FRS100 Multiburner Control User's Manual
Contents
1. Pull down Place the subbase LT Push the D rail JT mounting plate into the DIN rail 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 of 0 3Nem FRS100 Subbase ED FLAME RELAY POWER 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 be facing upward 32 UP i M4 2 locations T 2 Attach the subbase to the panel using two M4 screws at a maximum torque of 0 7Nem 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 3Nem 7 If necessary wire the flame voltage meter terminals 8 Mount the cover on the control body o Handli2. Valve open 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 separately for protection from lightning surge High voltage side H m Ground side G Surge absorber 83968019 001 Metal mounting bracket ground M o Handling Precautions e Use a JIS C 3306 0 75mm power lead lead diameter 0 18 30 strand or higher for wiring to the power supply e Attach a Faston receptacle 187 made by AMP to one end of the power lead and make the wire connection as short as possible e Ground the surge absorber mounting bracket by attaching to a grounded metal part such as the burner body 21 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION 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 p
3. No CP SP 1074E FRS100 Multiburner Control User s Manual Thank you for purchasing the FRS100 Multiburner Control 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 Yamatake Corporation RESTRICTIONS ON USE This product has been designed developed and manufactured for general purpose application in machinery and equipment Accordingly when used in applications outlined below special care should be taken to implement a fail safe and or redundant design concept as well as a periodic maintenance program e Safety devices for plant worker protection e Start stop control devices for transportation and material handling machines e Aeronautical aerospace machines e Control devices for nuclear reactors Never use this product in applications where human safety may be put at risk 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 a
4. upper interlock transformer 1 Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION MH Security function The FRS100 is designed to ensure safety and plays an important safety role by monitoring the burner operation and the flame 1 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 2 Startup operation and shutoff of combustion equipment e The FRS100 operates each device according to a predetermined sequence and timing 3 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 4 Redundant design e Maintains safety even if its own self check circuit fails e Will not deviate from the proper ignition sequence M Precautions for facility instrumentation In designing facilities that use combustion safety devices be sure to give careful consideration to the safety guidelines listed below e For safety standards for industrial facilities using combustion equipment see the technical guidelines published by the Ministry of Health Labour and Welfare e For general safety rules for industrial combustion furnaces see JIS B 8415 e For technical safety guidelines for gas combustion
5. Start check completion Flame output Flame voltage 0 5Vdc e When the high voltage side is distinguishable from the ground side con nect the high voltage side to terminal 1 and the ground side to terminal 2 14 Chapter 2 MOUNTING AND WIRING Explanation of operation e Normal operation Input status FRS100 activity Output activity Power ON Power is applied across terminals 1 and 2 POWER LED lights Start contacts ON Pressing the start contact supplies power across e Start check operation terminals 7 and 2 After completion of the start LED lights up check relay 1K turns on Since relay 1K turns on Start check completion the start check completion output from terminal output turns on 8 turns on Flame detection The flame detector detects the flame of the pilot 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 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 St
6. F probe terminal 6 to terminal G and terminal 6 to the terminal G plug 31 Chapter 5 SPECIFICATIONS E Specifications 200Vac 50 60 Hz FRS100B 3W max FRS100C 7W max Contact ratings 250VA terminal 3 4 for flame output 250VA 1K and 2k terminal 3 8 for start check output 250VA 1K Flame sensitivity Ignition detection level Flame voltage 1V or less Flame out detection level FRS100B series flame voltage 0 2V or more FRS100C series flame voltage 0 4V or more Flame signal output Use at least 0 75mm wire a max of 5m long with IV indoor vinyl insulation Output terminals A and B on body Required input impedance of externally connected equipment 100kQ 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 condensation not allowed Vibration resistance 4 9m s max 10 to 60Hz for 2h each in X Y and Z directions when directly mounted on panel Insulation resistance 50MQ min between terminals and ground terminal by 500Vdc megger Dielectric strength No failure after applying 1500Vac for 1min or 1800Vac for 1s between terminals and ground terminal excluding flame detector input of terminals 5 and 6 Lightning induced surge 10kV 1 2 x 50us JEC 187 surge impedance 75Q or more when the following surge absorber is attached to a power supply contact terminal 2 and the ground terminal e Recommended surge absorbe
