be plugged into the wiring sub base The sub base can be mounted by screws or onto a DIN rail e The power supply state and ignition detection can be verified easily from the LEDs on the front display Completion of the start check is indicated by the LED on the center of the body behind the front cover e Flame voltage output 0 to 5 Vdc can be checked by the FSP136A100 or continuously monitored by a panel meter or recorder The FRS100 has a dedicated connector so that the optional FRS60A Flame Meter can be attached E System configuration In terms of the overall system the FRS100 serves a
44. s ON 6 Blower stop Flame detection Start check 2s _ 2 Blower operation 4 lgnition switch ON 1 Power ON 5 ignition switch OFF 5 10s Limit Interlock contacts Blower operation Prepurge Prepurge completion signal Burner start contacts term 7 2 Ignition transformer Pilot valve Main valve Combustion lamp POWER LED FLAME LED Start check LED Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 13 Chapter 2 MOUNTING AND WIRING E Burner flame monitoring only In a case where the FRS100 is not used in its usual combustion safety role of shutting valves etc High potential Low potential Rs ORD Pa AR 7 Power a Power circuit 2 Burner start contacts _ L Start check completion Contact output common Flame output F ce Flame voltage Flame detector G ei 0 5 Vde Subbase J Handling Precautions If the power supply high potential and low potential are differentiated connect the high potential to terminal 1 and the low potential to terminal 2 14 Chapter 2 MOUNTING AND WIRING Explanation of operation Normal operation Input status FRS100 activity Output activity Power is applied across terminals 1 and 2 POWER LED lights up Start contacts ON When the start contacts are closed power is applied Start check LED lights across terminals 7 and 2 After completion of the up start check relay 1K turns
45. s the flame monitoring device It is used as shown in the diagram below High limit controller Temperature controller Air pressure lower interlock Exhaust detector T C T C j KR Combustion or chamber Fuel H x ue En Gas pressure PV PV lower interlock Gas pressure Ignition Combustion equipment upper interlock transformer Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION E Security function The FRS100 is designed to ensure safety and plays an important safety role by monitoring the burner operation and the flame L Combustion monitoring and safety shutoff e Detects flame failure in the burner and quickly shuts off the fuel and shuts down the burner e When an ignition failure flame failure or flame out occurs the FRS100 fol lows a fixed sequence in shutting down each piece of equipment Startup operation and shutoff of combustion equipment e The FRS100 operates each device according to a predetermined sequence and timing Safe startup e At every startup signal the FRS100 checks for false flame in the flame detec tor and flame detection circuit e If a problem is detected the FRS100 does not start the burner Redundant design e Maintains safety even if its own self check circuit fails e Will not deviate from the proper ignition sequence E Precautions for facility instrumentation In designing facilities that use combustion safety devices be su
46. t Ultraviolet ray sources Red hot chamber wall with temperature 1371 C or more Sparks Ignition transformer e Welding arc e Lightning Gas laser Sunlamp Germicidal lamp Strong flashlight toward UV sensor Gamma ray and X ray sources Regression analyzer Electron microscope X ray camera High voltage vacuum switch High voltage capacitor Radioactive isotope Other sources producing ultraviolet rays gamma rays and X rays M Safety shutoff test After all operational adjustments have been completed carry out the safety shutoff test e Pilot ignition failure ignition failure 1 Close the manual fuel valves to the pilot and main burners 2 Press the ignition switch to begin combustion 3 The pilot valve opens for pilot burner ignition but ignition is not possible Check that the FLAME LED does not light up and the main valve does not open Do not hold the ignition switch for a long time e Flame failure during normal combustion 1 Open the pilot and main manual fuel valves 2 Press the ignition switch to start operation 3 When the sequence has progressed correctly and normal combustion main valve open has begun close the pilot and main manual fuel valves to put out the burner flame Then check that the flame failure is detected and that safety shutoff occurs correctly 27 Chapter 4 MAINTENANCE AND INSPECTION WARNING Before removing mounting or wiring the FRS100 be sure to turn of
47. tector detects the flame of the pilot e FLAME LED lights up burner Relay 2K turns on Since relay 2K turns on Flame output ON the flame output from terminal 4 turns on Flame failure occurs After the flame response period relay 2K turns off e FLAME LED turns off the voltage supplied from terminal 4 is cut off and Flame output OFF the flame output turns off Start contacts OFF The power supplied across terminals 7 and 2 is e Start check LED turns cut off relay 1K turns off power to terminals 4 and off 8 is cut off and the start check completion output Start check completion turns off output OFF The FRS100 returns to standby status and waits for the next start signal 1 Power ON 2 Start contacts ON Start check 2s 4 Flame failure Flame response detection F 5 Start contacts OFF Start contact term 7 2 p aetect Start check completion SRE Flame output POWER LED a a EE FLAME LED it DE Start check LED CS UE gt Elapsed time Note It is possible that relay 2K may turn ON when the power is turned on 17 Chapter 2 MOUNTING AND WIRING False flame is detected at startup No Input status FRS100 activity Output activity 1 Power is applied across terminals 1 and 2 POWER LED lights up Flame detection Relay 2K is turned on by a false flame signal FLAME LED lights up 2 Start contacts ON When the start contacts are closed power is applied across terminals 7 and
48. th 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 C 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 vi Contents SAFETY PRECAUTIONS Conventions Used in This Manual Chapter 1 Chapter 2 2 1 2 2 Chapter 3 Chapter 4 Chapter 5 OVERVIEW AND PRODUCT CONFIGURATION O a ee ee dense de den san ete mosc dos PAS a de co oo System CONTIQUIANION 2 25 453560 seras secoue etes Security NGUN Sr ere ee ae Precautions for facility instru
49. 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 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 burner this device will not be able to detect a flame failure in the main burner 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 lf 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 regulator settings to their previous states If operation begins without the above steps damage to the equipment gas leak or explosion may result CAUTION Q 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 test is intended to check that the flame is reliabl
50. y transferred to the main burn er when the flame detector detects the pilot flame even 1f gas pressure and air pres sure change to their worst conditions L Handling Precautions e If a fuel pressure limit switch is used and its contacts are open turn it ON with a jumper cable during this test Test procedure 1 Turn the operation switch OFF 2 Close the manual valves to stop the gas supply to the pilot burner and main burner 3 Open the manual valve to the pilot burner 4 Turn the power switch ON and then turn the start switch on and press and hold the ignition switch The pilot will ignite and the pilot valve will open Ignition will begin and the combustion lamp will light Release the ignition switch 24 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION 5 Close the pilot manual valve slowly The pilot flame will gradually grow small er Continue to close the manual valve until the flame detector can not detect the flame Record the gas pressure immediately before the flame relay turns OFF and the combustion lamp is lit up 6 Open the manual valve for the pilot slowly to adjust the pressure to a level immediately before the combustion lamp goes off Then press the ignition switch again to ignite the pilot 7 Release the ignition switch Open the manual valve for the main burner and check that the main burner ignites smoothly within one second after the valve is opened 8 Try different gas pressures b
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