Azbil BC-R25 Series User manual

Thank you for purchasing the BC-R25
Series. This manual contains information
for ensuring the correct use of the BC-R25
Series.
This manual should be read by those who
design and maintain equipment that uses
the BC-R25 Series.
It also provides necessary information
for installation, maintenance, and
troubleshooting. Be sure to keep this
manual nearby for handy reference.
No. CP-SP-1388E
BC-R25 Series
Burner Controller
User's Manual

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 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 free from
inaccuracies and omissions. If you should find an error or omission, 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.
© 2015 Azbil Corporation All Rights Reserved.

i
Conventions Used in This Manual
■To prevent injury to the operator and others, and to prevent property damage, the following types of safety
precautions are indicated:
■In describing the product, this manual uses the icons and conventions listed below.
Use caution when handling the product.
The indicated action is prohibited.
Be sure to follow the indicated instructions.
Handling Precautions:
Handling Precautions indicate items that the user should pay attention to when handling
this module.
Note: Notes indicate information that might benefit the user.
This indicates the item or page that the user is requested to refer to.
(1)(2)(3) Numbers within parentheses indicate steps in a sequence or parts of an explanation.
WARNING Warnings are indicated when mishandling this product might result in
death or serious injury.
CAUTION Cautions are indicated when mishandling this product might result in
minor injury to the user, or physical damage to the product.

ii
Safety Precautions
WARNING
Use this device with combustion equipment that is started and stopped at least once in a 24-hour
period.
This device cannot be used with combustion equipment that operates continuously for 24 hours or
longer.
Before removing, mounting, or wiring the BC-R25 Series, be sure to turn off the power to the
BC-R25 Series and all connected devices. Failure to do so might cause electric shock.
If lockout occurs, reset it only after removing the cause. Also, do not enter reset input repeatedly.
Operating this product improperly could result in a serious combustion equipment accident.
Never input a reset command 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 given in this manual.
Check the model number carefully and check that the sequence timing is as specied by the combustion
equipment manufacturer. Installing the wrong model can result in an explosion hazard.
Do not touch terminal 14 (F) immediately after the power has been turned o. Because the terminal retains
an electrical charge, there is a danger of electric shock.
Do not use the monitor output or alarm relay output as safety output.
This device has an operating life and should be replaced within that time. Continued use beyond the
lifespan may result in device failure.
Do not start regular operation of the equipment without rst completing the adjustments and tests for this
device, as well as the tests specied by the equipment manufacturer.
Do not disassemble this device. Malfunction, device failure, or electric shock may result.
CAUTION
In order to use this product correctly, be sure to follow this manual, the manuals for any associated
devices, and the manuals for the combustion equipment. When designing a flame safeguard
control system, please consult with a representative of the azbil Group.
Installation, wiring, inspection, adjustment, maintenance, etc. should be carried out only by trained
and experienced technicians who have knowledge and technical skills related to this product and
associated equipment.
Be sure to use this device correctly, within the ranges specified in this user's manual. Otherwise
device failure or malfunction could result.
Avoid installing the device where it will be subject to conditions such as the following. Otherwise
device failure could result.
• Certain chemicals or corrosive gases
• High temperatures
• Splashing water or excessive humidity.
• Prolonged vibration

iii
CAUTION
Wire this device in compliance with established norms, using the types of wire and wiring methods
specified in this manual. Otherwise there is a risk of device failure or malfunction.
Carry out maintenance and inspection correctly according to the methods, procedures,
replacement cycles, etc., specified in this manual.
When discarding this product, dispose of it as industrial waste, following local regulations.
Do not connect a load that exceeds the rating stated in the specifications to the control load
terminals (terminals 2–1, 2–6, 2–7, or 2–8), and do not short-circuit the load. Doing so will burn out
the internal fuse, making the device unusable. To comply with CE standards, it is necessary to take
measures to prevent the use of a device whose relay contacts can be damaged by a connected
load that exceeds the rating or by a load short-circuit. For this reason, this device uses an internal
fuse that cannot be replaced.

iv
Contents
Conventions Used in This Manual
Safety Precautions
Chapter 1. Overview
■Instructions for proper use ……………………………………………………………… 1
■Precautions on facility design …………………………………………………………… 1
■Most important points for ensuring safety …………………………………………… 1
■Model number …………………………………………………………………………… 2
■Related equipment ……………………………………………………………………… 3
Chapter 2. Installation, Wiring
■Installation method ……………………………………………………………………… 5
■Cautions regarding installation ………………………………………………………… 6
■Installation orientation …………………………………………………………………… 6
■DIN rail mounting ………………………………………………………………………… 6
■Mounting in a panel ……………………………………………………………………… 7
■Mounting/removing the device and sub-base (sold separately) …………………… 7
■Terminal numbers, front panel item names …………………………………………… 8
■Example of wiring connection with external device …………………………………10
Chapter 3. Operation
■Names of parts ……………………………………………………………………………13
■Operation …………………………………………………………………………………13
■Trial operation mode ………………………………………………………………………16
■Function selection mode (for POC and host communications (RS-485) address)……18
■Host communication settings using the Smart Loader Package (SLP-BCR) …………20
Chapter 4. Explanation of Operation
■Example of wiring connection with external device: Internal block diagram ………21
■Example sequence …………………………………………………………………………23
■Alarm and occurrence sequence …………………………………………………………37
Chapter 5. Trial Operation and Adjustment
■Preliminary inspection ……………………………………………………………………38
■Inspection procedure ……………………………………………………………………38
■Ignition spark response (UV sensor) ……………………………………………………39
■Measurement of flame voltage …………………………………………………………40
■Pilot turn-down test ………………………………………………………………………42
■Safety shutoff check ………………………………………………………………………43

