No.

CP-UM-1218E

RA890G
PROTECTORELAY
Burner Controller
User's Manual

Thank you for purchasing the RA890G

PROTECTORELAY Burner Controller.
This manual contains information for ensur-
ing the correct use of the RA890G. It also
provides necessary information for installa-
tion, maintenance, and troubleshooting.
This manual should be read by those who
design and maintain equipment that uses
the RA890G. Be sure to keep this manual
nearby for handy reference.
 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.

© 1984-2013 Azbil Corporation All Rights Reserved.

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:

Warnings are indicated when mishandling this product might result in

WARNING death or serious injury.

Cautions are indicated when mishandling this product might result in

CAUTION 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.

Be sure to follow the indicated instructions.

Handling Precautions:
Handling Precautions indicate items that the user should pay attention to when handling
the RA890G.

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.

i
Safety Precautions
Safety precautions are intended to ensure the safe and correct use of this product, to prevent injury to the operator and
others, and to prevent damage to property. Be sure to observe these safety precautions. Please make sure you under-
stand the safety guidelines before reading the rest of this manual.
The use of this product in a manner not specified by the manufacturer will impair its built-in safety features.

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 24h or longer).
This device performs recycle operation during flame failure. Therefore, when it is to be used together
with a gas-fired combustion system, operate it in non-recycle sequence by using an on-delay timer.
This device does not have the prepurge functions required for burner ignition. Give careful consider-
ation to various safety guidelines, etc., when setting timers and sequencing times.
Wire terminals 1 and 2 so that they receive power continuously whenever 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 terminal 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 de-
vice. If they are not directly connected, combustion safety cannot be ensured.
Do not allow the pilot or main burner 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 wiring, mounting, or removing this device, be sure to turn the power off. Wiring with the
power on can result in an electric shock.
Do not connect a solenoid valve to the high voltage 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 pre-
vent 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 terminal F.
Carry out the pilot turndown test. If the flame detector is set so that it detects a pilot flame that is
too small to ignite the main burner, this device will not be able to detect a flame failure in the main
burner. 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.
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/regulator 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 completing the trial-run adjustments
for this device, as well as the tests specified by the equipment manufacturer.

ii
 WARNING
If lockout occurs, be sure to remove the cause of the lockout and reset it. Also, be sure to do a pre-
purge 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.
To prevent electric shock, turn the power off and discharge any remaining electrical charge before
removing this device from the subbase. Use lead wires to connect terminals F and G of the flame
simulator (FSP300C100) to terminals F and G of this device for 10 seconds or more.
Do not touch this device's internal relay. Doing so might damage the relay or cause this device and/
or the combustion equipment to malfunction.

CAUTION
Use the RA890G for the oil-fired or gas-fired combustion equipment up to approx. 700 kW in com-
bustion rate.
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
Make sure the load connected to each terminal does not exceed the rating indicated in the specifica-
tions.
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.
Do 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.
The ignition transformer ground lead should be connected directly to the burner body or to a metal-
lic part electrically connected to the burner body.
Connect the blue signal lead from the Minipeeper Ultraviolet Flame Detector to terminal F and the
white lead to terminal G. Turning on the power while the flame detector is incorrectly wired could
damage the UV tube.
A thermostat for low-voltage use is usually put between terminals T1 and T2.

Run the high-voltage ignition transformer cable separately and keep it at least 10 cm away from this
device.
Keep power lines and ignition transformer high-voltage cables separate from the flame detector
wires.
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.

iii
 CAUTION
Always connect the power supply last. Otherwise, touching a terminal accidentally could result in
electric shock or damage.
Always supply electric power at the voltage and frequency stated on the model label of this device.

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 position of the detector or the ignition electrode.
Only an experienced technician who has knowledge and technical skills related to combustion equip-
ment 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 com-
bustion equipment. Carefully follow the instructions for its use that are given in this user's manual.
Do not use this device with the cover removed. Doing so might cause faulty operation.

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 4, INSPECTION AND
ADJUSTMENT.
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 manufac-
turer.
When cleaning the burner, clean the flame detector as well.

iv
Contents
Conventions Used in This Manual
Safety Precautions

Chapter 1. OVERVIEW

■■ Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
■■ Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
■■ System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
■■ Security function and precautions for facility instrumentation . . . . . . . . . . . . . . . . 2
■■ Names of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 2. MOUNTING

■■ Mounting the subbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

■■ Mounting the RA890G onto the subbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 3. WIRING

■■ Non-recycling gas-fired combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

■■ Recycling oil-fired combustion (2-stage combustion). . . . . . . . . . . . . . . . . . . . . . .12
■■ Wiring the solenoid valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
■■ Wiring AUD100 series Advanced UV Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 4. INSPECTION AND ADJUSTMENT

■■ Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
■■ Ignition spark response test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
■■ Pilot turndown test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
■■ Safety shutdown checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 5. MAINTENANCE

■■ Maintenance and inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

■■ Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chapter 6. SPECIFICATIONS

■■ Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
■■ External dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

v
Chapter 1. OVERVIEW

■■ Overview
The RA890G is an electronic burner controller to be used for the automatic opera-
tion and safety operation of gas, oil or combination gas-oil combustion equipment,
up to 700 kW in batch operation. And it is used combined with the AUD100 series
advanced ultraviolet flame detector. For combustion equipment in continuous
operation, use the AUR450C dynamic self-checking burner controller. This device
can configure a prepurge function using external instrumentation, and automati-
cally ignite pilot and main burners, and monitor the flame. The RA890G performs
recycle operation during flame failure.
Compatible burner Purge Ignition Behavior if flame Compatible flame
operation type function function failure occurs detector
Batch No Yes Recycle AUD 100 Series
Advanced Ultraviolet
Flame Detector

■■ Features
• I f the burner fails in ignition, the safety switch is operated to shut off fuel
automatically.
•A
 safeguard circuit is incorporated to prevent the RA890G from being operated,
when the flame detector detects a false flame.
•W
 hen connected to temperature controllers, etc., the RA890G can automatically
start and stop combustion.
•A
 test jack is provided to permit the flame current to be read.
•A
 pplicable to the intermittent pilot system.
•T
 he RA890G is operated after mounted directly onto the Q270A subbase.

■■ System configuration
In terms of the overall system, the RA890G serves as the ignition controller and the
flame monitoring device. It is used as shown in the diagram below.
High limit controller

Temperature
Air pressure controller
lower interlock

RA890G Flame Exhaust

detector T/C T/C
Air PS L
Combustion
chamber
PS L PS
H
Fuel
MV MV

Gas pressure PV PV
lower interlock IG
Gas pressure Ignition Combustion equipment
upper interlock transformer

1
Chapter 1. OVERVIEW

■■ Security function and precautions for facility instrumentation

The RA890G is designed to ensure safety, and plays an important safety role by
monitoring the burner operation and the flame.

(1) Combustion monitoring and safety shutoff

• D
 etects flame failure in the burner and quickly shuts off the fuel and shuts
down the burner.
• W
 hen an ignition failure, flame failure or flame-out occurs, the RA890G fol-
lows a fixed sequence to stop each piece of equipment.

