Azbil AUR455 User manual

Thank you for purchasing an Azbil
Corporation product.
This manual contains information for
ensuring the correct use of this product.
It also provides necessary information
for installation, maintenance, and
troubleshooting.
This manual should be read by those
who design and maintain equipment
that uses this product. Be sure to keep
this manual nearby for handy reference.
No. CP-SP-1439E
Dynamic Self-Checking
Burner Controller
Model AUR455
User’s Manual

NOTICE
Please make sure that this manual is available to the user of the product.
Unauthorized duplication of this user’s manual in part or in whole is
forbidden.
The information and specifications in this manual are subject to change
without notice.
Considerable effort has been made to ensure that this manual is complete
and accurate, but if you should find an omission or error, please contact us.
Please understand that we cannot in some cases accept responsibility for
the results of the use of this equipment by the customer.
© 2019–2021 Corporation. All Rights Reserved.

The safety precautions explained below aim to prevent injury to you and others, and to prevent property damage.
WARNING Warnings are indicated when mishandling this product may
result in death or serious injury.
CAUTION Cautions are indicated when mishandling this product may
result in minor injury or property damage only.
In describing the product, this manual uses the icons and wording listed below.
Indicates that caution is required in handling.
The indicated action is prohibited.
Be sure to follow the indicated instructions.
Handling Precautions:
Information to be aware of when handling.
Note: Indicates information that may be useful.
: Indicates an item or page to which the user may refer.
(1) (2) (3): Steps in a sequence or parts of a figure, etc.
Conventions Used in This Manual

ii
Safety Precautions
WARNING
This device is equipped with functions that are extremely important for the safe operation of
combustion equipment. Be sure to follow the instructions stated in this user’s manual.
This device does not have a prepurge function. Use this device as part of a system whose
design gives careful consideration to the prepurge timer and ignition sequence timing,
following established safety guidelines.
Check the model number carefully and check that the sequence timing is as specified by the
combustion equipment manufacturer. Installing the wrong model can result in an explosion
hazard.
Make sure that the AUD flame sensor does not detect UV rays from a source other than the
burner.
Do not touch terminal 14 (F) after turning the power off. An electric charge may remain on
terminal 14 (F) and may cause an electric shock.
Carry out the pilot turndown test carefully.
Be sure to do a prepurge before restarting the system when lockout occurs. If the combustion
chamber and gas flue are not ventilated to remove any unburned gas, the ignition process
may cause an explosion.
Do not reset this device until the cause of the problem has been eliminated when lockedout
occurs.
Do not reset this device repeatedly when lockout occurs. If this device is misused, a serious
combustion equipment accident may occur.
Do not reset this device from a remote location. Because it is difficult to make a safety check
when far from the equipment, there is an increased risk of explosion.
Do not use the event output or alarm output as safety output.
This device has a limited product life. Beyond the product life, the risk of device failure
becomes higher. Replace this device within its product life.
Do not disassemble this device. Doing so may cause malfunction, device failure, or electric
shock.
Do not operate this device without first completing its adjustment and testing, and also the
testing specified by the combustion equipment manufacturer.
Do not extend the lead wires of the contact reset for more than the allowable length of
10 meters. If the device is reset from a location where it is difficult to check the safety of
combustion, there is a risk of explosion.
The ignition time for the pilot and main burners should not exceed the time defined by the
burner or device manufacturer. If it does, fuel will accumulate in the combustion chamber
and form an explosive mixture, resulting in a very dangerous situation in which an explosion
could occur.
Do not connect the solenoid valve to the high potential side (L1). If it is connected to L1 and a
ground fault occurs, current can leak to the solenoid valve and open it, allowing fuel to flow
out, regardless of the status of the burner controller.