7. 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 Q After the wiring is complete be sure to check that it is correct Incorrect wiring may cause damage or faulty operation Q Q Q Q Q Q Q Q Q Q Q Chapter 2 MOUNTING AND WIRING MH Manual ignition intermittent pilot High voltage side Ground side Interlock contact Emergency j normal status stop switch RRQ switch an Starting purge O O Q Q O O Purge timer Stop switch During purge Purge completion Ignition transformer Pilot valve SS ea lamp FI pO yam votage Purge completion 102X Start contact 1 F Subbase o Handling Precautions e When the high voltage side is distinguishable from the ground side con nect the high voltage side to terminal 1 and the ground side to terminal 2 Chapter 2 MOUNTING AND WIRING Exp
8. e Flame failure during combustion Input status FRS100 activity Output activity Power ON Power is applied across terminals 1 and 2 POWER LED lights Start contacts ON Pressing the start contact supplies power across Start check operation terminals 7 and 2 After completion of the start LED lights up check relay 1K turns on Since relay 1K turns on Start check completion the start check completion output from terminal output turns on 8 turns on 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 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 3 Flame Flame response detection p 5 Start contacts OFF Start contact term 7 2 Start check completion CR Flame output CEE POWER LEO SSSR FLAME LED oi Start ch
9. furnaces in industrial use see publications by the Japan Gas Association Important points for ensuring safety 1 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 P z Model Model No Rated power supply ae Flame detector a flame voltage 4 2V High sensitivity 7W max 3 1s model flame voltage 3 5V FRS100C154 100Vac 50 60Hz 2s max FRS100C254 200Vac 50 60Hz flame voltage 3 5V FRS100C100 100Vac 50 60Hz 7W max 3 1s FRS100C200 200Vac 50 60Hz flame voltage 4 2V Flame Rod C7007A C7008A Ultraviolet Flame Detector C7012A C7012C Minipeeper Ultraviolet Flame Detector C7035A C7027A Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION E Names of parts FRS100 body FRS50A100 subbase sold separately r POWER LED green Indicates power ON OFF FLAME LED red Indicates flame detection 2K relay Indicator DIN rail f ei 4 Cover removed Body mounting screw Connector for optional flame meter sold separately Start c
10. 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 060660 60 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 foll
11. steps below e Procedure for the C7035 1 Remove the ultraviolet tube 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 wire e Connect the minus probe to the No 3 pin on the socket blue wire Digital voltmeter Ee Pin No 3 Tester on the market Oprove CS Pin No 1 prove Socket e Reference voltage by TR6841 of ADVANTEST Power voltage Observed voltage 100 160 to 210Vdc 110 180 to 230Vdc Handling Precautions e f the above measured value is negative the wiring is probably reversed e Before mounting the UV tube make sure that the wiring is correct 30 Chapter 4 MAINTENANCE AND INSPECTION Connecting a flame simulator models FSP300 121708 and 123514 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 e FSP300 1 Wire terminals F to F and G to G as shown below 2 Turn the FLAME MODE switch of the FSP300 on FRS100C FLAME RELAY FSP 300C Terminal 6 G Flame mode gt switch ON e 121708 e 123514A FRS100B FRS100B Terminal 6 F terminal wire G terminal wire G terminal wire prove 123514A Connect terminal 5 to terminal F and Connect terminal 5 to the terminal
12. CATIONS M Specifications E External dimensions vil Overview 288805 cateeee dae tide tse erdemeemededadamdeg es ams E FOAUINES 2558 AE E tireur den EE E I EE RE Gee NEe eee eE SSS System configuration Security MHCHON tinct ire tienne Precautions for facility instrumentation Model selection guide Names of parts CONIGUIAUGN 5 ririscmermenmerenesemnetemaieenrens antenne Chapter 1 OVERVIEW AND PRODUCT CONFIGURATION MH Overview The FRS100 Multiburner Control is a combustion safety control with a safe start circuit for use with manually ignited combustion equipment To ensure safety 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 conjunc tion with an ultraviolet flame detector or flame rod for batch operation of a burner For continuous burner operation nonstop combustion for 24h 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
