No. CP-UM-1217E RA890F PROTECTORELAY Burner Controller User's Manual Azbil CorporationPlease read the “Terms and Conditions" from the following URL before ordering or use: http://www-azbil.com/products/bi/order.html Precautions in Using (1)Since this protectorelay has the very important functions to operate a combustion equipment satel {0 use it correctly in accordance with this User's. manual : (2)The instalation, wiring, maintenance, Inspection and adjustment shall be made by tained, experienced flame safeguard control technicians. Contents General... Extemal dimensions, Installation and wiring Operation .. Checkout... Service Specifications ... 910 11~12 131. GENERAL ‘The RABOOF is a solid state electronic bumer controller to be used for the automatic operation and safety operation of gas, ol ‘oF combination gas-oil combustion equipment, up to 700 kW, in batch operation. The flame detector of a flame rod or the C7012A" Ultraviolet Flame Detectér is used in combination with the RABSOF. {fignition failure should occur during starting, the safety switch is operated to stop the combustion safely device safely. In this case, reslarting is prevented by safely design, unless the "RESET" pushbutton is operated. “The RA8SOF is a line voltage device, and operated after mounted directly onto the 270A subbase. * Discontinuation date: March 2012. © A safeguard circuit is incorporated to prevent the © The input circuits protected against the high voltage of FRABOOF Irom being operated, when a false lame signal the ignition tansformer, when a flame rod flame detoo- is detected by the flame detector tor is. used © I the bumer fils in ignition, the safety switch is ope- «Adaptable to combustion equipment in batch operation ‘ated to close the fuel valve automaticaly. (slaried and stopped once or more per 24 hours). Not © A test jack is provided to permit the flame current to be to be used for continuous operation read, © The RAB9OF performs recycle operation during flame © Combustion contol is also permitted by connecting failure. Therefore, when itis to be used togethor with a together line voltage controller or low voage contol gas-fired combustion system, operate it in non-recycle let Bequence by using an on-delay timex. (Refer to Fig. 4) © Applicable to the intorupted plot system or intermittent pilot system. EXTERNAL DIMENSIONS “Tominalserow 6.92UNG Unit: mm Unit: mm a a {#5 Mouning holes (8) @oO aur a == 922 Knockout les 9) aE — en J a 250 Se WPA, 250 Series aceptace Fast tab / insulating sleeve, 9 pes provided, 34 2 Salty sutcn reset pushoton Ping om USIP ‘ Se 4 24 ae | aed] u ma =“ GO-0 ABSOF Subbase Fig. 1 External Dimensions Fig. 2 Mounting Dimension Drawing[3 INSTALLATION AND WIRING 3.1 Cautions in Installation and Wiring (1) Absolutely avoid installing the RAB9OF at any of ‘the following places: ® There are special chemicals or corrosive gases (ammonia, sulfur, chlorine, ethylene com- pounds, acid, and the like). @ There are water drops or excessive moisture. @ Exposed to high temperature. @ Allarge vibration exceeding the special vibration resistance continues for a long time. (2) Carry out installation and wiring in accordance with this instruction manual or that supplied by the other set manufacturer such as boiler manu- facturer, (3) All the wiring shall comply with the specified standards. (4) Connect the power source finally to prevent | possible electric shocks or damages. If the power line should touch any other terminal, a trouble or damage may be caused. (8) Never connect a load, which exceeds the rating given in the specications, to the load terminals. (6) Supply the power source of the same voltage and frequency as indicated on the RABSOF. (7) When using timers and/or auxilary relays, add 3.2 How to Mount the Subbase ‘Mount the subbase so that the top is horizontal and the back Is vertical as shown in Fig. 3. The subbase may lean backward as much as 45 degrees if necessary. (1) Open knockout holes for conduits as required, as shown in Fig. 3, and attach wiring conduits there, (2) Fix the subbase at the specified position with screws. 