(2) Startup, operation, and shutoff of combustion equipment

• T
 he RA890G operates each device according to the predetermined sequence
and timing.

(3) Safe startup

• A t every startup signal, the RA890G checks for false flame in the flame detec-
tor and flame detection circuit.
• I f a problem is detected, the RA890G does not start the burner.

(4) Redundant design

• Maintains safety even if its own self-check circuit fails.
• Will not deviate from the proper ignition sequence.
• The sequence timing is designed so that it is failsafe.

In designing facilities that use combustion safety devices, be sure to give careful
consideration to the safety guidelines listed below.

• F
 or safety standards for industrial facilities using combustion equipment, see the
technical guidelines published by the Ministry of Health, Labour and Welfare.
• F
 or general safety rules for industrial combustion furnaces, see JIS B 8415.
• F
 or technical safety guidelines for gas combustion furnaces in industrial use, see
publications by the Japan Gas Association.

●● Important points for ensuring safety

(1) Connect the load directly to the RA890G.
(2) Design the interlock so that it can directly cut off power to the load.
(3) Be sure to use a safe startup circuit upon startup.
(4) Do not set up a bypass, such as manual operation, for any load.
(5) Have a redundant main valve and pilot valve.

●● Precautions for system design

• S ince the RA890G does not have purge and ignition functions, they must be pro-
vided externally.
• T
 o stop the recycle at flame failure, provide a timer circuit externally.

2
 Chapter 1. OVERVIEW

■■ Names of parts
Terminal block

Load relay Flame relay

(1K) (2K)

Safety switch

Q270A1024
Subbase Flame current
(sold separately) test jack

Transformer 2
Mounting base Transformer 1 (TR2)
(TR1) Safety switch
reset button
Cover Cover retaining
screw

3
Chapter 2. MOUNTING

Handling Precautions
• 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.

■■ Mounting the subbase

CAUTION
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
When installing and wiring, be sure to follow the instructions in this manual and in the user's
manual for the combustion equipment.

●● Mounting method
(1) Mount the subbase as shown below, so that the three knockouts on the back are
in the lower part of the back, the top edge is horizontal, and the back is vertical.
The subbase may lean backward within 45 degrees if necessary.
(2) Open knockout holes for conduits as required, and attach wiring conduits there.
(3) Fix the subbase at the specified position with screws (3).
Vertical
Horizontal
Maximum lean 45˚

.
73

. .

104.8
ø22 Knockout
Mounting holes (3)

OK OK

4
 Chapter 2. MOUNTING

■■ Mounting the RA890G onto the subbase

Mount the RA890G onto the subbase after the completion of external wiring.
(1) Loosen the cover retaining screws and remove the cover from the RA890G.
(2) Set the position of the RA890G mounting base to that of the subbase.
(3) T
 ighten the terminal screws (10 pcs) of the RA890G securely in the individual
terminal thread holes in the subbase using 1 N·m tightening torque. (Electrical
connection with the subbase is completed when the RA890G is mounted.)
(4) Replace the cover to the RA890G.

Terminal screw holes (10)

Terminal screws (10 pcs): Tighten securely

Q270A subbase

RA890G mounting base

Cover Cover retaining screw

Handling Precautions
• The RA890G is connected electrically with a subbase by terminal screws.
A loose terminal screw makes the RA890G malfunction. Be sure that there is
no loose terminal screw.

5
Chapter 3. WIRING

WARNING
The RA890G performs recycle operation during flame failure. Therefore, when it is to be used
together with a gas-fired combustion system, operate it in non-recycle sequence by using an on-
delay timer.
Wire terminals 1 and 2 so that they receive power continuously whenever 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 terminal 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 de-
vice. If they are not directly connected, combustion safety cannot be ensured.

CAUTION
Connect the blue signal lead from the Minipeeper Ultraviolet Flame Detector to terminal F and the
white lead to terminal G. Turning on the power when the flame detector is incorrectly wired could
damage the UV tube.
When installing and wiring, be sure to follow the instructions in this manual and in the user's man-
ual for the combustion equipment.
Make sure the load connected to each terminal does not exceed the rating indicated in the
specifications.
Always supply electric power at the voltage and frequency stated on the model label of this device.

If timers and auxiliary relays are needed for additional functions, select ones with high reliability,
and be sure to design the circuit correctly.
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.
Keep power lines and ignition transformer high-voltage cables separate from the flame detector
wires.
Run the ignition transformer high-voltage cable separately and keep it at least 10 cm away from this
device.
Always connect the power supply last. Otherwise, touching a terminal accidentally could result in
electric shock or damage.

Handling Precautions
• Use a PVC insulated wire (such as IV (2 mm2) wire) with 600 Vac voltage proof
for each terminal.
• For the terminals F and G, the allowable wiring length shall be 200 m or less.

6
 Chapter 3 WIRING

■■ Non-recycling gas-fired combustion

WARNING
In the case of gas-fired combustion equipment, do not connect the main valves to terminal 3.
If ignition failure occurs, the main valves would remain open and allow fuel to flow out until lockout
occurs, causing a serious hazard.

CAUTION
Give careful consideration to safety guidelines, etc., when setting timers.

Handling Precautions
• Relay 1K has contacts 1K1 to 1K4 for the ignition transformer, pilot valves, and
main valves. Relay 2K has contacts 2K1 to 2K4 for the flame detector.
• In the case of gas-fired combustion equipment, be sure to connect an on-
delay timer and auxiliary relay to disable recycling.

●● Wiring diagram
Power supply Power supply
(H) (G)

Blower on-off circuit / prepurge circuit

Thermostat*1
(for power supply)
Limit/interlock circuit
(limit switch, interlock switch)

RA890G
AUD100 2K
Series
Blue F TR2 2
Flame
White G detection
1 103
X
Burner
start contacts 1K1 2K2 TM1
6 5
Main valve 1
Prepurge
completion Main valve 2
signal TM1
2K1 4
Ignition
transformer
3 TM1
Pilot valve 1
Start check Safety switch 103X
circuit 2K3 heater TR1 Pilot valve 2

Thermostat*1 Thermistor 2K4 TM

1K2
(for low voltage) 1K4 1
T1
On delay
1K3 R timer
T2 SS1*2
1K NC
COM SS2*2
NO 101
X
Alarm

*1 Use the thermostat for either the power supply or for low voltage.
*2 SS1 and SS2 are contacts for the safety switch heater. Design the circuit so that the blower on-off circuit/prepurge
circuit will always be reset if an alarm occurs (101X: ON).
7
Chapter 3 WIRING