13. F 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 tart tacts ON 3 S ar S sO Start check 2s 6 Start contacts OFF 2 Operation switch 4 Ignition switch 1 Power ON No flame detection 5 ignition switch 1 OFF 5 10s Interlock contact Operation switch z i i Stop switch o Purge timer 100T During purge 101X ez Purge completion 102x a Start contact term 7 2 _ Ignition transformer Pilot valve Main valve Combustion lamp POWER LED FLAME LED os StartcheckLED Li M Elapsed time 11 Chapter 2 MOUNTING AND WIRING e Flame failure during combustion Input status FRS100 activity Output activity Power ON Receives power across terminals 1 and 2 POWER LED lights up Push button If the system is ready for operation with interlock Purge completion 102X operation switch ON contacts in their normal state closed when the operation button is pushed the prepurge begins When the time preset for the purge timer 100T has elapsed the purge completion relay 102X is energized After the prepurge ends the FRS100 accepts the following operations Start contacts ON If the limit switch status is normal contacts closed Start check operation LED pushing the start button applies powe
14. Vac IV indoor vinyl insulated power lead e Allowable lead length Approx 200m Wiring between the Flame Rod and the FRS100B Flame rod Terminal 5 Terminal 6 e Allowable lead length e Type of signal lead High frequency coaxial cable 5C2V 7C2V e Allowable lead length Approx 30m Wiring between the C7012A C7012C Ultraviolet Flame Detector and the FRS100B Terminal 5 Terminal 5 _ F Terminal A i TION Black t Terminal taa ii G G e Allowable lead length e Type of signal lead High frequency coaxial cable 5C2V 7C2V e Allowable lead length Approx 50m 19 Chapter 2 MOUNTING AND WIRING E Wiring the solenoid valve CAUTION Do not connect a solenoid valve to the high voltage 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 Correct connection High voltage side H 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 voltage side H causes a ground fault Accordingly the valve will not open eliminating the risk of fuel discharge Wrong connection Ground fault High voltage side H NN Power Ground side G Combustion unit
15. ame failure is detected and that safety shutoff occurs correctly 27 Chapter 4 MAINTENANCE AND INSPECTION WARNING Before wiring mounting or removing this device be sure to turn the power off Wiring with the power on can result in an 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 Q Q 9 Q Q Q 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 If 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 li
16. anel power switch and wiring terminal 7 OFF After startup The flame is being terminal 7 detected normal ON operation The flame has not Check flame detector burner been detected flame relay valves ignition transformer and flame relay False flame Check burner flame flame detector and flame relay 1K relay is not ON Check power supply at operation input terminal 7 Check 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 The following table shows the required flame voltages FRS100C Standard model 2V min High sensitivity model 3V min FRS100B Standard model 2V min How to connect the flame simulator e 123514A B flame simulator Contact the terminal 5 lead wire to the probe end Contact the terminal 6 lead wire to the plug end e 121708 flame simulator Contact the terminal 5 to the F lug Contact the terminal 6 to the G lug o Handling Precautions e Keep the check time short and remove the simulator promptly after completion of the check e Do not touch the terminals F and G during operation or during the check Doing so might cause electric shock 29 Chapter 4 MAINTENANCE AND INSPECTION Wiring check of ultraviolet flame detector used with the FRS100C Check that the wiring to the ultraviolet flame detector is correct using the
17. art contacts OFF Start check 2s as detection Start contact term 7 2 Start check completion RS Flame output C E POWER LED EEEE FLAME LED BE Startcheck LED M Elapsed time 15 Chapter 2 MOUNTING AND WIRING 16 e Ignition failure Input status FRS100 activity Output activity Power ON Power is applied across terminals 1 and 2 POWER LED lights Start contacts ON Ignition failure Pressing the start contact supplies power across Start check operation terminals 7 and 2 After completion of the start LED lights up check relay 1K turns on Since relay 1K turns on Start check completion the start check completion output from terminal output turns on 8 turns on If the burner does not ignite the flame detector does not detect a burner flame and relay 2K does not turn on Start contacts OFF Start contact term 7 2 rs Start check completion ESS Flame output POWER LED EE FLAME LED Start check LED 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 e 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 Elapsed time Chapter 2 MOUNTING AND WIRING