iii
WARNING
Before doing the pilot turn-down test, always make sure that all manual fuel valves are
closed.
If the pilot turn-down test must be repeated, stop the combustion equipment completely
each time and discharge all of the unburned gas and oil from the fuel chamber and flue.
Failure to discharge unburned gas may result in an explosion hazard.
After completing the pilot turn-down test, turn off the power switch to turn off the power
supply. Make sure to return all test jumpers and limit or controller settings to their original
values. Resuming normal operation without returning the settings to their original values,
etc., may damage the equipment or cause a gas leak or explosion.
Close the fuel valve before using the flame simulator for a check while this device is attached.
If you use the flame simulator during normal operation, since a flame will seem to be present,
fuel will continue to be supplied even if the pilot burner or main burner is off, possibly
causing an explosion.
CAUTION
To ensure proper operation of this device, follow the directions given in this user’s manual
and in the manuals for the combustion equipment and for any other devices that are used.
When planning a combustion safety control system, please discuss the details with our sales
representatives.
Installation, wiring, maintenance, inspection, and adjustment must be carried out by a
professional with technical training in combustion equipment and flame safeguard system.
Use this product correctly within the range of the rated specifications stated in the user’s
manual. Not doing so may cause device failure or malfunction.
Do not install where exposed to any of the following:
• Certain chemicals or corrosive gases (ammonia, sulfur, chlorine, ethylene compounds,
acid, etc.)
• Splashing water or excessive humidity.
• High temperatures
• Prolonged vibration
All wiring and installation must comply with applicable local electrical codes, ordinances and
regulations.
Provide appropriate maintenance and inspection for the product, following the methods,
procedures, replacement cycle, etc., specified by this user’s manual.
When discarding of this device, dispose of it as industrial waste, following local regulations.
If timers and auxiliary relays are needed for additional functions, select ones with being
listed or component recognized by authorities, and be sure to design the circuit correctly.
Use this device within the operating ranges given in the specifications for temperature,
humidity, voltage, vibration, shock, mounting position, atmosphere, etc.
Make sure that the flame detector does not detect the ignition spark. If the ignition spark is
detected, change the position of the flame detector or ignition electrode.

iv
CAUTION
Do not connect a load that exceeds the rating stated in the specifications to the control load
terminals (6, 7, 8), and do not short-circuit the load. Doing so will burn out the internal fuse,
making this device unusable.
The protection rating of this device is equivalent to IP10 or IP40. According to equipment
requirements, install this device in a control panel with appropriate protection rating.
For mounting and wiring, follow the instructions in this user’s manual or in manuals provided
by the combustion equipment manufacturer.
The ignition transformer ground must be directly connected to the burner itself or to metal
that is electrically connected to the burner.
Keep power wires and the ignition transformer high voltage cable separate from the flame
detector wiring.
Make sure that ignition transformer high-voltage cables are properly connected to
prevent faulty contact. Faulty contact may generate high-frequency radio waves, causing
malfunction.
Always supply electricity at the voltage and frequency stated on the model label of this
device.
Make sure the burner frame is properly grounded in compliance with applicable local
electrical codes, ordinances, and regulations.
The pilot turn-down test should be carried out only by an experienced specialist possessing
knowledge and skills pertaining to combustion equipment and combustion safety.
If the combustion equipment is restarted as a result of a lockout, do all of the inspection steps
described in Chapter 5, “Trial Operation and Adjustment.”
When doing a maintenance inspection of the burner, be sure to do the pilot turn-down test.
Inspection must be done at least once a year.
Inspect the combustion equipment periodically in accordance with the instructions given in
the manual provided by the equipment manufacturer.
When cleaning the burner, clean the flame detector also.
When transporting or storing this device, temporarily remove it from the sub-base and pack
it in the box it was originally shipped in. Transportation while attached to a panel, etc., may
cause damage.