●● Normal operation
Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformers TR1 and TR2.
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Ignition transformer
ON closed) and the burner start contacts are closed, power is supplied to starts
Thermostat terminals 6 and 2, and voltage is applied to transformer TR1. Pilot valves open
(for low voltage) ON • A start request from the thermostat closes the contacts between (TM1 starts)
terminals T1 and T2, and current flows as follows: internal SS1 →
relay 1K → terminal T2 → thermostat (for low voltage) → terminal 1
→ thermistor → contacts 2K3 → safety switch heater.
• When current flows to the thermistor, the thermistor's resistance
declines, and 3 seconds later, relay 1K is energized.
• When contacts 1K1 close, voltage is applied to terminal 4 to turn on
the ignition transformer, and to terminal 3 so that the pilot valves
are opened and external timer TM1 starts.
• Contacts 1K3 close and relay 1K forms a self-maintaining circuit.
• Since contacts 1K2 are closed, the thermistor stops heating, and the
safety switch heater begins heating via contacts 2K3, 1K2, and 1K3.
The flame detector • If the flame detector senses a flame within the safety switch's lock- Ignition transformer
detects a flame out time (about 15 seconds), relay 2K is energized. stops
• When contacts 2K1 open, voltage to terminal 4 is cut off, and igni- (103X: ON)
tion transformer operation stops. (Contacts TM1: ON)
Main valves open
• When contacts 2K2 close, voltage is applied to terminal 5, and exter-
nal relay 103X turns on.
• When the time set for TM1 operation has passed and contacts TM1
have turned on, the main valves open.
• Contacts 2K3 open, and the safety switch heater stops heating.
Thermostat • When the thermostat ends its start request, the contacts between Pilot valves close
(for low voltage) OFF terminals T1 and T2 open, relay 1K turns off, contacts 1K1, 1K2, and (103X: OFF)
1K3 open, and contacts 1K4 close. Main valves close
• Voltage to terminals 3, 4, and 5 stops, and all loads stop operation. (TM1 stopped)
• The RA890G returns to the initial state and is ready for the next re-
quest from the thermostat (for low voltage).

Burner start contacts ON

Thermostat (for low voltage) ON
Start check (appox. 3s)
Blower ON Flame detection Thermostat (for low voltage) OFF
Power ON Blower OFF
TM1
on-delay time
Limit & interlock
Blower ON
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Pilot valve
Main valves
Alarm
Elapsed time

8
 Chapter 3 WIRING

WARNING
If lockout occurs, be sure to do a prepurge before restarting the system. If the combustion chamber
and flue are not ventilated to remove accumulated unburned gas, the ignition process may cause an
explosion.

Handling Precautions
• Even if the on-delay timer is set to more than 15 s, the ignition transformer
stops after the lockout time of 15 s.

●● Ignition failure
Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformer TR2.
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Ignition transformer
ON closed) and the burner start contacts are closed, power is supplied to starts
Thermostat terminals 6 and 2, and voltage is applied to transformer TR1. Pilot valves open
(for low voltage) ON • A start request from the thermostat closes the contacts between (TM1 starts)
terminals T1 and T2, and current flows as follows: internal SS1 →
relay 1K → terminal T2 → thermostat (for low voltage) → terminal 1
→ thermistor → contacts 2K3 → safety switch heater.
• When current flows to the thermistor, the thermistor's resistance de-
clines, and 3 seconds later, relay 1K is energized.
• When contacts 1K1 close, voltage is applied to terminal 4 to turn on
the ignition transformer, and to terminal 3 so that the pilot valves are
opened and external timer TM1 starts.
• Contacts 1K3 close and relay 1K forms a self-maintaining circuit.
• Since contacts 1K2 are closed, the thermistor stops heating, and the
safety switch heater begins heating via contacts 2K3, 1K2, and 1K3.
Flame detector does • When the time set for TM1 has passed after the start of ignition Ignition transformer
not detect a flame transformer operation, voltage to the transformer is cut off, the stops
within the safety transformer ceases operation, and the pilot valves also close. Pilot valves close
switch time • If the flame detector cannot detect a flame within the safety switch (Contacts TM1: OFF)
heater's lockout time (about 15 seconds), the heater is locked out, (TM1 stopped)
contacts SS1 open, relay 1K turns off, contacts 1K1, 1K2, and 1K3 Alarm
open, and contacts 1K4 close. (101X: ON)
• Voltage to terminals 3, 4, and 5 stops, and all loads stop operation.
Also, contacts SS2 close and activate an alarm.

Burner start contacts ON

Thermostat (for low voltage) ON
Start check (appox. 3s)
Blower ON
Lockout timing (appox. 15s)
Power ON

Limit & interlock

Blower ON
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Pilot valve
Main valves
Alarm
TM1 Elapsed time
on-delay time

9
Chapter 3 WIRING

●● Flame failure during combustion

Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformer TR2.
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Ignition transformer
ON closed) and the burner start contacts are closed, power is supplied to starts
Thermostat terminals 6 and 2, and voltage is applied to transformer TR1. Pilot valves open
(for low voltage) ON • A start request from the thermostat closes the contacts between (TM1 starts)
terminals T1 and T2, and current flows as follows: internal SS1 →
relay 1K → terminal T2 → thermostat (for low voltage) → terminal 1
→ thermistor → contacts 2K3 → safety switch heater.
• When current flows to the thermistor, the thermistor's resistance de-
clines, and 3 seconds later, relay 1K is energized.
• When contacts 1K1 close, voltage is applied to terminal 4 to turn on
the ignition transformer, and to terminal 3 so that the pilot valves are
opened and external timer TM1 starts.
• Contacts 1K3 close and relay 1K forms a self-maintaining circuit.
• Since contacts 1K2 are closed, the thermistor stops heating, and the
safety switch heater begins heating via contacts 2K3, 1K2, and 1K3.
The flame detector • If the flame detector senses a flame within the safety switch's lock- Ignition transformer
detects a flame out time (about 15 seconds), relay 2K is energized. stops
• When contacts 2K1 open, voltage to terminal 4 is cut off, and igni- (103X: ON)
tion transformer operation stops. (Contacts TM1: ON)
Main valves open
• When contacts 2K2 close, voltage is applied to terminal 5, and exter-
nal relay 103X turns on.
• When the time set for TM1 operation has passed and contacts TM1
have turned on, the main valves open.
• Contacts 2K3 open, and the safety switch heater stops heating.
During combustion, • During combustion, if the flame detector can no longer detect a Main valves close
flame detector can flame, relay 2K turns off, contacts 2K2 open, voltage to terminal 5 is (103X: OFF)
no longer detect a cut off, the main valves close, and external relay 103X also turns off. Pilot valves close
flame • When contacts 103X open, the pilot valves close. (TM1 stopped)
Alarm
• Contacts 2K3 close and the safety switch heater starts heating. (101X: ON)
When relay 2K turns off, contacts 2K1 close. However, because
TM1's time has expired, voltage is no longer reapplied to the igni-
tion transformer.
• The safety switch heater continues operating, and when its lockout
time (about 15 seconds) has passed the switch is locked out, con-
tacts SS1 open, relay 1K turns off, contacts 1K1, 1K2, and 1K3 open,
and contacts 1K4 close.
• Voltage to terminals 3, 4, and 5 stops, and all loads stop operation.
Also, contacts SS2 close and activate an alarm.