18. as shown below for heat radiation and to facili tate mounting removal wiring and maintenance Above 50mm min Above 50mm min GRMN FLAME RELAY POWER WRENN FLAME RELAY POWER RERNA FLAME RELAY POWER FLAME 20mm min lt _ lt gt 20mm min 20mm min 20mm min Below 20mm min Below 20mm min Gang mounting Stand alone mounting o Handling Precautions e 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 e Mount a vertical plane so that the arrow on the subbase is facing upwards EN es aa sie ANA KA m U g WBE FLAME RELAY OWER FLAME Indicator _ gt e Do not mount below direction WYK DIN rail mounting 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 Push in DIN rail mounting plate into the DIN rail E Aaa UP ee SS
19. ase 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 between 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 M Ignition spark response test 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 Ultraviolet f
20. 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 occurs detectors type e Ultraviolet sensor Flame rod E Features 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 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 Flame voltage output 0 to 5Vdc 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 MH System configuration In terms of the overall system the FRS100 serves as the flame monitoring device It is used as shown in the diagram below High limit controller Temperature Air pressure controller lower interlock Flame Exhaust detector T C TIC Combustion chamber Gas pressure lower interlock 7 Gas pressure Ignition Combustion equipment
21. eck LED Elapsed time 17 Chapter 2 MOUNTING AND WIRING 18 e False flame is detected at startup Input status FRS100 activity Output activity Power ON Power is applied across terminals 1 and 2 POWER LED lights Start contacts ON By pushing the start contacts power is applied FLAME LED lights across terminals 7 and 2 The start check is carried out and relay 1K does not turn on because a false flame is detected Start contacts OFF Start contact erm 7 2 SSSR Start check completion Flame output POWER LED FLAME LED Start check LED moy i Power across terminals 7 and 2 is cut off The FLAME LED turns off FRS100 returns to standby status and waits for the next start signal 1 Power ON Flame detection 2 Start contacts ON 3 Start contacts OFF j Start check 2s Elapsed time Chapter 2 MOUNTING AND WIRING E Wiring the flame detector CAUTION Q Connect the blue signal lead from the Minipeeper 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 UV tube Wiring between the C7035 C7027 Minipeeper Ultraviolet Flame Detector and the FRS100C iis C7027A Terminal 5 F Blue Terminal 6 G White Terminal 6 G White C7035A Terminal 5 F Blue e Allowable lead length e Type of signal lead 2mm2 600
22. elay 1K does not turn on because a false flame is detected 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 The ignition switch contacts open and relays 1K and 2K remain off No voltage is supplied from terminal 4 and the load is not energized The power across terminals 7 and 2 is cut off and the FRS100 returns to standby status and waits for the next start signal Start contacts ON Ignition switch ON Ignition switch OFF Start contacts OFF FLAME LED turns off 3 Start contacts ON Flame detection 2 Operation 6 Start contacts OFF Start check 2s 1 Power ON Interlock contact Operation switch Stop switch Purge timer 100T During purge 101X Purge completion 102X __ SSI Start contact term 7 2 __ re Ignition transformer Pilot valve Main valve i Combustion lamp POWER LED SE FLAME LED SE A Start check LED D it i Elapsed time 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 voltage side Start contact Operation input circuit Contact output common 2K LL Flame amplifier circuit Subbase o Handling Precautions Ground side
23. er 07 Specifications are subject to change without notice Printed in Japan 1st Edition Issued in Oct 1999 14th Edition Issued in Dec 2007
24. fe 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 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 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 The power is not ON Check p
25. flame detector is incorrectly wired could damage the UV tube 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 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