v
There are three different manuals related to model AUR455. Read them as necessary for your specific requirements.
If you do not have a manual you require, please contact us or one of our dealers.
Dynamic Self-Checking Burner Controller Model AUR455 User’s Manual
Document No. CP-SP-1439E
This manual.
Personnel who are using model AUR455 for the first time, or are designing combustion
equipment that uses the AUR455, or are designing hardware used to incorporate it
into a control panel, etc., or are maintaining the AUR455, should read this manual
thoroughly. This manual gives an overview of the product, tells how to install and
wire it for incorporation into equipment, and gives an overview of operation, trial
operation and adjustment methods, communication, maintenance and inspection, and
specifications.
Dynamic Self-Checking Burner Controller Model AUR455
User’s Manual for Installation Document No. CP-UM-5955JE
This manual is supplied with the AUR455.
Personnel who design or maintain equipment that uses the AUR455 should read
this manual thoroughly. This manual describes installation of this device.
Installation and Usage Guide for Smart Loader Package Model SLP-A55
for Burner Controller Model AUR_55 Document No. CP-UM-5956JE
This manual is supplied with Smart Loader Package model SLP-A55.
Personnel who design equipment that uses the AUR455 or who configure and
maintain the AUR455 using the SLP-A55 should read this manual thoroughly. It
describes the PC software used to configure various settings for the AUR455 and
to read out internal data from the AUR455. The manual describes installation of
the software on a PC, its operation on the PC, and setup procedures.
The Role of This Manual

vi
Contents
Conventions Used in This Manual
Safety Precautions
The Role of This Manual
Chapter 1. Overview 1
 Handling Precautions 1
 Cautions for combustion equipment design 2
 Most important points for ensuring safety 2
 Precautions for system design 2
 Model No. 3
 Related devices 4
Chapter 2. Installation, Wiring 5
 Installation method 7
 Cautions regarding installation 8
 Installation orientation 8
 Mounting on a DIN Rail 9
 Mounting in a panel 9
 Mounting/removing the unit and the sub-base 10
 Terminal numbers, front panel item names 10
 Terminal No. 11
 Example of wiring with external devices
(terminals 1–24: sub-base; terminals 25–35: front connector) 13
 Connection with model AUD300C/500C 15
 Check of wiring between this device and model AUD300C or AUD500C 15
 Connections to solenoid valve 16
Chapter 3. Operation 17
 Part names 17
 Operation 17
 Turn-down test and communication setting modes 20
 Host communication setting using the Smart Loader Package (model SLP-A55) 23
Chapter 4. Explanation of Operation 25
 Instrumentation example of model AUR455 for an interrupted pilot 25
 Notes about the instrumentation and circuit configuration for an interrupted pilot 25
 Internal block diagram (interrupted pilot) 26
 Sequence chart 28
 Instrumentation example of model AUR455 for an intermittent pilot 32
 Notes about the instrumentation and circuit configuration for an intermittent pilot 32
 Internal block diagram (intermittent pilot) 33
 Wiring for replacement of model AUR450 35
 Alarms and combustion sequence 37
 Instantaneous power failure or instantaneous voltage drop during operation 37

vii
Chapter 5. Trial Operation and Adjustment 39
 Preliminary inspection 39
 Inspection procedure 39
Chapter 6. Maintenance and Inspection 45
 General maintenance and inspection 45
 Maintenance and inspection cycle 45
 Alarm codes and details 46
 What to do if E951 occurs 48
 Failure inspection flowchart 49
Chapter 7. Specification 51
 External dimensions 53