45 dogrees tionally as required, select high reliabilty ones having the sufficient load capacity, and configu: fate a proper circuit with them. (@) Be sure to ground the casing of the boiler to an Earth of less than 10002 (9) Never clamp the flame detector cable togéther with the power cable or the high voltage cable of the ignition transformer, nor put them in the same. conduit, but wire them separately from each other. Particularly, wire the high voltage cable in- dependently of the others, and keep it 10 cm or more away from the RABSOF. Connect the high voltage cable of the ignition transformer tightly nat to cause poor contact Otherwise, high frequency electromagneic waves may be generated, thus causing radio receivers to generate noise, or the RA89OF to malfunction. {iso install the ignition transtormer directly onto the burner body or the metal part connected to the burner body electrically. ‘Aiter the completion of wiring, be sure to check it the connestions are made properly, as miswiring causes a damage or malfunction. ifa terminal screw is loose, faulty operation may ‘occur. Be sure to check that the terminal screws are not loose. (10) an (2) (2) Set the position of the RA890F mounting base to that of the subbase. (@) Tighten the terminal screws (10 pes) of the RABSOF mounting base securely in the individual terminal thread holes in the subbase. (Electrical connection with the subbase Is completed when the RAB9OF is mounted.) (4) Replace the cover to the RABSOF. G0 Saaty | opr eng ee ste crane) ‘eran | EOE ners Tm Fig. 8 Mounting the Subbase 3.3 Terminal Arrangement of Subbase For the terminal arrangement of the subbase, refer to Figs. 4 and 5. The terminal Nos. required for wiring are stamped white on the terminal block of the subbase. 34 Terminal Arrangement of RA89OF The terminal arrangement of the RAB9OF corresponds to that of the subbase. 3,5 How to Mount the RA890F onto the Subbase Mount the RASSOF onto the subbase after the completion of external wiring, (1) Loosen the cover mounting screws and remove the cover from the RABSOF. Photo 1 RAS90F and G270A Subbase Regular Pilot System (manual ignition system) When the RA890F is to be used in the manual ignition system, cut off the plot link shorting lead (refer to Photo 2) ‘on the PCB of the RAB9OF. Avoid twisting off this lead. Otherwise, the PCB may be damaged. lo ink short lead‘8.6 How to Wire the Subbase in Non-recycle or Recycle Mode (1) Fig, 4 shows the extemal wiring diagram when used with gas burner, while Fig. 5 shows the one when used with oiLfired combustion equipment. (2) When tne power source is provided with ground potential, connect its voltage side (H) to the terminal ©, and is ground side (G) to the terminal @. For the connection betwaen the power source and valve, refer to Fig. 7. (3) For wiring to each terminal, use the moisture-resisting {ype covered wire of 1.66 or more. For the witing be- {ween the terminals © and © of the Q270A subbase and the ignition detector, refer io Tablo 1 Table 1. Type ‘lewable Length C7OI2A Flame rod YAN standard AG-11/U__| Approx. 50m _| Approx. 30 m_ JAN stanclard AG-114/U | “Approx 75 m_| Approx. 50 m [ en Coated Cable equivalent to RG-11/U...602 or 702 V | ras ito [nme [0 cree} @ @ ote [orm A090 Fame rod terminal —— ian i, YD ee fame oaeter a ae _tminas Powor supply tor Boxe Groza $—Baek 7a 3 ame oeector “ Dscontion te: March 2012, soe ot] Neto Us nots prt ous. (Mi etas Eanonequpren. sod comeing ten ee wie open cit pte ese roe onl egos mer etn 85 SS prewte ange of eponen cot gn sega pected sis nap ere coe unger he oma wh ne ote tener car ren andi och w:s0feesara dng apercn bee bay Gero eet ce rr cso Fig. 6 Wiring of Each Flame Detector (1) Improper wiring Priary ce Fig. 4 External Wiring Diagram when Used with Gas- Fired Combustion Equipment (non-recycle) & f ‘uomant Ine wie between ine proteciotelay and valve causes aground ‘due Toinlaion breakdown in The miswarg sats as show inthe ‘lagi above, the roure! alt uront few Uugh fe wave, ahd Ihevalo opens, and han the gas overiows, ths causing dangor of exposion (2) Proper wiring i - tet Note (1) Use an vertoad potter as raquies 2) Faritemtentgnien, comet onten Sei Tensioner be torial ©. (@) When ang volage ampere contoler 16 be used instead ol the low votage temporaure caolen jumper the tomnals @) and G3. and eanneet tbe ine vollge tempsatne eaewoler Dsiween tne temPel @ en Ime ‘Wen the proper wing fs wade es shown in tha above agra, no ‘round fat euro tows tou ‘reuncsagt has ‘Scr de to mlaon renksoun onthe vokage side The foe, hore eno danger of ges overow wie Fig. 5 External Wiring Diagram when Used with Oil- fired Combustion Equipment (recycle) Fig. 7 Wiring between Power Source and Valve (with the power source provided with voltage and round electrodes)3.7 Subbase Connection for Interrupted Pilot vet 7 toe a | ee Tan eae tonsa -©) + i | i 2 he [rere om) Le rHA.O9 PP wey TR Low tape BE er HH Sn, Note (1) Te ne orn ged pot sat oy be Tt check) et atontme-—a.". «ain gion nah (vans to met. lh me (2 The TM a nonreoyl nero preven rotons ner 7 {esse pt rion fine smutty. fe (2) State nontecyoe crak be caro sncethepiotvaveis (OM ZA —h pen unl he aly sun aperatod alr fae are wren i— fepot towels aig =a (2) Useitign vetoiy tne wen witsang he fad capacty ‘atiouay wae vane (WIE a Fig. 8 External Timer Connection for Interrupted Pilot 3.8 Subbase Connection using Contacts whose Pre-purge has been|Completed Note Ut etch Tirevotace 1 pa sts ; Wain fl velve 7 » © + teas). fgg ition cmttO Ot | a tempectre © Od ' ' aa ie Op TTT] a Cy “ow tape #3 Be 1 Note (1) To cmbutton sin const alter te conpleor ot po puge shal be eid in sees SEE sith th cena ol the ie voage o lw voltage tonporature contol. a Fig. 9 External Contacts Connections using Pre-purge Timers4, OPERATION 4-1, Gas-Fired Combustion Equipment inet together ‘equipment. connec! the endelay 5 @ eH ae SSeeel] — oth 5 : Lo | —_| = a : T © Nate ees tome imate wnsee |_| 388 Ei brmaerecumeres LL TS arta Peppered boy sai we ej eases ae Transiomer “Se, supaly Internal Block Circuits of RA89OF (1) Normal Operation (Refer to Figs. 10 and 11) Fig. 10 Example of Connection of Gas-Fired Combustion Equipment with External Devices and Power Switch and (Operation of RABSOF Equipment Status (on) ‘excited, nor the system is started Contotler Power switch ON ‘The power voltage is appliod to the transformer of RABOOF. Limit Controller ON Each Gontroler 1. While the relay 2K i excited by a false fare signal in the fame detector | Nol stared, Comnoustion command Creat, the relay contact 2K3 is tuned OFF. Theretore, the lay TK is neither 2. Ifthe relay 2X is nol excited with no false flame signal, the relay contact 2K istumed ON and, after the delay time of approx. 3300 fr heatag the thermistor, the relay 1K is excited and the relay contact 1K1 i tuned ON. Then, the circuit between terminal @, @ and @)is closed, and tne relay contacts 1K3 and 1K are tuned ON. Therefore, aseltnold circuit's ‘contigurated for he relay 1K, and the safety swiich heater stars to be heated. * This is the start check time of approx. 3 sec at the rated voltage and the ‘rormal tamperature. Especially, this time is affected by the ambient temperature. It changes by approx. 20 103 sec within the ambient temperature range of ~20 10 +40°C atthe rated voltage Biot valve “open” Ignition wansforrner starts ‘operation, Flame check by lame | The rolay 2K is excited and the relay contact 2K1 Is tuned OFF. The cut Ignition transformer flame detector ‘Combustion command for the controller detector between the terminals @ and @ is opened and that between terminals @ and | stops operation, @is closed, Further. the relay Contact 23 is turned OFF, and the saely ‘Main fu valve “open ‘Swiich heater stops heating, Controller combustion | The realy 1K isnot excited, and the relay contact 1K1 is tured OFF The Main fel vaive and plot stop command (OFF) | circuit between terminals @ and @)is opened, and at he seme time, the relay | valve “close” Contacts 1KS and 1K are also turnod OFF. Flame failure check by | Relay 2K isnot excited, and the contol le plaoed in wat stalus of ‘All units stop.—— Caution — To reset the RABSOF safety switch, after 3 minutes has elapsed from the time it has operated and then atter the malfunction has been rectified, press the reset pushbutton to reset. Do not try 3 times or more. (2) Ignition Failure (Refer to Fig. 12) Alter the ignition transformer starts the ignition operation ‘and the pilot valve is “opened”, the voltage is applied to the @. Ifa flame is not detected within the on-delay set time of the @ the contact of the timer is turned OFF, and the ignition operation is stopped, Alter the safety switch timing of 18 sec, the safety switch is locked out, and the SSI is turned OFF. The 1K relay is ‘ot excited, and the pilot valve is “closed”. If the set time of the @ is more than 15 sec, the timer ‘operation is cut off in 15 soc because the safety switch timing of 18 sec has priority. Generally, the set time of the @ is 10 sec max, For the time setting of the @, refer to the guidance of the Japan or Local Gas Association. (Gafety technology guidance of industrial gas combustion facilities) (8) Flame Failure during Combustion (Refer to Fig. 13) Ifa flame failure is detected by the flame detector during operation, the fiame relay 2K is released, and the relay ‘contact 22 is turned OFF, and then no power is supplied to the terminal @), but the main valve is “closed”. The re- lay contact 2K3 is turned ON, and the voltage is applied to the safety switch heater. In the gas-fired system, the on-delay timer is operated, and the contact is turned OFF. Therefore, re-igntion is prevented, but lockout occurs after timing of safety switch, ‘The contact SS1 of the safety switch is turned OFF, and the control circuit is deenergized. The relay 1K is released, and the relay contact 1K‘ is tumed OFF, and then power is supplied between the terminals @) and @, At the same time the contact SS2 is tured ON, and an