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 Chapter 3 WIRING

Burner start contacts ON

Thermostat (for low voltage) ON Start check (appox. 3s)
Blower ON Flame detection
Flame failure
Power ON
Flame response (appox. 3s)
Limit & interlock
Blower ON
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Pilot valve
Main valves
Alarm
TM1 Elapsed time
On-delay time Lockout timing
(appox. 15s)

●● False flame signal at startup

Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformer TR2.
False flame signal is • If there is a false flame signal, relay 2K turns on.
detected
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Alarm
ON closed) and the burner start contacts are closed, power is supplied to (101X: ON)
Thermostat terminals 6 and 2, and voltage is applied to transformer TR1.
(for low voltage) ON • Current flows as follows: SS1 → resistor R → contacts 1K4 → con-
tacts 2K4 → safety switch heater. Next, the thermistor starts heat-
ing. When the lockout time (about 15 seconds) has passed, lockout
occurs and contacts SS1 open.
Also, contacts SS2 close and activate an alarm.

Burner start contacts ON

Blower ON Thermostat (for low voltage) ON
Power ON Flame detection

Limit & interlock

Blower ON
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Pilot valve
Main valves
Alarm
False flame signal
Elapsed time
Lockout timing
(appox. 15s)

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Chapter 3 WIRING

■■ Recycling oil-fired combustion (2-stage combustion)

CAUTION
For oil-fired combustion equipment that must be operated on a non-recycling basis, use a timer
and auxiliary relay in the same way as for gas-fired equipment.

Handling Precautions
• Relay 1K has contacts 1K1 to 1K4 for the ignition transformer and fuel valves.
Relay 2K has contacts 2K1 to 2K4 for the flame detector.

●● Wiring diagram
Power supply Power supply
(H) (G)

Blower on-off circuit / Prepurge circuit

Thermostat*1
Limit/interlock circuit (for power supply)
(limit switch, interlock switch)

RA890G

AUD100 2K
Series
Blue F TR2
Flame 2
White G detection
1

Burner
start contacts 1K1 2K2 Secondary
6 5
fuel oil valve
Prepurge
completion 2K1 4 Ignition
signal transformer
3
Primary
Start check Safety switch fuel oil valve
circuit 2K3 heater TR1
Thermostat*1 Thermistor 2K4
(for low voltage) 1K2
T1 1K4
1K3 R *2
T2 SS1
1K *2 NC
COM SS2
NO 101
X
Alarm

*1 Use the thermostat for either the power supply or for low voltage.
*2 SS1 and SS2 are contacts for the safety switch heater. Design the circuit so that the blower on-off circuit/prepurge
circuit will always be reset if an alarm occurs (101X: ON).

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 Chapter 3 WIRING

●● Normal operation
Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformers TR2.
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Ignition transformer
ON closed) and the burner start contacts are closed, power is supplied starts
Thermostat to terminals 6 and 2, and voltage is applied to transformer TR1. Primary fuel oil valve
(for low voltage) ON • A start request from the thermostat closes the contacts between opens
terminals T1 and T2, and current flows as follows: internal SS1 →
relay 1K → terminal T2 → thermostat (for low voltage) → terminal 1
→ thermistor → contacts 2K3 → safety switch heater.
• When current flows to the thermistor, the thermistor's resistance
declines, and 3 seconds later, relay 1K is energized.
• When contacts 1K1 close, voltage is applied to terminal 4 to turn on
the ignition transformer, and to terminal 3 to open the primary fuel
oil valve.
• Contacts 1K3 close and relay 1K forms a self-maintaining circuit.
• Since contacts 1K2 are closed, the thermistor stops heating, and the
safety switch heater begins heating via contacts 2K3, 1K2, and 1K3.
The flame detector • If the flame detector senses a flame within the safety switch's lock- Ignition transformer
detects a flame out time (about 15 seconds), relay 2K is energized. stops
• When contacts 2K1 open, voltage to terminal 4 is cut off, and igni- Secondary fuel oil
tion transformer operation stops. valve opens
• When contacts 2K2 close, voltage is applied to terminal 5 to open
the secondary fuel oil valve.
• Contacts 2K3 open, and the safety switch heater stops heating.
Thermostat • When the thermostat ends its start request, the contacts between Primary fuel oil valve
(for low voltage) OFF terminals T1 and T2 open, relay 1K turns off, contacts 1K1, 1K2, and closes
1K3 open, and contacts 1K4 close. Secondary fuel oil
• Voltage to terminals 3, 4, and 5 stops, and all loads stop operation. valve closes
• The RA890G returns to its initial status and is ready for the next re-
quest from the thermostat (for low voltage).

Burner start contacts ON

Thermostat (for low voltage) ON
Start check (appox. 3s)
Blower ON Thermostat (for low voltage) OFF
Flame detection
Power ON Blower OFF

Limit, Interlock circuit

Blower on-off circuit
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Primary fuel oil valve
Secondary fuel oil valve
Alarm
Elapsed time

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Chapter 3 WIRING

WARNING
If the system is locked out, do not reset it until the cause of the problem has been eliminated.
Before restarting, be sure to do a prepurge. Failure to discharge unburned gas that has accumu-
lated in the flue and combustion chamber may result in an explosion.

●● Ignition failure
Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformer TR2.
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Ignition transformer
ON closed) and the burner start contacts are closed, power is supplied starts
Thermostat to terminals 6 and 2, and voltage is applied to transformer TR1. Primary fuel oil valve
(for low voltage) ON • A start request from the thermostat closes the contacts between opens
terminals T1 and T2, and current flows as follows: internal SS1 →
relay 1K → terminal T2 → thermostat (for low voltage) → terminal 1
→ thermistor → contacts 2K3 → safety switch heater.
• When current flows to the thermistor, the thermistor's resistance
declines, and 3 seconds later, relay 1K is energized.
• When contacts 1K1 close, voltage is applied to terminal 4 to turn on
the ignition transformer, and to terminal 3 so that the primary fuel
oil valve opens and external timer TM1 starts.
• Contacts 1K3 close and relay 1K forms a self-maintaining circuit.
• Since contacts 1K2 are closed, the thermistor stops heating, and the
safety switch heater begins heating via contacts 2K3, 1K2, and 1K3.
Flame detector does • When the time set for TM1 has passed after the start of ignition Ignition transformer
not detect a flame transformer operation, voltage to the transformer is cut off, the stops
within the safety transformer ceases operation, and the pilot valves also close. Primary fuel oil valve
switch time • If the flame detector cannot detect a flame within the safety switch closes
heater's lockout time (about 15 seconds), the heater is locked out, Alarm
contacts SS1 open, relay 1K turns off, contacts 1K1, 1K2, and 1K3 (101X: ON)
open, and contacts 1K4 close.
• Voltage to terminals 3, 4, and 5 stops, and all loads stop operation.
Also, contacts SS2 close and activate an alarm.