1
Chapter 1. Overview
The AUR455 dynamic self-checking burner controller (hereafter “this device”) can be used for both continuous
operation and batch operation. It is a combustion safety controller that employs the correct ignition sequence
to automatically and safely ignite gas burners and oil burners. This device can be used in combination with the
AUD300C advanced ultraviolet flame detector, the AUD500C explosion-proof advanced ultraviolet flame detector,
or a flame rod.
The AUR455 drives the shutter that is built into the AUD300C/500C to continuously check both its own flame
detection circuit and the ultraviolet detector in order to provide flame detection for continuous burner operation.
When used with a flame rod, the AUR455 continuously checks its own built-in flame detection circuit to provide
flame detection for continuous burner operation. Also, it is equipped with a 7-segment display that can be used
in maintenance, a trial operation mode that is convenient for trial operation and adjustment, and other features.
Additionally, the device is equipped with host communications (RS-485) and a smart loader package function,
allowing more detailed observation of status and troubleshooting.
• The combustion sequence, alarm codes and flame voltage are shown on the 7-segment display.
• LED indicators show whether there is a flame signal and indicate lockout.
• Self-diagnosis of the internal control relay circuit
• If lockout occurs due to ignition failure or unexpected flame failure, the controller does not restart without a
manual reset.
• Equipped with host communications (RS-485) to enable remote monitoring.
• DIN rail mounting and a sub-base structure are provided for easy installation and replacement.
 Handling Precautions
• This device has 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.
• This device should be installed, wired, inspected, adjusted, and maintained by
experienced specialists who have knowledge and skills concerning combustion
equipment and flame safeguard system.

2
Chapter 1. Overview
 Cautions for combustion equipment design
Facilities that use flame safeguard system must be designed in compliance with
relevant laws, standards, safety guidelines, and the like.
If the system is designed to foreign specifications, please observe the local laws and
standards.
Main safety policies in Japan
• Technical Policy on Safety Standards for Combustion Equipment in Industrial
Furnaces, by Ministry of Health, Labor and Welfare
• Combustion Equipment in Compliance with the Safety Principles for Industrial
Incinerators - JIS B 8415
• Forced Draught Burners — Part 1: Gas Burners (JIS B 8407-1)
• Forced Draught Burners — Part 2: Oil Burners (JIS B 8407-2)
• Index of Safety Technology of Industrial Gas Combustion Equipment, by Japan
Gas Association
• Index of Safety Technology of Gas Boiler Combustion Facilities, by Japan Gas
Association
 Most important points for ensuring safety
Design the equipment observing the following points to ensure safety.
• Connect loads directly to this device.
• Make sure that the start check runs correctly at startup.
• Do not add a bypass circuit that allows manual operation of any load.
• Both the main valve and pilot valve must have redundant shutoffs.
 Precautions for system design
Provide a purge function with external instrumentation, taking into account factors
such as the conditions for purge and the time settings.

3
Chapter 1. Overview
 Model No.
The dedicated sub-base, sideboard, and front connector are not included with this
device. Please order them separately.
z Interrupted pilot type Example: AUR455C423100
Basic
model
No.
Flame
detector
Ignition
trial
Main
trial
Flame
failure
response
Power Pilot
sequence
Other Description Note
AUR455
B Flame rod CE certification
C UV CE certification
4 4.5±0.5 s
8 9.0±1.0 s
2 7.0±1.0 s
3 4.5±0.5 s JIS response time
2 2 s max. AUR455C only
3 4 s max.
1100 V AC
2200 V AC
3120 V AC
5230 V AC
0 Interrupted pilot *
0 Without inspection data
D With inspection data
* If the ignition method is an intermittent pilot, select a direct ignition model.
z Direct ignition type Example: AUR455C433110
Basic
model
No.
Flame
detector
Ignition
trial
(Not used)
Flame
failure
response
Power Pilot
sequence
Other Description Note
AUR455
B Flame rod CE certification
C UV CE certification
4 4.5±0.5 s
8 9.0±1.0 s
3 Fixed
2 2 s max. AUR455C only
3 4 s max.
1100 V AC
2200 V AC
3120 V AC
5230 V AC
1 Direct ignition, no shutoff
valve closure check
0 Without inspection data
D With inspection data

