Azbil AUR890 Series User Manual
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Azbil AUR890 Series User Manual

Burner controller
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No. CP-SP-1380E
Burner Controller
Model AUR890
User's Manual
Thank you for purchasing your Azbil
Corporation product.
This manual contains information for
ensuring the safe and correct use of the
product.
Those designing or maintaining
equipment that uses this product should
first read and understand this manual.
This manual contains information not only
for installation, but also for maintenance,
troubleshooting, etc. Be sure to keep it
nearby for handy reference.

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Summary of Contents for Azbil AUR890 Series

  • Page 1 No. CP-SP-1380E Burner Controller Model AUR890 User's Manual Thank you for purchasing your Azbil Corporation product. This manual contains information for ensuring the safe and correct use of the product. Those designing or maintaining equipment that uses this product should first read and understand this manual.
  • Page 2 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. In no event is Azbil Corporation liable to anyone for any indirect, special, or consequential damages as a result of using this product.
  • Page 3 Conventions Used in This Manual „ The safety precautions explained below aim to prevent injury to you and others, and to prevent property damage. Warnings are indicated when mishandling this product may WARNING result in death or serious injury. Cautions are indicated when mishandling this product may CAUTION result in minor injury or property damage only.
  • Page 4 Safety Precautions WARNING Use this device with combustion equipment that starts and stops at least once in a 24-hour period. This device cannot be used for equipment with combustion continuing for 24 hours or longer. 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.
  • Page 5 WARNING Do not disassemble this device. Doing so may cause malfunction, device failure, or electric shock. Do not use alarm relay output as safety output. This device has a limited product life. Beyond the product life, the risk of device failure becomes higher.
  • Page 6 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.

  • Page 7: Table Of Contents

    Contents Conventions Used in This Manual Safety Precautions Chapter 1. Overview „ Features ..............1 „...
  • Page 8 Chapter 6. Maintenance and Inspection „ General maintenance and inspection ......... .41 „...

  • Page 9: Chapter 1. Overview

    Chapter 1. Overview AUR890 burner controllers were developed as an upgrade for the RA890 burner controller, and are designed for batch operation of combustion equipment (at least one start and stop in a 24-hour period). This device is used in combination with an AUD100 series Advanced Ultraviolet Flame Detector or a flame rod.

  • Page 10: X84; Handling Precautions

    Chapter 1. Overview • Starting, running, and stopping of combustion equipment according to a pre- defined sequence • Operates each device according to the predefined sequence and timing. • Safety startup • Checks the flame detector and the flame detection circuit for flame detection error each time the start signal is issued.

  • Page 11: X84; Model Number

    Chapter 1. Overview „ Model number Basic Flame Power Flame Additional Description model No. detector response function AUR890 Burner controller Flame rod AUD100/110/120 Advanced Ultraviolet Flame Detector 100 V AC 200 V AC 1 s max. 3 ± 1 s *1 Flame voltage at 2 V DC None *2 Flame voltage at 3 V DC...

  • Page 12: Chapter 2. Installation, Wiring

    Chapter 2. Installation, Wiring „ Installation, Precautions for wiring 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. Check the model number carefully and check that the sequence timing is as specified by the combustion equipment manufacturer.
  • Page 13 Chapter 2. Installation, Wiring CAUTION 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.

  • Page 14: X84; Installation Method

    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 an electric shock. CAUTION Installation, wiring, maintenance, inspection, and adjustment must be carried out by a professional with technical training in combustion equipment and combustion safety equipment.

  • Page 15: X84; When The Sub-Base (Model Bc-R05A100) Is Used

    Chapter 2. Installation, Wiring „ When the sub-base (Model BC-R05A100) is used z Installation orientation Attach the device in the orientation shown below. Correct Correct Display area AUR890 main unit AUR890 main unit Do not install it in the orientations illustrated below. Incorrect AUR890 main unit...
  • Page 16 Chapter 2. Installation, Wiring CAUTION Turn the power off before mounting the device on the sub-base. Otherwise, device failure may result. z Mounting/removing the device and sub-base (sold separately) z Mounting (1) Align the indentation in the center of the top of the device with the projection on the sub-base.

  • Page 17: X84; When The Base Unit (Q890A100) For Model Ra890 Replacement Is Used

    Chapter 2. Installation, Wiring „ When the base unit (Q890A100) for model RA890 replacement is used z Installation orientation Attach the device in the orientation shown below. Correct Correct AUR890 Display area main unit AUR890 main unit Do not install it in the orientations illustrated below. Incorrect AUR890 main unit...
  • Page 18 Chapter 2. Installation, Wiring (3) Insert screws into the three mounting holes in the lower part of the base unit, and tighten the screws. φ 5.5 mounting holes (3) (4) Wire the external connections to the terminal block on the lower part of the replacement base unit, and then connect the cable connectors of the upper part of the base unit to the connectors on the lower part.