Burner start contacts ON

Thermostat (for low voltage) ON
Start check (appox. 3s)
Blower ON
Lockout timing (appox. 15s) Blower OFF
Power ON

Limit, Interlock circuit

Blower on-off circuit
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Primary fuel oil valve
Secondary fuel oil valve
Alarm
Elapsed time

14
 Chapter 3 WIRING

●● Flame failure during RUN

Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformer TR2.
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start contacts • If the limit and interlock conditions are normal (limit contacts are Ignition transformer
ON closed) and the burner start contacts are closed, power is supplied starts
Thermostat to terminals 6 and 2, and voltage is applied to transformer TR1. Primary fuel oil valve
(for low voltage) ON • A start request from the thermostat closes the contacts between opens
terminals T1 and T2, and current flows as follows: internal SS1 →
relay 1K → terminal T2 → thermostat (for low voltage) → terminal 1
→ thermistor → contacts 2K3 → safety switch heater.
• When current flows to the thermistor, the thermistor's resistance
declines, and 3 seconds later, relay 1K is energized.
• When contacts 1K1 close, voltage is applied to terminal 4 to turn on
the ignition transformer, and to terminal 3 so that the primary fuel
oil valve opens and external timer TM1 starts.
• Contacts 1K3 close and relay 1K forms a self-maintaining circuit.
• Since contacts 1K2 are closed, the thermistor stops heating, and the
safety switch heater begins heating via contacts 2K3, 1K2, and 1K3.
The flame detector • If the flame detector senses a flame within the safety switch's lock- Ignition transformer
detects a flame out time (about 15 seconds), relay 2K is energized. stops
• When contacts 2K1 open, voltage to terminal 4 is cut off, and igni- Secondary fuel oil
tion transformer operation stops. valve opens
• When contacts 2K2 close, voltage is applied to terminal 5, and sec-
ondary fuel oil valve opens.
• Contacts 2K3 open, and the safety switch heater stops heating.
During combustion, • During combustion, if the flame detector can no longer detect a Secondary fuel oil
flame detector can flame, relay 2K turns off, contacts 2K2 open, voltage to terminal 5 is valve closes
no longer detect a cut off, and secondary oil fuel valve closes. Ignition transformer
flame • Contacts 2K3 close and the safety switch heater starts heating. starts
• When relay 2K turns off, closing contacts 2K1, voltage is again ap-
plied to terminal 4 and the ignition transformer operation starts.
Recycle operation at • When the flame detector again detects a flame, relay 2K turns on, Ignition transformer
flame failure opening contacts 2K1. Contacts 2K2 close, voltage to terminal 4 stops
is cut off, voltage is applied to terminal 5, and ignition transformer Secondary fuel oil
operation stops. valve opens
• Voltage is applied to terminal 5 and thereby to the secondary fuel
oil valve, which opens.
• If no flame is detected during recycling, the safety switch heater If a flame is not
continues heating and lockout occurs when the lockout time (about detected again, an
15 seconds) has passed. Contacts SS1 open, relay 1K turns off, con- alarm occurs.
tacts 1K1, 1K2, and 1K3 open, and contacts 1K4 close. (101X: ON)
• Voltage to terminals 3, 4, and 5 stops, and all loads stop operation.
Also, contacts SS2 close and activate an alarm.

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Chapter 3 WIRING

• When the system restarts

Burner start contacts ON Start check (appox. 3s)

Thermostat (for low voltage) ON
Flame detection
Blower ON Flame Flame response (appox. 3s)
failure Flame detection
Power ON

Limit, Interlock circuit

Blower on-off circuit
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Primary fuel oil valve
Secondary fuel oil valve
Alarm
Elapsed time

• When system restart fails

Burner start contacts ON

Thermostat (for low voltage) ON Start check
Flame detection
Blower ON Flame Flame response (appox. 3s)
failure Blower OFF
Power ON

Limit, Interlock circuit

Blower on-off circuit
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Primary fuel oil valve
Secondary fuel oil valve
Alarm
Elapsed time
Lockout timing
(appox. 15s)

16
 Chapter 3 WIRING

●● False flame signal at the start of operation

Input status RA890G operation Output status
Power ON • Power is supplied to terminals 1 and 2, and voltage is applied to
transformer TR2.
False flame sig- • If there is a false flame signal, relay 2K turns on.
nal is detected
Blower ON • The blower turns on. When the prepurge ends, the prepurge com-
pletion signal is generated to make the next process possible.
Burner start • If the limit and interlock conditions are normal (limit contacts are Alarm
contacts ON closed) and the burner start contacts are closed, power is supplied (101X: ON)
Thermostat to terminals 6 and 2, and voltage is applied to transformer TR1.
(for low voltage) • Current flows as follows: SS1 → resistor R → contacts 1K4 →
ON contacts 2K4 → safety switch heater. Next, the thermistor starts
heating. When the lockout time (about 15 seconds) has passed,
lockout occurs and contacts SS1 open.
Also, contacts SS2 close and activate an alarm.

Burner start contacts ON

Thermostat (for low voltage) ON
Blower ON
Power ON Flame detection

Limit, Interlock circuit

Blower on-off circuit
Prepurge
Prepurge completion signal
Burner start contacts
Ignition transformer
Primary fuel oil valve
Secondary fuel oil valve
Alarm
False flame signal
Elapsed time
Lockout timing
(appox. 15s)

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Chapter 3 WIRING

■■ Wiring the solenoid valve

CAUTION
Do not connect a solenoid valve to the high voltage side of the circuit. If a ground fault occurs, the
ground fault current may energize and open the solenoid valve, and fuel will flow out.

●● Correct connection

High voltage side (H)

Combustion unit
Power 100V
RA890G

Burner
Ground side (G)
N L (Ground fault)
Valve (closed)

Fuel

Ground current will not flow to the solenoid valve with the valve wired as shown
in the figure above, even if faulty insulation on the voltage side (H) causes a ground
fault. Accordingly, the valve will not open, eliminating the risk of fuel discharge.

●● Wrong connection
(Ground fault)

High voltage side (H)

Combustion unit
Power 100V
RA890G
Ground side (G) Burner
N L
Valve (open)

Fuel

Ground current will flow to the solenoid valve with the valve wired as shown
in the figure above. Accordingly, the solenoid valve will open regardless of the
Protectorelay, causing fuel discharge.

■■ Wiring the flame detector

Connect the blue signal lead from the AUD 100 Series Advanced Ultraviolet Flame
Detector to terminal F and the white lead to terminal G.

Correct connection
Blue
F
AUD 100 Series RA890G
G
White
Wrong connection
Blue
F
AUD 100 Series RA890G
G
White

18
Chapter 4. INSPECTION AND ADJUSTMENT

Handling Precautions
• A trained and experienced technician who has knowledge and technical
skills related to combustion equipment and flame safeguard control devices
should carry out inspection, adjustment, etc.

WARNING
Do not allow the pilot or main burner 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.
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 terminal F.
Do not start regular operation of the equipment without first completing the trial-run adjustments
for this device, as well as the tests specified by the equipment manufacturer.
Do not touch this device's internal relay. Doing so might damage the relay or cause this device and/
or the combustion equipment to malfunction.

CAUTION
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.

■■ Inspection
To operate the system more safety, check for the items below satisfactorily.

●● Required equipment
• Analog flame meter FSP136A100
• Manometer (pressure gauge)
• Digital voltmeter (tester)

●● Checkout procedure
(1) Preliminary check
(2) Loosen the cover retaining screw, and then remove the cover.
(3) Flame current check
(4) Ignition spark response test
(5) Pilot turndown test
(6) Safety shutoff test
(7) Mount the cover on the base with the cover retaining screw.