4
Chapter 1. Overview
 Related devices
z Compatible ultraviolet flame detector (sold separately)
Model No. Name
AUD500C11000 Explosion-proof advanced ultraviolet flame detector
AUD300C100_ Advanced ultraviolet flame detector
AUD300C110_
_: 0 Standard product
D With inspection record (with data)
T With tropicalization
Y With traceability certificate
DT With tropicalization and inspection certificate
YT With traceability certificate and tropicalization
z Optional parts (sold separately)
Model No. Name
BC-R05A100 Dedicated sub-base (a requirement for the AUR455)
81447514-001 Connector for front wiring
Weidmüller model number BL3.5/11F
Compatible wire: 0.2–1.5 mm
2
(28–14 AWG)
81447514-002 Connector for front wiring (for right-side wiring)
Weidmüller model number BL3.5/11/270F
Compatible wire: 0.2–1.5 mm
2
(28–14 AWG)
81447515-001 Sideboards (2)
SLP-A55J91 Smart Loader Package (without cable)
81441177-001 USB loader cable
FSP136A100 Analog flame meter
81447519-001 Jack cover (1)
83968019-001 Surge absorber

5
Chapter 2. Installation, Wiring
WARNING
Do not reset this device from a remote location. Because it is difficult to make a safety check
when far from the equipment, there is an increased risk of explosion.
This device is equipped with functions that are extremely important for the safe operation of
combustion equipment. Be sure to follow the instructions stated in this user’s manual.
Check the model number carefully and check that the sequence timing is as specified by the
combustion equipment manufacturer. Installing the wrong model can result in an explosion
hazard.
Connect the load (ignition transformer, solenoid valve, etc.) directly to the output terminals of
this device. If it is not directly connected, combustion safety cannot be ensured.
Before mounting, removing, or wiring, be sure to turn off the power to this device and all
connected devices. Failure to do so may result in electric shock.
Never short-circuit the start contact in order to start and stop this device by switching the
power on and off. This is very important for reliable activation of the self-check circuit at
device startup. Failure to observe this warning could lead to an explosion.
Do not extend the lead wires of the contact reset for more than the allowable length of
10 meters. If the device is reset from a location where it is difficult to check the safety of
combustion, there is a risk of explosion.
CAUTION
For mounting and wiring, follow the instructions in this user’s manual or in manuals provided
by the combustion equipment manufacturer.
All wiring and installation must comply with applicable local electrical codes, ordinances and
regulations.
Do not use unused terminals on the device as relay terminals.
Use this product correctly within the range of the rated specifications stated in the user’s
manual. Not doing so may cause device failure or malfunction.
Always supply electricity at the voltage and frequency stated on the model label of this
device.
Make sure the burner frame is properly grounded in compliance with applicable local
electrical codes, ordinances, and regulations.
Run the high-voltage ignition transformer cable separately and keep it at least 30 cm away
from this device.
Keep power wires and the ignition transformer high voltage cable separate from the flame
detector wiring.
Make sure that ignition transformer high-voltage cables are properly connected to prevent
faulty contact. Faulty contact may generate high-frequency radio waves, causing malfunction.

6
Chapter 2. Installation, Wiring
CAUTION
The ignition transformer ground must be directly connected to the burner itself or to metal
that is electrically connected to the burner.
Check that the wiring is correct before use. Incorrect wiring may cause damage or faulty
operation.
If the wiring from this device exceeds the recommended length, prevent malfunction due
to the effects of external noise by running wires from the control panel to the case through
a conduit, keeping power lines and input lines apart from each other, and other measures.
Check the operation of the system after installation.
Use non-voltage contacts for connections to the input terminals of this device (19 through 24).
This device does not start operation until about 8 seconds after power-on.
When discarding of this device, dispose of it as industrial waste, following local regulations.
Use a surge protector or similar device if there is a risk of power surges caused by lightning.
Do not configure a circuit that turns off the interlock input (terminals 22–19 or 22–20) using
the alarm output contacts (terminals 9–10). With such a circuit, if a false flame, UV alarm,
ignition failure, or flame failure occurs, the interlock alarm (E1) may be displayed.
When the control load wiring is grounded, an alarm occurs.
Use the contact reset (terminal 24) input in isolation. Do not share the terminal with other
AUR455 devices.
Do not share the output common (terminals 4 & 5) and the input common (terminals 19 & 20)
with other AUR455 devices.
Do not provide instrumentation to stop the power to the device as soon as the alarm operates.
When the power to this device is turned on again, an alarm may be activated (E908).
To prevent malfunction caused by the effect of external noise, in operations other than trial
operation, maintenance, or troubleshooting, do not keep the loader cable connected during
the operation.
Take countermeasures based on the instruction manual for that device if there is a device such
as an inverter nearby that generates strong electrical noise.
Firmly tighten the terminal screws to the torque listed in the specifications.