alarm is issued. For restarting, it is necessary to reset the safety switch manually Caution Ii there has been a power failure before lock-out after a flame failure while the device is operating but then power is recovered, ignition will start at the same time as the power is recovered. This is because the on: delay timer was reset when the power failure occurred, If there has been a power fallure after lock-out and then the power is recovered, 1K will not be turned ON. because safety switch contact SS1 is open even when the power is recovered because lock-out has already occurred (1K OFF, 2K OFF). To restart, Confirm that it is safe to do so and then manually reset the safety switch, (4) In Case there is a False Flame at Start (Refer to Fig. 14) It there is a false flame before the start of combustion, the: relay 2K is excited after power ON, and the relay 1K is kept released. ‘Thorefore, tho rolay 1K is not started, but kept released, ‘even when the temperature controller is tured ON. a {Power auton ot Power swish on Tempe fototr ON temperate ‘Minox gee conte OFF) + (et chee lgnton pM st arsirmer — cm ILI Ce Frame detection Fig. 11 Normal Operation Power ewich ON Temperature ontoier ON [OM Safety teh tring Boney ing rtorme Piotvave Yl, 3 i a een wok YAATETE Fig. 12 Ignition Failure Wan vane Todcout ame faire got | ‘gniton anetormee Pct valve main vave Qe Asean Man veve | (2 ‘Nan it falas fare Fig. 14 With False Flame at Start4-2. Oil-Fired Combustion Equipment (This is a recycle combustion equipment) ‘equipment. When no-recycle is required, add a timer as in a gas-fired combustion an Ts Note (1) Connect the tne volage lemoerature contol shown he figure. and Iumper ‘ne termina, TT ay and Internal Block Circuits of RABOOF (1) Normal Operations (Refer to Figs. 15 and 16) Fig. 15 Example of Connection of Oil-Fired Combustion Equipment with External Units, (On Power Swatch _ ‘and Contoior (Operation of RABOOF Equipment Status Power switch ON ‘Tho power voltage is applied tothe tanstormer of RABDOF. mit Contioller ON Each Contoler | Wile the relay 2K is excited by a false ile signal inthe ame detector | Not slavted Combustion command circuit, he relay contact 2K3 ' turned OFF. Therafore, the elay 1K nether exc'ted, nor the system is started 2 When there is no false flame signal he relay contact 2K3 fs tuned ON and, alter the delay ime of approx. 33ec" for heating the thermistor, the fesay 1K 's exctod, and the elay contact 1K is turned ON. Then, the crcut between| rminals @, @ and @)is closed, and the relay contacts 1K3 and 1K4 are ned ON. Therelore, a self hold circu is conigurated trough the relay, 1K, and the saety switch heater starts to be heated, “This the stat check time of approx. 8 sac a the rated voltage and tne ‘normal temperature. Especially, tis time is aflected by the ambient temperature. It changes by approx. 20 to 3 sec within the ambient temperature range of =20'0 “+40°C atthe rated voltage Tgniton translonner starts operation Burner motor starts il combustion valve “open Flame check by tame otactor The relay 2K ie excitod and the relay contact 2K1 is tumed OFF. The circuit between terminals @ and @)is opened and thal between the terminals @) and @is closed. Further. the relay contact 2K3 is tured OFF, and the satety Switch heater siops heating, "nition transformer ‘stops operation, Socond:-siage ol ‘combustion valve —_ Controller combustion stop command (OFF) The realy 1K is released, and the relay contact 1K is tumed OFF. The circuit, between terminals @ and @)Is opened and atthe same time, the relay, ‘contacts 1KS and 14 are turned OFF. Second:siage all valve and ol valve are 1 “elosed", andthe burner | | ‘motor is stopped. Flame fare check by flame detect Te relay 2K is released and the conirller Is placed in combustion waling status, ‘All system stops,Caution To reset the RA8GOF safety switch, after 3 minutes has elapsed from the time it has operated and then after the malfunction has been rectified, prass the reset pushbutton to reset. Do nat ty 3 times or more, (2) Ignition Failure (non-fired) (Refer to Fig. 17) If the flame detector does not detect a flame within the lockout timing (approx. 