19
Chapter 4 INSPECTION AND ADJUSTMENT

●● Preliminary check
(1) Check all the wiring points.
(2) Make sure that the 10 terminal screws are tightened firmly.
(3) M
 ake sure that the RA890G is installed at a place within the allowable ambient
temperature range.
(4) C
 heck if the flame detector is installed properly. (Refer to the instruction man-
ual for the flame detector)
(5) Check if the burner has been adjusted properly.
(6) Check the exhaust mechanism in the flue.
(7) Press the green pushbutton at the front of the RA890G to reset the safety switch.

●● Wiring check of the AUD 100 Series Advanced Ultraviolet Flame Detector
Check that the wiring to the AUD 100 Series Advanced Ultraviolet Flame Detector
is correct using the steps below.

• P
 rocedure for the AUD 100C with the AUD 15C
(1) Remove the AUD 15C tube unit from the AUD 100 socket.
(2) Supply the power to the RA890G.
(3) M
 easure the DC voltage in the socket with a digital voltmeter or tester.
• Connect the plus probe to the No.1 pin on the socket (white wire).
• Connect the minus probe to the No.3 pin on the socket (blue wire).

Blue −

White
F Digital voltage meter
G (or circuit tester)

Hole No. 3 (blue) Hole No. 1 (white)

for neg. (–) probe Socket for pos. (+) probe

• Reference voltage (by TR6841 of ADVANTEST)

Hole No. Tester probe Voltage
3 (blue):F − 160 to 220 Vdc
1 (white):G +

Handling Precautions
• If the above measured voltage is negative, the wiring is reversed.
• Before mounting the AUD 15C tube unit, make sure that the wiring is
correct.

20
 Chapter 4 INSPECTION AND ADJUSTMENT

●● Flame current check

The flame current check is the best way to identify the proper flame detector in-
stallation. Set the range changeover switch of FSP136A100 Analog Flame Meter
at 15 µA, and insert the current measurement plug of an analog flame meter
FSP136A100 into the flame current test jack of the RA890G. Then, operate the
burner and read the flame current from the analog flame meter. If the flame cur-
rent is abnormal, see the users' manual for the flame detector.

Checkpoints
• The flame current should be steady, without excessive fluctuation of the indicator.
• T
 he flame current should be 1.5 microamperes or more.

• A UD100 Series Advanced Ultraviolet Flame Detector

AUD100/100 Socket for the AUD15 Tube Unit User's Manual CP-UM-5640JE
• Advanced Ultraviolet Sensor AUD15 Tube Unit for the AUD100/110
 CP-UM-5639JE

●● How to measure the flame current

Analog flame meter RA890G
FSP136A100

Current
measurement
plug

Flame current
test jack

21
Chapter 4 INSPECTION AND ADJUSTMENT

■■ Ignition spark response test

CAUTION
Make sure that the flame detector does not detect the ignition spark. If the flame detector detects
the spark, change the position of the detector or the ignition electrode.
Adjust the flame detector so that it detects only the ultraviolet rays 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 serious explosion hazard.

Make arrangement so that the flame relay 2K may not be excited by the sparks
generated during the operation of the ignition transformer. Check the response of
the flame detector to the ignition sparks in the following procedure, and check the
mounting position.
(1) C
 lose the manual fuel valves for the pilot burner and main burner to shut off the
fuel.
(2) S tart operation and make sure that relay 2K is not turned on during the pilot
ignition sequence.
(3) I f relay 2K is energized, adjust as follows:
• C  hange the location of the flame detector or ignition spark rod and check that
the change does not affect its operation.
• I nstall a shield plate or the like to prevent the ultraviolet rays of the spark
from intruding into the flame detector's field of view, and adjust it so that
relay 2K is not energized because of the spark.

●● Cautions regarding UV sources other than flames

The table below shows various radiation sources other than the burner flame that
may activate the flame detector. Make sure that the flame voltage is not affected by
any of these sources under any operating conditions.
Ultraviolet ray sources Red-hot chamber wall with temperature 1371 °C or more
Sparks
• Ignition transformer • Welding arc • Lightning
Gas laser
Sunlamp
Germicidal lamp
Strong flashlight (toward UV sensor)
Gamma ray and X-ray sources X-ray diffraction equipment and gamma-ray analysis measurement equipment
Electron microscope
X-ray camera
High-voltage vacuum switch
High-voltage capacitor
Radioactive isotope
Other sources producing ultraviolet rays, gamma rays and X-rays

22
 Chapter 4 INSPECTION AND ADJUSTMENT

■■ Pilot turndown test

WARNING
Do not allow the pilot or main burner 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.
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 burner, this device will not be able to detect a flame failure in the
main burner. In that case, fuel will continue to be supplied, causing a serious explosion hazard.
 efore the pilot turndown test or ignition spark response test, make sure that all manual fuel valves
B
are closed.
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. Restore all test jumpers and limit
interlock/regulator settings to their previous states. If the equipment is operated without restoring
the previous settings, damage to the equipment, gas leak or explosion may result.

This test is intended to prove that even with a worst-case change of gas pressure
and air pressure, if the flame detector detects a pilot flame, the main burner can be
lighted without fail.
Check the following:
• A
 ny pilot flame large enough to light the main burner can be detected without
fail.
• No pilot flame that is too small to light the main burner can be detected.
• The ignition spark is not detected as a flame.

(1) C
 lose the manual fuel valves for the pilot burner and main burner to shut off the
fuel.
(2) C
 onnect a manometer to the downstream side of the pilot valve.
(3) O
 pen the manual valve of the pilot burner.
(4) S tart the system by raising the set point of the thermostat. The relay 1K is ex-
cited and the pilot valve opens, and then ignition operation starts.
(5) G
 radually reduce the size of the pilot flame until the flame detector can detect
no flame, by slowly closing the manual valve of the pilot burner. The flame relay
(2K) and relay 1K become OFF and the pilot valve closes, and then the pressure
of the manometer drops down suddenly. The safety switch heater starts heating
and lockout occurs 15 seconds after. Take notes the pressure just before the pilot
valve closes.
(6) R
 eset the safety switch and restart the system.
(7) G
 radually open the manual valve of the pilot burner again and set it to the pres-
sure just before the shutoff measured in step (5).
(8) C
 heck if the main burner is lighted smoothly within 1 second after the manual
valve of the main gas line is opened.

23
Chapter 4 INSPECTION AND ADJUSTMENT

(9) W
 hile changing the gas pressure to minimum and maximum values, repeat
ignition to the main burner 5 or 6 times. Then, check if ignition is performed
smoothly within 1 second every time.
(10) I f the main burner cannot be lighted, it is necessary to enlarge the size of the
pilot flame. After enlarging the pilot flame, make the adjustment to keep the
viewing line of the AUD100 Series, C7027A or C7035A a little away from the
axis of the pilot flame, or make correction with the flame size reduced.
(11) A
 fter the adjustment, check if the main burner is lighted smoothly by repeating
steps (5) to (9).
(12) A
 fter the end of test, restore the manual valve on the pilot burner and the main
burner to the fully open position and check if the flame current is proper.
(13) Disconnect the manometer.