7
Chapter 2. Installation, Wiring
 Installation method
WARNING
Before mounting, removing, or wiring, be sure to turn off the power to this device and all
connected devices. Failure to do so may result in electric shock.
CAUTION
Installation, wiring, maintenance, inspection, and adjustment must be carried out by a
professional with technical training in combustion equipment and flame safeguard system.
Do not install where exposed to any of the following:
• Certain chemicals or corrosive gases (ammonia, sulfur, chlorine, ethylene compounds, acid,
etc.)
• Splashing water or excessive humidity.
• High temperatures
• Prolonged vibration
Do not connect a load that exceeds the rating stated in the specifications to the control load
terminals (6, 7, 8), and do not short-circuit the load. Doing so will burn out the internal fuse,
making this device unusable.
When using this device as a burner control system, install it in a control panel with a rating of
IP40 or more. If IP40 is required for this device, also use the sideboards (sold separately). The
protective structure of this device is equivalent to IP10.

8
Chapter 2. Installation, Wiring
 Cautions regarding installation
• Leave space 50 mm above and below, 50 mm on the left and right, and 80 mm in
the front as space for removal, wiring, and maintenance. Also, do not install this
device close to electrical power devices or other sources of heat.
50 mm 80 mm
From the front
Wiring, ducts, etc.
Main unit
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
50 mm
• This device must be installed in a grounded and conductive control panel to
ensure safety.
• Do not pull on the wiring while it is attached to the device. Doing so can cause
failure of the connectors or this device itself.
• If there is room, leave as much space as possible between them for heat
dissipation.
• If the ambient temperature is close to the allowable upper limit, install a panel air
conditioner or a fan to lower the temperature inside the panel.
Upper limit of allowable ambient temperature, for installation of single unit:
60°C, for gang mounting: 45°C
• Firmly tighten the terminal screws with a torque of 0.5 N·m or less.
 Installation orientation
Attach the device in the orientation shown below.
Display
Main unit
Main unit
Do not install it in the orientation illustrated below.
Main unit

9
Chapter 2. Installation, Wiring
 Mounting on a DIN Rail
(1) Pull down the sub-base’s DIN rail clamps.
(2) Attach the sub-base to the DIN rail, making sure that the sub-base is not
upside-down.
(3) Push up the DIN rail clamp to fasten the sub-base to the DIN rail.
Pull down the DIN rail clamps Push the DIN rail clamps
upward to x in place
Attach sub-base to DIN rail
 Mounting in a panel
(1) Cut two M4 threaded holes in the panel.
Unit: mm
62.5
M4
(2 locations)
(2) Use screws to mount the sub-base in the panel.
(Maximum tightening torque: 1.2 N·m)

10
Chapter 2. Installation, Wiring
CAUTION
Turn the power off before mounting the device on the sub-base. Otherwise, device failure may
result.
 Mounting/removing the unit and the sub-base
z Mounting
(1) Align the indentation in the center of the top of the
device with the projection on the sub-base.
(2) Once aligned as in (1), slowly push the device toward
the sub-base.
(3) Tighten the device’s retaining screws to secure it in the
sub-base. (Maximum tightening torque: 0.5 N·m).
z Removing
(1) Remove the mounting screws.
(2) Pull the device out toward you while holding down the
sub-base.
 Terminal numbers, front panel item names
Sub-base (sold separately)
Terminal block*
2
RESET switch
DISP switch
Display
Loader jack*1
Front connector
Front
DIN rail clamp
*1 Also used as a Smart Loader Package jack
*2 Firmly tighten the terminal screws with a torque of 0.5 N·m or less.