  • Page 19: X84; Terminal Numbers, Front Panel Item Names

    Chapter 2. Installation, Wiring „ Terminal numbers, front panel item names Front BC-R05A100 sub-base (sold separately) Display RESET switch DISP switch Front connector cover (connector is behind cover) Loader jack * DIN rail clamp Terminal board * Not used (for inspection and adjustment before shipment) z Terminal No.
  • Page 20 Chapter 2. Installation, Wiring z Connector for front wiring (81447514-001) terminal layout Mounting screw Wiring Wiring fastener screw Mounting screw z Connector for front wiring (for right side wiring) (81447514-002) terminal layout Mounting screw Wiring Wiring fastener screw Mounting screw...
  • Page 21 Chapter 2. Installation, Wiring z External connection terminals of the RA890 replacement base unit (Q890A100) External connection terminals of Q890A100 Q890A100 external-connection terminal Nos. Function AC power supply (L1) AC power supply (L2 (N)) Pilot valve output Ignition transformer output Main valve output Line voltage temp.

  • Page 22: X84; Example Of Wiring Connection With External Device

    Chapter 2. Installation, Wiring „ Example of wiring connection with external device WARNING 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.
  • Page 23 Chapter 2. Installation, Wiring z Non-recycling oil-fired combustion (2-level combustion) L2(N) Circuit breaker Burner on-off circuit Limit / interlock circuit Blower operation circuit / prepurge circuit Prepurge completion signal AUR890/BC-R05A100 Line voltage temp. controller AC input circuit Flame Power Flame detection supply circuit detector...
  • Page 24 Chapter 2. Installation, Wiring z Q890A100 base unit for RA890-AUR890 replacement z Non-recycling gas-fired combustion L2(N) Circuit breaker Burner on-off circuit Limit / interlock circuit Blower operation circuit / prepurge circuit Line voltage Prepurge completion signal temp. controller Terminal numbers of Q890A100 base unit (for RA890 replacement) AUR890/BC-R05A100 Display RESET...
  • Page 25 Chapter 2. Installation, Wiring z Non-recycling oil-fired combustion (2-level combustion) L2(N) Circuit breaker Burner on-off circuit Limit / interlock circuit Blower operation circuit / prepurge circuit Line voltage temp. controller Prepurge completion signal Terminal numbers of Q890A100 base unit (for RA890 replacement) AUR890/BC-R05A100 RESET Display...
  • Page 26 Chapter 2. Installation, Wiring z Wiring to a flame detector (ultraviolet sensor) z AUD100C+AUD15C Blue Terminal 14 White Terminal 15 z AUD110C+AUD15C Terminal Terminal 14 (F) Terminal 15 z AUD120C+AUD15C Blue Terminal 14 White Terminal 15 If connection of the blue and white lead wires is reversed, or if the connections to terminals F and G are reversed, the AUD15C tube unit may be damaged.
  • Page 27 Chapter 2. Installation, Wiring z Example countermeasures against power surges caused by lightning When using a line surge suppressor as a countermeasure against power surges caused by lightning, connect it between Terminal 3 and the ground, as shown below. The mounting brackets of the surge absorber are electrically connected internally by crimping to the ground side of the absorber.
  • Page 28 Chapter 2. Installation, Wiring z Connections to solenoid valve WARNING 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.

  • Page 29: Chapter 3. Operation

    Chapter 3. Operation „ Part names Retaining screw for AUR890 main unit 7-segment LED (green) When normal: Sequence code/Flame voltage When an error occurs: Alarm code/Flame voltage DISP switch RESET switch Switch to change as follows: Switch to cancel lockout Flame voltage/Sequence code or (Press and hold for approximately 1s) Flame voltage/Alarm code...
  • Page 30 Chapter 3. Operation When an error occurs The 7-segment display shows a alarm code and the sequence code for which the alarm was issued alternately. Every time the DISP switch is pressed, the display is changed between a alarm code and the sequence code for which the alarm was issued alternately as well as the flame voltage.