■■ Safety shutdown checks

After the completion of all adjustment, perform safety shutdown checks.
(1) L
 imit action check
While the burner is operating, lower the high limit setting of boiler or furnace
to simulate an overheated boiler or furnace, and normal shutdown will occur.
When shutdown starts, restore the nomal limit setting of the boiler or furnace,
and the burner will restart.
(2) F
 lame failure check
While the burner is operating, close the manual fuel valves to simulate a flame
failure, and the system will lock out in safety switch time (approx. 15 s). After
the safety switch has cooled (3 minutes or more), open the manual fuel valves,
reset the safety switch, and restart the burner.
(3) P
 ower failure check
While the burner is operating, turn the power off temporalily to simulate a
power failure. After some time, turn the power on again and make sure that the
burner restarts and operates normally.

24
Chapter 5. MAINTENANCE

Handling Precautions
• The maintenance, inspection and adjustment shall be made by trained, expe-
rienced flame safeguard control technicians.

WARNING
Before wiring, mounting, or removing this device, be sure to turn the power on and then immedi-
ately off. Wiring with the power on can result in an electric shock.
Do not touch this device's internal relay. Doing so might damage the relay or cause this device and/
or the combustion equipment to malfunction.
E ven after the power to this device is turned off, terminal F continues to hold an electrical charge.
To avoid electrical shock, do not touch terminal F.
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 terminals F and G of this device for 10 seconds or more.

CAUTION
In the event that this device is replaced, do all of the checks listed in chapter 4 INSPECTION AND
ADJUSTMENT.
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.

■■ Maintenance and inspection intervals

Determine a specific maintenance schedule, taking into account the type of equip-
ment controlled, operating conditions (dust, ambient temperature, etc.), the amount
of damage in case of shutdown by some failure during operation, and so on.
(1) P
 erform a safe shutdown check at least once a month, as described in Chapter 4,
“Inspection and Adjustment”.
(2) C
 heck a soot condition on the viewing window of the flame detector, and clean
it periodically.
(3) C
 heck a flame current at least once a month.

25
Chapter 5 MAINTENANCE

■■ Troubleshooting

WARNING
Use utmost care while troubleshooting the RA890G since the line voltage can be present on most
terminals when power is on.
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 terminals F and G of the RA890G for 10 seconds or more.

If trouble occurs in the heating system, check the following step-by-step procedure.

Step 1.
Initial check
(1) A fter remove the cover, check 10 terminal screws are tightened firmly.
(2) S et the controller not to call for heat.
Terminal screws (10): Tighten firmly
(3) R eset the safety switch on the RA890G by
pushing it.
(4) Close the line switch.
(5) C heck for the line voltage between the ter-
minals 2 and 6. (The voltage will be zero if
a line voltage controller is used. Check for
the line voltage when the controller is set
Mounting base
to call for heat.)
• The voltage must be within +10 to -15 % of the rated voltage.
• If the voltage is zero (with the thermostat connected to the terminals T1
and T2), check if the limit switch contacts are closed, and power is supplied.
Check for blown fuses, open circuit or open disconnect switch.

When replacing the RA890G is required, before removing it from the subbase,
turn on the FLAME MODE switch of the flame simulator, and connect terminals
F and G to terminals F and G of the RA890G with lead wires.

FSP300C100
S2
S1
G
F
ON

Step 2.
Flame status check
(1) If the flame relay is not excited, proceed to step 3.
(2) I f the flame relay is excited, check for a flame simulation condition.
Disconnect the wiring to the flame detector.
• If the flame relay is excited, replace the RA890G.
• I f the flame relay is not excited, the flame detector or external circuit is defec-
tive. Check them.

26
 Chapter 5 MAINTENANCE

Step 3.
Set the controller to call for heat.
If the line voltage temperature controller is connected to the terminal 6, go back to
steps 1 and 2.

Step 4.
Check if the load relay is excited.
(1) W hen the load relay is excited to light the pilot and start the burners, proceed to
step 8.
(2) If the load relay is not excited, proceed to step 5.
(3) I f the load relay is excited, but the pilot does not light, or the burner does not
start, proceed to step 7.

Step 5.
Check the line voltage controller and limit switch for proper operation if the line
voltage controller is connected to the terminal 6. If the load relay is not excited,
turn ON the controller and check the voltage between the terminals 2 and 6 again.
Replace the RA890G if the load relay is not excited still, although the rated voltage is
obtained there. If a low voltage thermostat is used, proceed to step 6.

Step 6.
Check the low voltage thermostat, if used, for proper operation.
(1) W hen the load relay is excited with the terminals T1 and T2 short-circuited,
check the low voltage thermostat and external connection circuit.
(2) I f the load relay is not excited with the terminals T1 and T2 short-circuited, re-
place the RA890G.

Step 7.
If the load relay is excited, but the pilot won't light or the burner won't start, check
the voltage at the terminals 2-3 or 2-4.
(1) I f no voltage is obtained at the terminals 2-3 or 2-4, replace the RA890G.
(2) I f the normal line voltage is obtained at the terminals 2-3 or 2-4, check the
external circuits of the burner, ignition transformer and fuel valve. Check the
wiring, burner adjustment, ignition system including the electrode spacing
and location, oil quality, character and efficiency of oil atomization, fuel sup-
ply pressure, flame pattern, flame character and quality, pilot burner location
with respect to main burner, flame detector, or other conditions that may delay
ignition.

Step 8.
Observe the flame relay (right-hand relay) for excitation when the burner is lighted.
(1) When the flame relay is excited, proceed to step 10.
(2) When the flame relay is not excited, proceed to step 9.

27
Chapter 5 MAINTENANCE

Step 9.
Check the flame relay with the FSP300C100 flame simulator, if available, or in the
following procedure:
(1) Check the flame current (see page 25)
(2) If the flame current is satisfactory, replace the RA890G.
(3) I f the flame current is not satisfactory, one or more of the following items are
considered:
• The power supply is not suitable.
• T  he connection of the flame detector is improper.
- Open status
- Short circuit status
- Insulation breakdown of leads caused by moisture and contamination
• Unsuitable viewing position and viewing window
• Dirty light receiving face of the flame detector
• Improper flame detector

Step 10.
Observation of sequencing operation
Observe the operation of the main fuel valve when the flame relay is excited. If the
main fuel valve does not open, check the voltage at the terminals 2-5.
(1) W
 hen the normal voltage is obtained, check the main fuel valve and valve
circuit.
(2) If the normal voltage is not obtained, replace the RA890G.

Step 11.
Check if sparks are cut off when the flame relay is excited, if the ignition trans-
former is connected to the terminal 4. Check if the wiring is proper. If sparks re-
main, replace the RA890G.

●● Other problems
• Relay chattering
The relay 1K (load) chattering may result from the extreme low power supply
voltage (check the power supply voltage) or from a loose terminal connection
(retighten).
The relay 2K (flame) chattering may result from improper combustion (adjust the
burner) or soot or carbon on the viewing part of the flame detector (clean).
• Loose terminal screw
If faulty operation has occurred, check if there is a loose terminal screw.