26. han 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 test Ultraviolet ray sources Red hot chamber wall with temperature 1260 C or more Sparks e 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 MH 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 fl
27. heck operation LED green Indicates start check operation 1K relay M3 5 terminal screws 2 t DIN rail mounting plate Flame voltage meter terminals FRS50A100 subbase sold separately M3 5 terminal screws 8 DIN rail Subbase mounting holes 2 DIN rail mounting plate MH Configuration Flame Detector FRS100B FRS100C Name Model No Ultraviolet Flame Detector C7012A C Flame Rod C7007A C7008A Minipeeper Ultraviolet Flame C7035A C7027A Detector Optional Parts sold separately Model No Name Model No FRS50A100 Flame Meter RS60A Flame simulator for FSP300 Flame Simulator for 123514A 121708 C7035A C7027A Flame Rod Lightning surge absorber 83968019 001 Name Model No 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
28. ilot turndown test or ignition spark response test make sure that all manual fuel valves are closed Do not start regular operation of the equipment without 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 E 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 100kQ or more Range 0 to 300Vac 0 to 5Vdc e Two jumper leads with crocodile clips AWG14 2mm or more approximately 30cm long e Insulation tester 500Vdc megger Preliminary inspection e Check all connections e Make sure that the controller is mounted at a location withi
29. inues Since power is supplied through relays 1K and 2K open power through terminal 4 continues to maintain the Main valve opens 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 Start contacts OFF The power applied across terminals 7 and 2 is cut Pilot valve closes relay 1K turns off and the power to terminal 4is Main valve closes also cut The pilot valve and main valve close and FLAME LED turns off the combustion lamp turns off All loads are de energized and when the flame Combustion lamp turns detector detects the flame failure relay 2K turns off off The FRS100 returns to standby status and waits e Start check operation for the next start signal LED turns off tart tacts ON 3 S a cones sO Start check 2s 6 Start contacts OFF 2 Operation switch 4 lgnition switch 1 Power ON Flame detection 5 ignition switch 1 OFF 5 10s Interlock contact Operation switch Stop switch o Le 0 Purge timer 100T _ During purge 101X Pd Purge completion 102X NS Start contact term 7 2 __ et Ignition transformer Zai Ss Pilot valve Main valve Combustion lamp POWER LED FLAME LED Start check LED Elapsed time 10 p Chapter 2 MOUNTING AND WIRING e Ignition failure Input status FRS100 activity Output activity Power ON Receives power ac
30. lame detector 7 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 burner flame goes out As a result fuel will continue to be discharged causing a very serious explosion hazard Carry out the following test to check that the ultraviolet flame detector or flame rod does not respond to the UV rays emitted from the ignition 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 ultraviolet sensor or flame rod so that there is no effect e Put a shielding plate in the optical path of the ultraviolet sensor so that the effect of the spark on the flame voltage is 0 4Vdc or less 26 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION Cautions regarding UV sources other than flames The table below shows various radiation sources other t
31. lanation of operation e Normal operation and shutdown Input status FRS100 activity Output activity Power ON Receives power across terminals 1 and 2 POWER LED lights up Push button If the system is ready for operation with interlock Purge completion 102X operation switch ON contacts in their normal state closed when the operation button is pushed the prepurge begins When the time preset for the purge timer 100T has elapsed the purge completion relay 102X is energized After the prepurge ends the FRS100 accepts the following operations Start contacts ON If the limit switch status is normal contacts closed Start check operation LED pushing the start button applies power across lights terminals 7 and 2 Then after completion of the start check relay 1K turns on Ignition switch ON When the ignition switch is pushed contacts closed e Ignition transformer ON terminal 8 supplies power to the pilot valve and e Pilot valve opens ignition transformer The ignition transformer turns on and the pilot valve opens The flame detector detects the pilot burner flame FLAME LED lights Relay 2K turns on When relay 2K turns on power Combustion lamp lights is supplied through terminal 4 and the combustion lamp lights up Ignition switch OFF The N O contacts of the ignition switch open cutting Ignition transformer OFF power to the ignition transformer which turns off e Pilot valve cont