15 sec) after the ignition transtor- ‘mer starts the operation and the oil valve is “opened” as shown in the normal operation of Fig. 14, the safety switch heater ig heated, and the contact SS1 Is turned OFF, and then the 1K telay is released. The contact 1Kt is turned OFF, and the ignition operation is stopped, and then the oil valve is “closed”. At the same time, the contact S82 is tumed ON, and an alarm is issued. (8) Flame Failure during Combustion (Refer to Figs. 18 and 19) If the flame detector detects a flame failure during opera- tion, the flame relay 2K is released, and the relay contact 2K2 is tumed OFF, and then no power is supplied to the terminal @) but the second-stage oil valve is “closed. The relay contact 2K3 is turned ON and the voltage is applied to the safety switch heater. When the ignition transformer is connected to the terminal @ the rolay 2K is reloasod and at the samo timo, the relay contact 2K1 is turned ON, and the ignition transformer is ‘operated so as to re-ignite the burner, thus performing a recycle operation. ‘When a flame is detected again within the safoty switch timing, the second-stage oil valve “opens”, and the normal ‘combustion starts. (Refer to Fig. 18.) Ifa flame cannot be detected again, lockout occurs atter the safety switch timing The safely switch contact SSt is turned OFF, and relay 1K is released. The relay contact 1K1 is tumed OFF, and no [power is supplied to the terminals @) and @. At the same time, the contact $S2 is tured ON, and an alarm is issued. For restarting, it is necessary to reset the safety switch ‘manually. (Refer to Fig. 19.) (4) In Case there is a False Flame at Start (Refer to Fig. 20) It there is a false flame before the start of combustion, the folay 2K is excited after power ON, and the relay 1K is kept released. Therefore, the relay 1K is not started, but kept released, ‘even when the temperature controller is turned ON. over snich On| Tegsae, Fo eth Oa sax ar OFF) Were ‘Sucon Iain anstormer ovate WLLL, ‘Second-stage valve: VL ‘Alar uit fe are Fig. 16 Normal Operation er Balch ON Tempera senor ON ocho ‘gee, “=p Sofety sch timing lgnton tanstomer aii Secondstege vave, C7 __—"ilimia — Tine ova ‘ew uit Fig. 17 Ignition Failure (not fired) Fame ca lage va eno sain ero) ame cetocton "ff So tn bea ‘anion tanstorme onvale Seconaeiage vate Fig. 18 Recycle at Flame Failure (with re-ignition) le falrol Soong wage Lockout wpometat Pepe iperlame osponsa eg —L-Saloty etch ting losonvartomer ——} olvave CLL, secon te vb Zl am art C——mm: detected again) ower ewtch ON tortion tanstomer one Seceestane vive [3 Nasr vt CT False flame TLE The Fig. 20 In Case There is a False Flame at Start| 5. — Caution — Use utmost care wrile testing the RABSOF, since the line voltage can be present on the most terminals when power is ON. 1, Preliminary Checks (1) Check through wing, (2) Check if the RA89OF is installed at a place within the allowable ambient temperature range. (3) Check ifthe flame detector is installed propery. (Refer to the Instruction manual for the flame detector) (4) Check if the burner has been adjusted propery. (6) Check the exhaust mechanism in the flue. (6) Press the green pushbutton at the front of the RABQOF to reset the safety switch. 2. Checkout Procedure ‘To operate the system more safely, check for the following items satisfactorily (1) Flame current check (2) Ignition spark test (@) Pilot turndown test (8) Safe shutdown crecks (8) Check of hot refractory influence (only in the case of photocell) (1) Flame current check ‘The flame current chack is the best way to identify the proper flame detector nstallation. The check shall be done ft the time of installaton, every time service is done, and at least once a month, or more often. This will prevent shutdowns due to pocr flame signal Aniiog tame meter FSPia6q100 4 i ° ra . o “© Fame current testiack CHECKOUT Fig. 21 How to Measure the Flame Current When measuring the flame current, insert the current ‘measurement plug of an Analog flame’ meter FSP136A100 into the flame current est jack of the RAB9OF protectorelay. ‘Then, operate the buner and read the flame current from ‘Analog flame meter ‘Fig. 21). When reading the flame ‘current, ensure thatthe folowing two criteria are met. ® Tho flame current must be steady. ® The flame current must be at least 2 microam- peres. The normal operating range will be 2 to 7 ‘microamperes. Ifthe stable flame current is not obtained, one or more of the following items is considered. ‘# The power supply is not suitable. © The.connection of the flame desector is improper. Open status — Short circuit status — Insulation breakdown of leads caused by mois ture and contamination Unsuitable viewing position anc viewing window Dirty ight receiving face of ultra-vision Improper ultra-vision Improper application of a flame rod, including — insufficient flame contact area —poor location of flame rod in flame excessive heat on flame rod insulator (greater than approx. 