  • Page 31: Chapter 4. Explanation Of Operation

    Chapter 4. Explanation of Operation CAUTION After turning on the power, allow sufficient time before checking the output of this device. This device does not start operation until about 8 seconds after power-on. The AC and DC input circuits use approximately 1 second for checking after the input signal turns „...
  • Page 32 Chapter 4. Explanation of Operation z Non-recycling oil-fired combustion (2-level combustion) L2(N) Circuit breaker Burner on-off circuit Limit / interlock circuit Blower operation circuit / prepurge circuit Prepurge completion signal AUR890/BC-R05A100 Line voltage temp. controller AC input circuit Flame Power Flame detection supply circuit...
  • Page 33 Chapter 4. Explanation of Operation z Q890A100 base unit for RA890-AUR890 replacement z Non-recycling gas-fired combustion L2(N) Circuit breaker Burner on-off circuit Limit / interlock circuit Blower operation circuit / prepurge circuit Line voltage Prepurge completion signal temp. controller Terminal numbers of Q890A100 base unit (for RA890 replacement) AUR890/BC-R05A100 Display RESET...
  • Page 34 Chapter 4. Explanation of Operation z Non-recycling oil-fired combustion (2-level combustion) L2(N) Circuit breaker Burner on-off circuit Limit / interlock circuit Blower operation circuit / prepurge circuit Line voltage temp. controller Prepurge completion signal Terminal numbers of Q890A100 base unit (for RA890 replacement) AUR890/BC-R05A100 RESET Display...

  • Page 35: X84; Example Sequence

    Chapter 4. Explanation of Operation „ Example sequence z Normal operation (Non-recycling gas-fired combustion) [7-segment display] –– –– –– [Input] Power supply Limit, Interlock Burner operation switch Blower Controller Flame signal RESET switch [Output] TM1 on delay time Ignition transformer AUR890 Pilot valve Main valve...
  • Page 36 Chapter 4. Explanation of Operation WARNING If lockout occurs, be sure to do a prepurge before restarting the system. If the combustion chamber and gas flue are not ventilated to remove any unburned gas, the ignition process may cause an explosion.
  • Page 37 Chapter 4. Explanation of Operation z Operation when a flame failure occurs (Non-recycling gas-fired combustion) [7-segment display] –– –– P8/E7 P8/E7 –– [Input] Power supply Limit, Interlock Burner operation switch Blower Controller Flame signal RESET switch [Output] Ignition transformer AUR890 Pilot valve Main valve Alarm output...
  • Page 38 Chapter 4. Explanation of Operation z Operation when there is a false flame before start input (Non-recycling gas-fired combustion) [7-segment display] –– –– P1/E1 [Input] Power supply Limit, Interlock Burner operation switch Blower Controller Flame signal RESET switch [Output] 15 s Ignition transformer AUR890 Pilot valve...
  • Page 39 Chapter 4. Explanation of Operation z Normal operation (Non-recycling oil-fired combustion (2-level combustion)) [7-segment display] –– –– –– [Input] Power supply Limit, Interlock Burner operation switch Blower Controller Flame signal RESET switch [Output] Ignition transformer AUR890 Fuel oil valve Two-level fuel oil valve Alarm output [LED] FLAME LED (Green)
  • Page 40 Chapter 4. Explanation of Operation WARNING If lockout occurs, be sure to do a prepurge before restarting the system. If the combustion chamber and gas flue are not ventilated to remove any unburned gas, the ignition process may cause an explosion.
  • Page 41 Chapter 4. Explanation of Operation z Operation when a flame failure occurs (Non-recycling oil-fired combustion (2-level combustion)) [7-segment display] –– –– P8/E7 P8/E7 –– [Input] Power supply Limit, Interlock Burner operation switch Blower Controller Flame signal RESET switch [Output] Ignition transformer AUR890 Fuel oil valve Two-level fuel oil valve...
  • Page 42 Chapter 4. Explanation of Operation z Operation when there is a false flame before start input (Non-recycling oil-fired combustion (2-level combustion)) [7-segment display] –– –– P1/E1 [Input] Power supply Burner operation switch Blower Controller Flame signal RESET switch [Output] 15 s Ignition transformer AUR890 Fuel oil valve...

  • Page 43: Chapter 5. Trial Operation And Adjustment

    Chapter 5. Trial Operation and Adjustment WARNING 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.

  • Page 44: X84; Ignition Spark Response (Ultraviolet Sensor)

    Chapter 5. Trial Operation and Adjustment „ Ignition spark response (ultraviolet sensor) WARNING Ensure that the ultraviolet sensor does not detect ultraviolet rays other than those from the burner. If the sensor detects other ultraviolet rays, it will continue to send flame detection signals even if the burner flame goes out.

  • Page 45: X84; Measurement Of Flame Voltage

    Chapter 5. Trial Operation and Adjustment „ Measurement of flame voltage This device shows the flame voltage on the 7-segment display. It can be checked by changing the display using the DISP switch on the front of the device. Checking the flame voltage is the best way to determine whether or not the location of the flame detector is appropriate.
  • Page 46 Chapter 5. Trial Operation and Adjustment z Measurement method for flame voltage The voltage can be checked on the 7-segment display or by connecting a flame meter to terminals 25 and 26 of the front connector. Analog ame meter Flame voltage display FSP136A100 * Connector for front wiring (81447514-001/002) is required to connect FSP136A100 to AUR890.