32. lectrical 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 0e 0e 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 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 equipment manufacturer 6 o 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
33. mpers 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 o Handling Precautions e If a fuel pressure limit switch is used and its contacts are open turn it ON with a jamper 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 Rele
34. n error or omis sion please contact Yamatake Corporation In no event is Yamatake Corporation liable to anyone for any indirect special or consequential damages as a result of using this product 1999 Yamatake Corporation ALL RIGHTS RESERVED M SAFETY PRECAUTIONS J E About Icons The safety precautions described in this manual are indicated by various icons Please be sure you read and understand the icons and their meanings described below before reading the rest of the manual Safety precautions are intended to ensure the safe and correct use of this prod uct to prevent injury to the operator and others and to prevent damage to proper ty Be sure to observe these safety precautions Warnings are indicated when mishandling this A WA R N I N G 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 A Use caution when handling the product S The indicated action is prohibited Q Be sure to follow the indicated instructions 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 24h or longer This device does not have the prepurge and ignition sequencing func tions required for burner ignition Use this device as part
35. n the allowable ambi ent temperature 22 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION e Make sure that the flame detector is properly mounted 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 50MQ or more using an insulation tester or megger of 500Vdc 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 o Handling Precautions e When using the high sensitivity model limit the flame voltage to 4 5V 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 SS Terminal B Tester A O O 0 to 5Vdc range Input impedance 100kQ or more Black Red 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 2Vdc min must be free of dirt The monitoring tube must not be blocked with soot 4 If the flame signal fluctuates check the flame detect
36. ng Precautions e Do not tighten the subbase mounting screws using a torque exceeding the maximum torque Doing so might damage the subbase 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 Connect 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 A 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
37. 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 wiring mounting or removing this device be sure to turn the power off Wiring with the power on can result in an electric shock Do not connect a solenoid valve to the high voltage 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 e
38. or mounting position and wiring again 23 Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION M Pilot turndown test This test is intended to check that the flame is reliably transferred to the main burn er when the flame detector detects the pilot flame even if gas pressure and air pres sure change to their worst conditions 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 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 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 ju
39. owing conventions are used in this manual CJ 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 OVERVIEW AND PRODUCT CONFIGURATION Chapter 2 MOUNTING AND WIRING 2 1 Mounting and Wiring the Subbase 2 2 WING ss 460s ms ner torni Teese ead Reet tanto Ee E Burner flame monitoring only E Wiring the flame detector E Wiring the solenoid valve E Wiring the surge absorber Chapter 3 ADJUSTMENTS FOR TRIAL OPERATION OUTING eens iets meme ane dee eine den en et How to measure the flame signal Pilot t rndown test 2 23 oireet aed eae eae poses Ignition spark response test Safety shutoff 16St Er dire ideas bebe raies EEES Chapter 4 MAINTENANCE AND INSPECTION M Frequency of maintenance and inspection M Troubleshooting Chapter 5 SPECIFI