300°C) —ignition transformer influence ‘© Improper application of a photacell, including —iatpecenee over 74° (towabe, tenerae range) —dirty photocell envelope (2) Ignition spark response test ‘Make arrangement so that the flame relay 2K may not be ‘excited by the sparks generated during the operation of the ignition transtormer. ‘Check the response of the flame detector to the ignition sparks in the following procedure, and check the mounting position @ Close the manual fuel"valves for the pilot burner and main burner to shut off the fuel ® Close the power switch, and raise the set positions Of the controlier or close the start/stop switch to start the system. ® The ignition transformer is operated and sparks are generated between the ignition electrode and flame ground, @® Make sure that the flame relay is not excited at that time. The systom is shut off after the safety switch timing of the protectorelay. © Ihe flame relay is excited, change the location of the flame detector or the ignition electrode. (3) Pilot Turndown Test ‘Caution The pilot turndown test shall be 2erformed only by qualified personnel, and the instructions given below shal be followed carefully. This testis intended to prove that the main burner can be lighted exactly so far as a pilot flame is detected by the flame detector, even when the gas pressure and air pres sure are changed into the worst conaitions. Be sure to execute the pilot tumdow test in service. ‘© Shutoff the fuel supply to the pilot burner and main burner by closing their manual shutoff valves. ® Connect a manometer to the downstream side of the pilot solenoid valve. Open the manual valve on the pilot gas line. Start the system by raising the set point of the con- troller. The relay 1K is excited and the pilot vaive ‘opens, and then the ignition operation starts. ® ®Gradually reduce the size of the pilot flame untl no fiame can be detected by the fame detector, by slowly closing the manual valve on the plot gas line, The lame relay 2K and relay 1K are released and the pilot solenoid valve closes, and then the pressure of the manometer drops down suddenly. ‘The safety switch heater starts heating and lock: out occurs 15 sec ater. Record the pressure im- ‘mediately beiore the plot solenoid valve closes. Foset the sefely switch and restart tho system. Gradually open the manual valve again on the pilot g2s line and set ito the pressure immediately be- fore the shutoff measured in step @). ‘Check if the main bumer is lighted smoothly within 7'sec alter the manual valve on the main gas ine is opened. Who changing the gas pressure to minimum and maximum values and repest ignition to the main bumer 5 oF 6 times. Then, check if ignition is per formed smoothly withn 1 sec every time Ifthe main bumer cant be lighted, itis necessary tovenlarge the size of he pilot fame, After enlarg- ing the pilot lame, make the adjustment to Keep the viewing line ofthe C70T2A oF photocell a iti away ftom the 2x ofthe plot lame, or make cor- rection withthe flame size reduced Inthe case ofthe flame rod, move it toate outer side from the center ef he plot flame. Alter the completion of adustment, check ifthe main burner is igited smoothly by repeating steps O10. ‘iter the end of fest, restore the manual valve on the main gas lino to the fully open positon and check if the flame current is proper. Disconnect the manometer e8 ® @ ® Caution If this test needs to be rapeated, stop the system completely once and perform the purge of unbumed gases or oll the firebox or flue before proceeding fo the next step. Also allow at least 30 sec for the ON/OFF interval of, the power supply to the RABSOF. Caution ———______ Make sure that the C7012A Ultraviolet Flame Detector | does not detect ignition sperks. If detected, change the location of the Ultra-vision or the ignition electrode. 10 Sate shutdown checks ® Limit action check ‘With the burner operating, lower the high limit sot- ting to simulate an overheated borer or furnace, ‘and normal shutdown will occur. Restore the nor- ‘mal limit setting, and the burner will restart. It is recommended to use a manual resetting type high limit. When the manual reset type high limit is, used, the system does not make recycle operation, but the cause can be located if the system stops. Flame failure check With the bumer operating, close the manual fuel valves to simulate a flame failure, and the system will Iock out in safety switch timing (approx. 