Azbil FRS100 User manual

FRS100
Multiburner Controller
User's Manual
No. CP-SP-1373E
Thank you for purchasing the FRS100
Multiburner Controller.
This manual contains information for
ensuring the correct use of the FRS100.
It also provides necessary information
for installation, maintenance, and trou-
bleshooting.
This manual should be read by those
who design and maintain equipment
that uses the FRS100. Be sure to keep
this manual nearby for handy reference.

NOTICE
© 2014 Azbil Corporation All Rights Reserved.
Be sure that the user receives this manual before the product is used.
Copying or duplicating this user’s manual in part or in whole is forbid-
den. The information and specifications in this manual are subject to
change without notice.
Considerable effort has been made to ensure that this manual is free
from inaccuracies and omissions. If you should find an error or omis-
sion, please contact Azbil Corporation.
In no event is Azbil Corporation liable to anyone for any indirect, special
or consequential damages as a result of using this product.

■About Icons
The safety precautions described in this manual are indicated by various icons.
Please be sure you read and understand the icons and their meanings described
below before reading the rest of the manual.
Safety precautions are intended to ensure the safe and correct use of this prod-
uct, to prevent injury to the operator and others, and to prevent damage to proper-
ty. Be sure to observe these safety precautions.
■Examples
i
Use caution when handling the product.
The indicated action is prohibited.
Be sure to follow the indicated instructions.
SAFETY PRECAUTIONS
WARNING Warnings are indicated when mishandling this
product might result in death or serious injury.
CAUTION Cautions are indicated when mishandling this product might result in minor injury to the user, or
only physical damage to the product.

ii
WARNING
Use this device for batch operation of the burner (at least one start and
stop in a 24-hour period). Do not use for continuous burner operation
(nonstop combustion for 24 h or longer).
This device does not have the prepurge and ignition sequencing func-
tions required for burner ignition. Use this device as part of a system
whose design gives careful consideration to the prepurge timer and
sequence timing, following established safety guidelines.
Wire terminals 1 and 2 so that they receive power continuously when-
ever the power switch is turned on. This is absolutely necessary to
ensure operation of the self-check circuits at startup.
Therefore, do not wire a thermostat between the power switch and ter-
minal 1 or 2. Doing so might cause a serious combustion equipment
accident.
Connect loads (ignition transformer, solenoid valve, etc.) directly to the
output terminals of this device. If they are not directly connected, com-
bustion safety cannot be ensured.
Do not allow the pilot or main burner "Safety Time" (ignition trial time)
to exceed the specifications of the burner or equipment manufacturer.
If they do, fuel may accumulate in the combustion chamber and form
an explosive air-fuel mixture, resulting in a serious explosion hazard.
Before removing, mounting, or wiring the FRS100, be sure to turn off
the power to the FRS100 and all connected devices. Failure to do so
might cause electric shock.
Do not connect a solenoid valve to the high potential side of the circuit.
If a ground fault occurs, the ground fault current may energize and
open the solenoid valve. This device will not be able to prevent the
valve from opening and fuel from flowing out.
Even after the power to this device is turned off, terminal F continues
to hold an electrical charge. To avoid electrical shock, do not touch ter-
minal F.
Carry out the pilot turndown test carefully. If the flame detector is set
so that it detects a pilot flame that is too small to ignite the main burn-
er, this device will not be able to detect a flame failure in the main burn-
er. In that case, fuel will continue to be supplied, causing a serious
explosion hazard.
Before the pilot turndown test or ignition spark response test, make
sure that all manual fuel valves are closed.

iii
WARNING
If the pilot turndown test must be carried out repeatedly, completely
shut down all equipment each time the test is finished, and completely
discharge unburned gas or fuel that has accumulated in the ducts and
combustion chamber. Failure to discharge unburned gas or fuel may
result in an explosion.
When the pilot turndown test is complete, turn OFF the power switch to
shut down the power. Restore all test jumpers and limit interlock/regu-
lator settings to their previous states. If operation begins without the
above steps, damage to the equipment, gas leak or explosion may
result.
Do not start regular operation of the equipment without first complet-
ing the trial-run adjustments for this device, as well as the tests speci-
fied by the combustion equipment manufacturer.
To prevent electric shock, turn the power off and discharge terminals F
and G before removing this device from the subbase. Use lead wires to
connect terminals F and G of the flame simulator (FSP300C100) to ter-
minals F and G of this device for 10 seconds or more.
CAUTION
Installation, wiring, inspection, adjustment, etc. should be carried out
by a trained and experienced technician who has knowledge and
technical skills related to combustion equipment and flame safeguard
control devices.
Do not install where exposed to any of the following:
• Certain chemicals or corrosive gases (ammonia, sulfur, chlorine,
ethylene compounds, acid, etc.)
• Splashing water or excessive humidity
• High temperatures
• Prolonged vibration
If timers and auxiliary relays are needed for additional functions, select
ones with high reliability, and be sure to design the circuit correctly.
When installing and wiring, be sure to follow the instructions in this
manual and in the user's manual for the combustion equipment.
Make sure the flame detector does not detect ultraviolet rays other
than those of the burner flame. If the flame detector responds to other
ultraviolet rays, it will report that there is a flame even if the burner
flame goes out. As a result, fuel will continue to be discharged,
causing a very serious explosion hazard.