40. r 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 Mass FRS100B Approx 270g FRS100C Approx 270g 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 121708 Flame Simulator for C7035A C7027A Model No FSP300C 32 Chapter 5 SPECIFICATIONS E External dimensions FRS100 mounted on FRS50A100 99 1 Unit mm 84 DIN rail Subbase FRS50A100 sold separately FRS100 2 EI FLE EUX O POER f A il i i ee ee EE O EE E E 1 Space required to mount and remove the body 2 Space required to mount and remove the body from DIN rail 33 Chapter 5 SPECIFICATIONS FRS50A100 subbase M3 5 terminal screws 8 Subbase mounting holes 2 DIN rail mounting plate NA ees CAN in D SE J SL l a ANT Le DIN rail a U T en 34 Revision History date CP SP 1074E 14th Edition sf Alloverrevision Allover revision revision azbil Yamatake Corporation Advanced Automation Company 1 12 2 Kawana Fujisawa Kanagawa 251 8522 Japan URL http www azbil com Printed on recycled pap
41. r across lights terminals 7 and 2 Then after completion of the start check relay 1K turns on Ignition switch ON When the ignition switch is pushed contacts closed e Ignition transformer ON terminal 8 supplies power to the pilot valve and e Pilot valve opens ignition transformer The ignition transformer turns on and the pilot valve opens The flame detector detects the pilot burner flame FLAME LED lights Relay 2K turns on When relay 2K turns on power Combustion lamp lights is supplied through terminal 4 and the combustion lamp lights up Ignition switch OFF The N O contacts of the ignition switch open cutting Ignition transformer OFF power to the ignition transformer which turns off Pilot valve continues Since power is supplied through relays 1K and 2K open power through terminal 4 continues to maintain the Main valve opens 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 Flame failure occurs Relay 2K turns off after the flame response period FLAME LED turns off the voltage that was supplied from terminal 4 is cut Pilot valve closes off the pilot valve and the main valve close and__ Main valve closes the combustion lamp turns off Combustion lamp turns off Start contacts OFF Power across terminals 7 and 2 is cut and relay Start check operation 1K t
42. ross terminals 1 and 2 POWER LED lights up Push button If the system is ready for operation with interlock Purge completion 102X operation switch ON contacts in their normal state closed when the operation button is pushed the prepurge begins When the time preset for the purge timer 100T has elapsed the purge completion relay 102X is energized After the prepurge ends the FRS100 accepts the following operations Start contacts ON If the limit switch status is normal contacts closed Start check operation LED pushing the start button applies power across lights terminals 7 and 2 Then after completion of the start check relay 1K turns on Ignition switch ON When the ignition switch is pushed contacts closed e Ignition transformer ON terminal 8 supplies power to the pilot valve and e Pilot valve opens ignition transformer The ignition transformer turns on and the pilot valve opens 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 e Ignition transformer OFF to the ignition transformer is cut and ignition e Pilot valve closes transformer operation stops Because relay 2K did not turn on the voltage at terminal 4 is zero and the pilot valve returns closed Voltage is also not supplied to the main valve so it does not open Start contacts OF
43. 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 e Splashing water or excessive humidity e High temperatures e 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 iii CAUTION Follow all applicable regulations when doing the wiring work Connect the blue signal lead from the Minipeeper Ultraviolet Flame Detector to terminal 5 and the white lead to terminal 6 Turning on the power when the
44. urns off LED turns off The FRS100 returns to standby status and waits for the next start signal tart tacts ON Start contacts ON T start check 25 2 Operation switch 4 lgnition switch Flame failure Flame detection Flame response ONES 5 lgnition switch 6 Start contacts OFF 5 10s OFF Interlock contact Operation switch E Stop switch st Purge timer 100T Z During purge 101X Purge completion 102X SSSR Start contact term 7 2 C a Ignition transformer od Pilot valve Main valve rit Combustion lamp C S POWER LED ree FLAME LED BRIE ll Start check LED Elapsed time 12 e False flame detection Input status Chapter 2 MOUNTING AND WIRING during startup FRS100 activity Output activity Power ON Receives power across terminals 1 and 2 POWER LED lights up Push button operation switch ON If the system is ready for operation with interlock Purge completion 102X contacts in their normal state closed when the operation button is pushed the prepurge begins When the time preset for the purge timer 100T has elapsed the purge completion relay 102X is energized After the prepurge ends the FRS100 accepts the following operations When the limit switch is in a normal state contacts FLAME LED lights up closed pushing the start button applies power across terminals 7 and 2 The start check is carried out but r
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