15 ‘8e0). Afier the safety switch has ecoled (in 3 min (or more), open the manual fuel valves and reset the safety switch, and the burner wil restart Caution Be sure to check if the protectorelay is operated nor: ‘mally by shutting down the burner marvally. ® Power failure check With the bumer operating, open and then im mediately close the power switch to simulate & power failure. The burner will shut down, and after a short delay, will restart and operate normally. @ ® (6) Hot refractory influence check (only when a photocell is used as a flame detector in oilfired system) It the flame relay Is excited by the hot refractory influence at the end of the burner-on cycle, the sysiem cannot re- start unl the system has been cooled, and the flame relay is released, Therefore, operate the burner until the normal operating status is obtained, and then shut down the turer. Check i the flame relay is released immediately without being affected by the hot refractory. If the flame relay remains excited, the photocell may be heated or the flame relay is affected by the hot refractory. Resolect the viewing posi- tion or reduce the sensitivity of the photocell by inserting an orifice or filer in the viewing window. (For the reselect- ing method of the viewing position or the sensitivity re- ducing method for the photocell, refer to the instruction ‘manual for the photocell.) — Caution ‘After the completion of individual adjustments, start the combustion with the beginning, and recheck if the system operates normally.1. General Service Cautions 1. Only qualified personnel shall attempt to service the heating equipment or controls. 2. Do all checks under the check items on pages 11 ‘and 12 when replacing the RA89OF or restoring | power to the system after shutdown in safety. 3. The captive mounting screws carry current. Be ‘sure to disconnect power before loosening or tight- ening the mounting screws, 4. On each service call, check the controllers for approximately correct calibration and differential, ‘and ensure that they are mounted securely. Never use oil on any part of the RABGOF. ‘When cleaning the burner, clean the flame detector as woll 7. Do not push the internal relays of the RABQOF ‘manually. This may damage the relays, and it is an unsafe practice because it overrides the protective {features of the relay. 2. Periodic Maintenance ‘The specific maintenance schedule setup will depend on a number of factors, including types of equipment being con- trolled, operating conditions (dirt and heat especially), the ‘cost of a nuisance shutdown, etc. (1) Perform a pilot tumdown test whenever the burner is serviced, and at least annually. (2) Perform a bumer shutdown check at least ‘monthly. (8) Inspect and clean the flame detector and any viewing windows as often as required by soot acoumulation and heat conditions at the detec- tor Do a flame current check at least monthly and ‘more often where a shutdown may be costly. 4 3, Troubleshooting lt trouble occurs in the heating system and its cause Is not immediately apparent, the service technician can apply the following step-by-step checkout to locate the cause of most problems. Refer to Figs. 4 and 5 for terminal loca- tions. (1) ‘Set the controller not to call for heat (2) Reset the safety switch for the protectorelay by pushing it. (8) Close the line switch. (4) Check for the line voltage between the terminals @ ‘and @. (The voltage will be zero if a line voltage con troller is used. Check for the line voltage when the controller is set to call for heat.) ® The voltage must be within +10 to ~15% of the rated vollage, ® I the vottage is zero (with the controller connected to the terminals © and @), check i the limit switch contacts are closed, and power is supplied. Check for blown fuses, open circuit or open disconnect " Caution Use utmost care while troubleshooting the RABSOF since the line voltage can be present on most ter- ‘minais when power is on. 4, Flame Status Check (1) Ifthe flame relay is not excited, proceed to step 5. (2) the flame relay is excited, check for a flame simula- tion condition Disconnect the wiring to the flame detector. @ Ifthe flame relay is excited, replace the RAB9OF. @® tthe flame relay is not excited, the flame detector oF external circut is defective. Check them. 5. Set the Controller to Call for Heat. If the controller is connected to the terminal @ line, go bback to steps @ and ©. 6. Check if the Load Relay is Excited. (1) When the load rolay is excited to light the pilot and start the bumers, proceed to step 10. (2) Ifthe load relay is not excited, proceed to step 7. () Ifthe load relay is excited, but the pilot doesn't light, ‘or the bumer doesn't start, proceed to step 9. 7. Check the line voltage controller and limit switch for proper operation if the line voltage controler is connected {o the terminal @. If the load relay is not excited, turn ON the controller and check the voltage between the terminals @ and @ again. Replace the RABSOF if the load relay is not excited stil, although the rated voltage is obtained there. If a low vol- tage controller is used, proceed to stop 8.8. Check the low voltage controler, i used, for proper op- eration, (1) When the load relay is excited with the terminals ‘and @ jumpered, check the low voltage controller and external connection circuit. (2) IWithe load relay is not excited with the terminals @ ‘and © jumpered, replace the RABSOF. 