  • Page 47: X84; Pilot Turn-Down Test

    Chapter 5. Trial Operation and Adjustment „ Pilot turn-down test WARNING Make sure that the pilot turn-down test is done properly. If the flame detector is able to detect a pilot flame that is too small to ignite the main burner, and if there is a flame failure of the main burner, this device will not be able to recognize the flame failure.

  • Page 48: X84; Safety Shutoff Check

    Chapter 5. Trial Operation and Adjustment Handling Precautions • If it is necessary to repeat the test, each time it is repeated be sure to stop all the equipment first to prevent an explosion and then discharge all unburned gas that has accumulated in the combustion chamber and exhaust flue. „...

  • Page 49: Chapter 6. Maintenance And Inspection

    Chapter 6. Maintenance and Inspection 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 an electric shock. Do not touch terminal 14 (F) after turning the power off. An electric charge may remain in the terminal 14 (F) and may cause an electric shock.

  • Page 50: X84; Alarm Codes And Details

    Chapter 6. Maintenance and Inspection „ Alarm codes and details When lockout occurs, an alarm code is displayed automatically. When an alarm occurs, the sequence number and alarm code issued when the lockout. ” If the sequence cannot be specified, the sequence code displayed when lockout occurred may be shown as [–...

  • Page 51: X84; Failure Inspection Flow

    Chapter 6. Maintenance and Inspection „ Failure inspection flow 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 an electric shock. If there is any problem with the device, follow the inspection procedure below. (Note: The terminal numbers are applicable in the case of the BC-R05A100 sub-base.) Turn start input OFF and press reset switch.

  • Page 52: Chapter 7. Specifications

    Chapter 7. Specifications Item Description Application Batch-operated combustion systems burning gas, oil, or gas/oil mixture Compatible flame detector AUD100/110/120 series ultraviolet sensor, flame rod Sequence Lockout timing 13.5 ± 1.5 s Standby for normal 0.4 s combustion Flame failure AUD100/110/120 series ultraviolet sensor Flame rod (Ionization) response timing 3 ±...
  • Page 53 Chapter 7. Specifications General Structure Structure of the replacement base unit or sub-base and main unit specifications Mounted orientation Vertical or horizontal However, for horizontal attachment, 7 segment display can only be mounted so that it faces directly overhead (DIN rail mounting or direct mounting through base screw holes) Dimensions •...

  • Page 54: X84; External Dimensions

    Chapter 7. Specifications „ External dimensions z AUR890 with the BC-R05A100 sub-base unit: mm z Body Sub-base (sold separately) AUR890 main unit fastening screw Sub-base Connector for (sold separately) front wiring DIN rail clamp AUR890 main unit fastening screw Model number 81447514-001 10.6 81447514-002...
  • Page 55 Chapter 7. Specifications unit: mm z Sub-base BC-R05A100 (sold separately) Knockout hole Knockout hole M3.5 (terminal screw) φ12 knockout hole φ12 knockout hole Sub-base mounting hole Sub-base mounting hole DIN rail clamp 62.5 z Sideboard 81447515-001 (sold separately) 30.7 Sub-base Sub-base φ19 knockout hole Sideboard...
  • Page 56 Chapter 7. Specifications z When combined with the Q890A100 base unit for RA890-AUR890 replacement unit: mm z Body 147* AUR890 main unit fastening screw Connector for front wiring AUR890 main unit fastening screw Sideboard (in package) Screw (4) securing the upper part of the replacement base unit Model number 81447514-001...
  • Page 57 Chapter 7. Specifications unit: mm z With the base unit (Q890A100) for RA890 replacement (purchased separately) Sideboard (in package) M4 ground screw φ23 hole (4 places) 25.5 Grommet (4 places) * This dimension is for a product with a date code (D/C) of 1828 or later. The height is 8 mm less than that of a product with an earlier date code.
  • Page 59 Revision History of CP-SP-1380E Printed Edn. Revised pages Description Feb. 2015 Nov. 2019 Overall revision. 2nd ed = 7th Jp ed.

  • Page 60: Terms And Conditions

    Warranty period and warranty scope 1.1 Warranty period Azbil Corporation’s products shall be warranted for one (1) year from the date of your purchase of the said products or the delivery of the said products to a place designated by you.
  • Page 61 Although acceleration of the above situation varies depending on the conditions or environment of use of the products, you are required not to use any Azbil Corporation’s products for a period exceeding ten (10) years unless otherwise stated in specifications or instruction manuals.
  • Page 62 Specifications are subject to change without notice. (11) 1-12-2 Kawana, Fujisawa Kanagawa 251-8522 Japan URL: https://www.azbil.com 1st edition: Feb. 2015 ( K ) 2nd edition: Nov. 2019 ( B )

This manual is also suitable for:

Aur890f seriesAur890g series81447514-00181447514-002

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