iv
CAUTION
Follow all applicable regulations when doing the wiring work.
Connect the blue signal lead from the AUD100 series Advanced
Ultraviolet Flame Detector to terminal 5 and the white lead to terminal
6. Turning on the power when the flame detector is incorrectly wired
could damage the AUD15C tube unit.
Run the high-voltage ignition transformer cable separately and keep it
at least 10 cm away from this device.
Make sure that ignition transformer high-voltage cables are properly
connected to prevent faulty contact. Faulty contact might generate
high-frequency radio waves which can cause malfunction.
The ignition transformer ground lead should be connected directly to
the burner body or to a metallic part electrically connected to the
burner body.
Keep power lines and ignition transformer high-voltage cables
separate from the flame detector wires.
Always supply electric power at the voltage and frequency stated on
the model label of this device.
Always connect the power supply last. Otherwise, touching a terminal
accidentally could result in electric shock or damage.
In keeping with technical standards for electrical equipment, the burner
body must have an earth ground connection with a resistance of less
than 100 Ω.
After the wiring is complete, be sure to check that it is correct.
Incorrect wiring may cause damage or faulty operation.
Make sure that the flame detector does not detect the ignition spark. If
the flame detector can detect the spark, change the detector's line of
sight or change the ignition electrode's position.
Only an experienced technician who has knowledge and technical
skills related to combustion equipment and combustion safety should
carry out the pilot turndown test.
This product is equipped with functions that are extremely important
for the safe operation of combustion equipment. Carefully follow the
instructions for its use that are given in this user's manual.

v
CAUTION
If the safety shutoff has been activated, check all of the items on the
checklists in Chapter 3, ADJUSTMENTS FOR TRIAL OPERATION
before restarting the equipment.
Check the flame current at least once per month. Doing so can prevent
shutdowns caused by a weak flame current signal.
This device has an operating life. Assuming that the operating life of
the combustion equipment used with this device is longer, be sure to
do periodic maintenance and replacement of this device.
In the event that this device is replaced, do all of the checks listed in
Chapter 3, ADJUSTMENTS FOR TRIAL OPERATION.
When doing a maintenance inspection of the burner, be sure to do the
pilot turndown test. Inspection must be done at least once a year.
Conduct periodic inspections in accordance with the user's manual of
the equipment manufacturer.
When cleaning the burner, clean the flame detector as well.
Do not transport this device while it is mounted on a DIN rail. Remove
it from the subbase and pack it in its original box. If it is transported
while on a DIN rail, it might fall off and be damaged.

Conventions Used in This Manual
vi
The following conventions are used in this manual:
Handling Precautions:
Handling Precautions indicate items that the user should pay attention to
when handling the FRS100.
Note: Notes indicate information that might benefit the user.
(1), (2), (3): Numbers within parentheses indicate steps in a sequence or parts of an
explanation.

Contents
vii
SAFETY PRECAUTIONS
Conventions Used in This Manual
Chapter 1. OVERVIEW AND PRODUCT CONFIGURATION
■Overview •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••1
■Features •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••1
■System configuration ••••••••••••••••••••••••••••••••••••••••••••••••••••1
■Security function•••••••••••••••••••••••••••••••••••••••••••••••••••••••••2
■Precautions for facility instrumentation••••••••••••••••••••••••••••••••••2
■Model selection guide••••••••••••••••••••••••••••••••••••••••••••••••••••3
■Names of parts•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••4
■Configuration ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••4
Chapter 2. MOUNTING AND WIRING
2-1 Mounting and Wiring the Subbase•••••••••••••••••••••••••••••••••••••••••••5
2-2 Wiring••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••8
■Manual ignition (intermittent pilot) •••••••••••••••••••••••••••••••••••••••9
■Burner flame monitoring only ••••••••••••••••••••••••••••••••••••••••••14
■Wiring the flame detector •••••••••••••••••••••••••••••••••••••••••••••••19
■Wiring the solenoid valve •••••••••••••••••••••••••••••••••••••••••••••••20
■Wiring the surge absorber ••••••••••••••••••••••••••••••••••••••••••••••21
Chapter 3. ADJUSTMENTS FOR TRIAL OPERATION
■Outline ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••22
■How to measure the flame signal •••••••••••••••••••••••••••••••••••••••23
■Pilot turndown test •••••••••••••••••••••••••••••••••••••••••••••••••••••24
■Ignition spark response test ••••••••••••••••••••••••••••••••••••••••••••26
■Safety shutoff test ••••••••••••••••••••••••••••••••••••••••••••••••••••••27
Chapter 4. MAINTENANCE AND INSPECTION
■Frequency of maintenance and inspection •••••••••••••••••••••••••••••28
■Troubleshooting ••••••••••••••••••••••••••••••••••••••••••••••••••••••••29
Chapter 5. SPECIFICATIONS
■Specifications ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••32
■External dimensions ••••••••••••••••••••••••••••••••••••••••••••••••••••33