6. ttn load relay is excited, bu the pot won't ight or the bumer wont star, check the voltage atthe terminals Qa @-2. (1) “Itno voltage is obtained atthe terminals @~@ or © {@), roplace the RABSOF (@) {the normal ino voltage is obtained at the terminals @-@ and (®-@, check the external circuits of the buimer,gntion transformer and fuel valve Check the wring, bumer adjustment, ignition system inaluding the eloctode spacing and location, ol qual: ty, charactor and offciency of ol stomization, Tua Supply pressure, flame pattom, flame character and Guat, piot bumer locaton with cespect to main burn Gr. lame detector, or other condtions that may delay ‘gniion Flame Detecting Function 10. Observe the flame relay (right-hand relay) for excita- tion when the bumner is lighted. (1) When the flame relay is oxcited, proceed to step 12. (2) When the flame relay is not excited, proceed to step. tt 11. Check the flame relay with a 1235148 flame simulator, ifavalable, orn the following procedure (1) Check the flame current (refer to pages 9 and 10.) (2) If the flame current is salistactory, replace the RABOOE, (3) Ifthe flame current is not gatistactory, check for all the items listed on pages 9 and 10. 12 Observation of Sequencing Operation 12, Observe the operation of the main fuel valve when the flame rolay is excited. If the main fue! valve does not open, ‘check the voltage at the terminals @)~@. (1) When the normal voltage is obtained, check the main fuel valve and valve circuit (2) If the normal voliage is not obtained, replace the RABOOF. 13. Check if sparks are cut off when the flame relay is excited, ifthe ignition transformer is connected to the ter- ‘minal @. Check if the wiring Is proper. If sparks remain, roplace the RABSOF. Miscellaneous Problems 414. Relay Chattering Load relay chattering may result from the extreme low power supply voltage (check the power supply voltage) or from a loose terminal connection (retighten). Flame relay chattering may result from improper combus- tion (adjust the bummer) or soot or carbon on the viewing pat of the flame detector (clean). 18. Repeated Lockout or Control Failure ‘The most common causes of repeated fallures of the con twoller or flame detector, or repeated lockouts are (High ambient temperature (for the allowable range, refer to the specifications). ® Supply voltage variation greater than +10 to 18% of the rating. Electrical overloading of the contacts Marginal flame current value Frequent start/stop operations at high ambient temperature ® @ ® 16. Loose Terminal Screw It faulty operation has occurred, check if there is ¢ loose terminal screw.Z. SPECIFICATIONS Protectorely: Tha somal onparars Rated normal humidity, and rated voltage) Operation ‘Web, | pes | ewes |e mm Pom om) __| Opaaten | rane Oxecor Votege Selicheck ocd Flame response (at_ | Flamo Failure vee om at start — flame currant of 2 wA) asoF aoe O88 Fane OU TOOT A peaeomeeee oft & RABOOFI411 x2 Approx. 3 & Sais Ulira-vision z Chrtrence | Appt 188 ete pass Crate a2 TaOOF 45242 Satin oes RAB 2862 gate °Y Ataad vag and artien emporio! 2010 O'S approx ZO Boe “2 Onno arse on /Adeplableeauipmant: Bach operation combustion Alowable volage: 8510 110% of raed ogo eatipment up (0700 KW i Atowable arte somone Tempers -20to+41°C (0H), 46°C (0H) object Sarbuston ge rot (opto Aonabl arnbiont Too KW in combustion tate) nei: 80% max, at aro Dielectric strength: 1500 Vac for 1 min between Contetetigs: timings BO.) and ease Vibration resistance: 48 fe" shin cach Sroston of Terminal ‘Load Contact rating: X,Y, and 2) eral 00a Mass: Tati 1 [paeoreaer Sova] evercoatcolor: Srey shamel $n a ae | uring of main unt; Mocrted ot the C270A eubbase ‘nominal eoews. i 7 80,0 am TEVA ‘Tho G2TOA es evalble at option, ame ir A Extemal dimensions: Refer to Fig. 1 In case the bumer motor and pilot valve are connected to the Mounting dimensions: Refer to Fig. 2. terminal @. Accessories: Receptacle for emrcrmnas_} 3 pos oach = auatng sores anal = Contact rating Auviliary equipment: (Option) r Tan vie | 20 ae SErbnloos Sutase [Saver [Rema] 2K 23614 Fao simular a |metor_['sart | | as8% | FSP198A100 Analog fae mtr ia 250k Femme cent ‘measuring test jack: Provided Power consumption: 50 Hz~8.5 W (17.0 VA) max. (60 Hz—7.0 W (13.0 VA) max, 13Azbil Corporation ‘Advanced Automation Company 1-12-2 Kawana, Fujisawa ‘Kanagawa 251-8522 Japan URL: ip-/www.azbil.com azbil ‘Specifications are subject to change without notice. (08) ‘stedtion: Mar. 1090, ‘Mth ection: Dec, 2012 (M)