Azbil AUD300C1000 Series 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.
AUD300C1000
Advanced Ultraviolet
Flame Detector
User’s Manual
No. CP-SP-1141E

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 the azbil Group.
In no event is Azbil Corporation liable to anyone for any indirect, special or
consequential damages as a result of using this product.
© 2008–2016 Azbil Corporation All Rights Reserved.

i
Conventions Used in This Manual
The safety precautions explained in the following section aim to prevent injury to the operator and
others, and to prevent property damage.
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.
In describing the product, this manual uses the icons and conventions listed below.
Use caution when handling the product.
The indicated action is prohibited.
Always follow the indicated instructions.
Handling Precautions:
Handling Precautions indicate items that the user should pay attention to when handling
the AUD300C1000.
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.
This indicates the item or page that the user is requested to refer to.
>>: Indicates the result of an operation, details displayed on the personal computer or other
devices, or the state of the device after operation.

ii
Safety Precautions
WARNING
Use this device only in combination with Azbil Corporation’s burner controllers.
Make sure that this device does not detect ultraviolet rays other than those of the burner flame.
If it responds to other ultraviolet radiation, flame failure in the burner will not be detected.
As a result, the outflow of fuel will continue, causing a very serious explosion hazard.
Before removing, mounting, or wiring this device, be sure to turn off the power to the device
and all connected devices. Failure to do so may cause electric shock.
Before doing any wiring work, be sure to disconnect the power to prevent electrical shock.
To prevent explosion, carry out the pilot turndown test carefully. If this device detects a pilot
flame that is too small to ignite the main burner, the burner controller will not be able to
recognize flame failure of the main burner, allowing the outflow of fuel to continue, leading to
a serious explosion hazard.
If the pilot turndown test is 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 combustion chamber and flue. If unburned gas and oil are not discharged completely,
an explosion may occur.
Do not touch terminals F or G on this device or on the burner controller immediately after the
power to the burner controller has been turned OFF. There is a danger of electric shock because
terminals F and G retain a charge for up to 1 minute after the power has been turned off.
When measuring the voltage between terminal F and terminal G of this device in order to check
the wiring, do not touch any part of the terminals. Doing so may result in an electric shock.
Do not use this device with the cover removed. Doing so may result in an electric shock. If the
cover has been removed from this device, be sure to reattach it and tighten the four mounting
screws completely before use.

iii
CAUTION
This device is designed for both batch operation of the burner (at least one start and stop in a
24-hour period) and continuous operation (nonstop combustion for 24h or longer). It must be
used with a burner controller having a dynamic self-checking function.
Installation, wiring, inspection, adjustment, etc., should be carried out by a trained and
experienced technician with knowledge and technical skills related to combustion equipment
and flame safeguard control devices.
Do not install where the product will be 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 this device is operated in an atmosphere where there is steam, sooty smoke, oil mist, dust,
and/or organic solvents that interfere with ultraviolet rays, take appropriate corrective
measures.
When using multiple burners, mount this unit in a position where it can detect only the flame
of the burner to be monitored.
Carry out the wiring work in conformity with the specified standards.
Be sure to route the signal wires of this device separately from high-voltage ignition
transformer cables and power cables, and put them in a separate conduit.
After the wiring work is complete, be sure to check that there are no mistakes. Incorrect wiring
can cause damage or malfunction.
Only an experienced technician with knowledge and technical skills related to combustion
equipment and combustion safety should carry out the pilot turndown test.
Do not transport this device while it is mounted on the combustion equipment. Shock or
vibration during transport may cause it to malfunction. Before transporting, dismount it and
put it in its specially designed shipping box.
The service life of the tube unit and shutter unit components of this device is a maximum
of 3 years. To ensure operational safety, be sure to replace these units with new ones within
the service life period. For replacement, use the AUD Maintenance Kit (AUD60A1000), which
includes the tube and shutter units.

iv
The Role of This Manual
A total of 4 different manuals are available for the AUD300C1000, AUR300C. Read them as necessary for your spe-
cific requirements. If a manual you require is not available, contact the azbil Group or its dealer.
AUD300C1000 Advanced Ultraviolet Flame Detector
Manual No.CP-SP-1141E
This manual.
The manual describes the mounting, wiring, maintenance and inspection, and trouble-
shooting when the AUD300C is built-into the combustion equipment.
AUR300C Advanced Ultraviolet Burner Controller
Manual No.CP-SP-1142E
The personnel in charge of design, mounting, operation, and maintenance of the
combustion equipment using the AUR300C must read this manual.
The manual describes the mounting, wiring, trial-run adjustment, and mainte-
nance and inspection of the AUR300C.
AUR350C Advanced Ultraviolet Burner Controller with Communications
Manual No.CP-SP-1175E
Personnel in charge of design, mounting, operation, and maintenance of combus-
tion equipment using the AUR350C should read this manual.
It describes the mounting, wiring, trial-run adjustment, maintenance, inspection
of the AUR350C.
AUR450C Dynamic Self-Checking Burner Controller
Manual No. CP-SP-1264E
This manual should be read by personnel using the AUR450C for the first time,
those in charge of designing combustion equipment that uses the AUR450C or
designing the hardware for mounting the device in a control panel, and personnel
performing maintenance.
The manual gives an overview of the product, its mounting and wiring for con-
nection to other equipment, its operation, trial-run adjustment, maintenance and
inspection, and specifications.