v
Chapter 6. Maintenance and Inspection
■General maintenance and inspection ……………………………………………………44
■Maintenance and inspection cycle ………………………………………………………44
■Alarm codes and details …………………………………………………………………45
■Failure inspection flow ……………………………………………………………………46
Chapter 7. Specifications
■External dimensions ………………………………………………………………………49

1
Chapter 1. Overview
BC-R25 burner controllers are designed for batch operation of combustion equipment (at least one start and stop
in a 24-hour period). The BC-R25 automatically executes ignition, flame monitoring, and fuel shutoff for ON/OFF-
controlled gas burners and oil burners. Its features include a 7-segment LED display that is useful for maintenance
and a test mode that is convenient for trial runs & adjustment. In addition, it is equipped with host communication
(RS-485) and Smart Loader Package compatibility, which make more detailed monitoring and troubleshooting
possible.
•7-segment display for sequence codes and alarm codes.
•LED indicators show whether there is a flame signal and whether lock-out is present.
•The monitor outputs the operating status of the flame signal, ignition failure, flame failure and lock-out
interlock.
•Perform fault diagnosis for the internal control relay circuit.
•The product is designed so that it cannot be restarted in the case of lock-out due to ignition failure, false
flame or other causes, unless it is reset manually.
•The design complies with JIS C 9730-2-5 and JIS C 9730-1.
•The air-flow switch (OFF/ON) is checked before and after start check. (JIS B 8407)
•POC (proof of closure) function based on shutoff valve closure confirmation switch input.
•Host communication (RS-485) allowing remote observation of status
•DIN rail mounting and sub-base structure are provided for easy installation and replacement
Instructions for proper use
• This device has functions that are extremely important for the safe operation
of combustion equipment. Therefore, use the device correctly, according to this
user's manual.
• The device must be installed, wired, maintained, inspected and adjusted by
experienced specialists who have gained knowledge and skills concerning
combustion equipment and combustion safety devices.
Precautions on facility design
The facilities that use the combustion safety device must be designed taking into
careful consideration the following safety guidelines and the like.
If the system is designed to a foreign specification, refer to laws and standards in the
relevant country.
•“Technical Policy on Safety Standards for Combustion Equipment in Industrial
Furnaces,” by the Ministry of Health, Labour and Welfare
•"GeneralSafetyCodeforIndustrialCombustionFurnaces"-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
•“SaftyGuidelineforGasBoilerCombustionEquipment”byTheJapanGas
Association
Most important points for ensuring safety
The design must take into consideration the following points to ensure safety.
1. Connect loads directly to the device.
2. Make sure that the start check circuit operates correctly at startup.
3. Do not make a manual operation circuit or other bypass circuit for any loads.
4. Use a redundant shutdown system for both main valve and pilot valve.

2
Chapter 1. Overview
Model number
(Note: The dedicated sub-base and sideboard are not provided with the BC-R25 series controller. Order them
separately.)
zDirect ignition type
III III IV VVI VII Example: BC-R25B1J0500
III III IV VVI VII Description
Base
model
number
Commu-
nications
function
Flame
detector
Power
supply
Function
code
Timing
Code
Additional
functions
BC-R Burner Controller
25 RS-485, with Smart Loader Package function
BFlame rod (Ionization)
C UV sensor (AUD100/110)
1100 Vac
2200 Vac
6220 Vac
JDirect ignition type
050 Pre-purge time 35 s
086 Pre-purge time 45 s
122 Pre-purge time 60 s
158 Pre-purge time 3 min
0None
D With inspection record (with data)
zInterrupted pilot type
III III IV VVI VII Example: BC-R25B1G0500
III III IV VVI VII Description
Base
model
number
Commu-
nications
function
Flame
detector
Power
supply
Function
code
Timing
Code
Additional
functions
BC-R Burner Controller
25 RS-485, with Smart Loader Package function
BFlame rod (Ionization)
C UV sensor (AUD100/110)
1100 Vac
2200 Vac
6220 Vac
G Interrupted pilot type
050 Pre-purge time 35 s
086 Pre-purge time 45 s
122 Pre-purge time 60 s
158 Pre-purge time 3 min
0None
D With inspection record (with data)