v
Contents
Conventions Used in This Manual
Safety Precautions
The Role of This Manual
Chapter 1. OVERVIEW 1
 Overview 1
 Features 1
 Names of parts 1
 Model selection table 1
Chapter 2. MOUNTING 3
 What to know before installation 3
 Methods of monitoring burner flame 4
 Mounting position 4
 Mounting orientation 5
 Mounting of the monitoring pipe 6
 Mounting procedure 8
Chapter 3. WIRING 9
 Wiring diagram 9
 Wiring check 10
Chapter 4. ADJUSTMENT 11
 Before measuring the flame voltage 11
 Measuring the flame voltage 11
 Pilot turndown test 12
 Ignition spark response test 13
 Permanent mounting of monitoring pipe 13
 Final check 13
Chapter 5. TROUBLESHOOTING 14
 Troubleshooting procedure 14
Chapter 6. MAINTENANCE AND INSPECTION 15
 Periodic inspection 15
 Replacement of the shutter unit and tube unit using the AUD Maintenance Kit
(AUD60A1000) 16

vi
Chapter 7. SPECIFICATIONS 19
 Specifications 19
 External dimensions 20
Terms and Conditions

1
Chapter 1. OVERVIEW
■Overview
The AUD300C1000 Advanced Ultraviolet Flame Detector (hereafter this/the de-
vice) is designed to detect ultraviolet radiation from an oil or gas burner flame, for
use with both batch and continuous operation burners. The AUD300C1000 is used
in combination with a dedicated burner controller. By means of the built-in shutter,
any malfunction of the UV flame detector or burner controller is detected by the
start check and continuous self-checking function (Dynamic Self-Check), ensuring
highly reliable combustion safety control.
■Features
•Maintenance parts such as the tube unit and shutter unit can be handled as a
single unit. This ensures easy replacement and maintenance work.
•As for a flame sensor for the self-check, this unit is compact and lightweight. This
ensures free burner mounting.
•The operating ambient temperature is 100°C (up to 120°C during flame detec-
tion) and the protection structure is IP66. This ensures excellent environment-
proof performance.
•Because it can be mounted vertically and has a maximum wire length of 200m,
flexible installation is possible.
■Names of parts
●Main unit
■Model selection table
Model No. Lens type Additional
AUD300C1000 Standard None
AUD300C100D Inspection report
AUD300C100T Tropicalization treatment
AUD300C100Y Traceability certificate
AUD300C100DT Inspection report + tropicalization treatment
AUD300C100YT Traceability certificate + tropicalization treatment
AUD300C1100 Condenser None
AUD300C110D Inspection report
AUD300C110T Tropicalization treatment
AUD300C110Y Traceability certificate
AUD300C110DT Inspection report + tropicalization treatment
AUD300C110YT Traceability certificate + tropicalization treatment
Cover mounting screws (4)
AUD Maintenance Kit
AUD60A1000
Mounting nut
Cover
Lead wires
Flange unit: 81446924-001 or -101

2
Chapter 1. OVERVIEW
Certification
•UL: File No. MH27717
•CSA: Master Report LR 078402
•CE*: Gas Appliance Directive
0063BS1427 (with AUR450C_2_____and Q241A104)
0063CN6671 (with RX-R4_C_____)
RoHS Directive
*CE marking appears to comply with RoHS
Combined burner controller
Model Name
RX-R40, RX-R44, RX-R46 Burner Control Module
AUR300C, AUR350C Advanced Ultraviolet Burner Controller
AUR450C Dynamic Self-Checking Burner Controller
Maintenance/optional parts
Model Name
AUD60A1000 AUD Maintenance Kit *1
81446924-001 Flange unit (Standard type)
81446924-101 Flange unit (Condenser type)
81447495-001 Nut packing
81447509-001 Bushing 1×3/4
FSP136A100 Analog flame meter
*1 AUD60A1000 Maintenance Kit
The AUD Maintenance Kit incorporates the tube and shutter units (tube unit: AUD10,
shutter unit: AUD50), including expendables like the expiration date label*2and the
O-ring used for sealing between the flange and cover of the AUD.
*2 Expiration date label Position of the expiration date label
Terminal G (yellow lead wire)
Terminal F (blue lead wire)
Tube unit retaining screws (2)
Shutter unit
Thermolabel
Label
Tube unit
Terminal for shutter driver connection
(white lead wire)