28
Chapter 6. SPECIFICATIONS

■■ Specifications
Item Specifications
Model number RA890G117_2 RA890G1278_2
Rated voltage 100 Vac 208 Vac
Allowable voltage 85 to 110 % of rated voltage
Rated frequency 50/60 Hz
Power consumption 10.5 W (18 VA) max. for 50 Hz
9.5 W (14 VA) max. for 60 Hz
Target combustion equipment 700 kW or less in combustion rate
Lockout time Approx. 15 s
Flame response period 3±1 s (at flame current of 2 µA)
Operating point 1.2 µA max. for light-up
0.5 µA min. for flame-out
Recommended flame current 1.5 µA
Operation against flame failure Recycle
Self check time at startup Approx. 3 at the rated voltage and in nomal temperature
Allowable operating temperature -20 to +55 °C
Allowable operating humidity 90 % RH at 40 °C (without condensation)
Allowable vibration 4.9 m/s2 max. 55 Hz max.
Dielectric strength 1500 Vac for 1 min. between terminals 2, 3, 4, 5 and case
Life 100,000 cycle of relay contact
Cover painting color Gray enamel paint (Munsell scale 0.5PB 4.2/0.2)
Mass 1.22 kg
Applicable flame detector AUD100 Series advanced ultraviolet flame detector
Minipeeper ultraviolet flame detector C7027A*, C7035A*
Subbase (sold separately) Q270A1024
Optional parts (sold separately) Flame simulator: FSP300C100
Analog flame meter: FSP136A100
* Discontinuation date: Dec. 2011.

●● Contact ratings
Terminal Load Contact rating
3 (note) Pilot valve/Primary fuel oil valve 200 VA
4 Ignition transformer 300 VA
5 Main valve/Secondary oil fuel valve 200 VA
NC, NO, COM Alarm 75 VA
T1, T2 Control circuit 0.17 A

For reference: If a burner motor and pilot valve are connected to terminal 3
Terminal Load Contact rating

100 Vac 200 Vac

3 Burner motor Normal 5.2 A 2.6 A
Start 31.2A 15.6 A
Pilot valve 25 VA 25 VA

29
Chapter 6 SPECIFICATIONS

■■ External dimensions
●● Main device
Terminal screws (#6-32UNC)
Warning label
Warning label
Safety switch
reset button

126
63
8

Faston tab 250 series

(Receptacle and insulating sleeve, 3 pcs each attached)

126
50.5
Cover retaining screw
Subbase (Q270A1024)
Cover

60

128
117
22
1.5

●● Q270A102A sub base (sold separately)

5 Mounting holes (3)

8 6 5

7 T 4
6 T 3
F 1
97

G 2
73
30

11

35 35 17

38.2 35 22 35
knockouts (9)
11 104.8 11

30
Revision History of CP-UM-1218E
Printed Edn. Revised pages Description
Mar. 1984 1
Nov. 2008 11 Overall revision. 11th ed = 16th Jp ed.
Nov. 2011 12 Overall revision due to discontinuation of 123514B flame simulator and
introduction of AUD100 series advanced ultraviolet flame detector
Apr. 2012 13 Company name changed.
Apr. 2013 14 Overall revision. 14th ed = 21th Jp ed.
 Terms and Conditions
We would like to express our appreciation for your purchase and use of Azbil Corporation's products.
You are required to acknowledge and agree upon the following terms and conditions for your purchase of Azbil Corporation's
products (field instruments, control valves, and control products), unless otherwise stated in any separate document, including,
without limitation, estimation sheets, written agreements, catalogs, specifications and instruction manuals.

1. 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.
1.2 Warranty scope
In the event that Azbil Corporation's products has any failure attributable to azbil during the aforementioned warranty
period, azbil shall, without charge, deliver a replacement for the said product to the place where you purchased, or repair
the said product and deliver it to the aforementioned place.
Notwithstanding the foregoing, any failure falling under one of the following shall not be covered under this warranty:
(1) Failure caused by your improper use of Azbil Corporation's products
(noncompliance with conditions, environment of use, precautions, etc. set forth in catalogs, specifications,
instruction manuals, etc.);
(2) Failure caused for other reasons than Azbil Corporation's products;
(3) Failure caused by any modification or repair made by any person other than azbil or azbil's subcontractors;
(4) Failure caused by your use of Azbil Corporation's products in a manner not conforming to the intended usage of
that product;
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(6) Failure that arose from any reason not attributable to Azbil Corporation, including, without limitation, acts of
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Please note that the term "warranty" as used herein refers to equipment-only-warranty, and Azbil Corporation shall not
be liable for any damages, including direct, indirect, special, incidental or consequential damages in connection with or
arising out of Azbil Corporation's products.

2. Ascertainment of suitability
You are required to ascertain the suitability of Azbil Corporation's products in case of your use of the same with your
machinery, equipment, etc. (hereinafter referred to as "Equipment") on your own responsibility, taking the following
matters into consideration:
(1) Regulations and standards or laws that your Equipment is to comply with.
(2) Examples of application described in any documents provided by Azbil Corporation are for your reference
purpose only, and you are required to check the functions and safety of your Equipment prior to your use.
(3) Measures to be taken to secure the required level of the reliability and safety of your Equipment in your use
Although Azbil Corporation is constantly making efforts to improve the quality and reliability of Azbil
Corporation's products, there exists a possibility that parts and machinery may break down.
You are required to provide your Equipment with fool-proof design, fail-safe design, anti-flame propagation
design, safety design, or the like so that the said Equipment may satisfy the level of the reliability and safety
required in your use, whereby preventing any occurrence of physical injuries, fires, significant damage, and so
forth.
3. Precautions and restrictions on application
Azbil Corporation's products other than those explicitly specified as applicable (e.g. azbil limit switch for Nuclear Energy)
shall not be used in a nuclear energy controlled area (radiation controlled area).
Any Azbil Corporation's products shall not be used for/with medical equipment.
In addition,
you are required to conduct a consultation with our sales representative and understand detail specifications, cautions
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Azbil Corporation's products for any purposes specified in (1) through (6) below.
Moreover, you are required to provide your Equipment with fool-proof design, fail-safe design, anti-flame propagation
design and other designs of protection/safety circuit on your own responsibility to ensure the reliability and safety,
whereby preventing problems caused by failure or nonconformity.
(1) For use under such conditions or in such environments as not stated in technical documents, including catalogs,
specification, and instruction manuals
(2) For use of specific purposes, such as:
* Nuclear energy/radiation related facilities
[For use outside nuclear energy controlled areas] [For use of Azbil Corporation's limit switch for Nuclear Energy]
* Machinery or equipment for space/sea bottom
* Transportation equipment
[Railway, aircraft, vessels, vehicle equipment, etc.]
* Antidisaster/crime-prevention equipment
* Burning appliances
* Electrothermal equipment
* Amusement facilities
(3) Supply systems such as electricity/gas/water supply systems, large-scale communication systems, and traffic/air
traffic control systems requiring high reliability
(4) Facilities that are to comply with regulations of governmental/public agencies or specific industries
(5) Machinery or equipment that may affect human lives, human bodies or properties
(6) Other machinery or equipment equivalent to those set forth in items (1) to (5) above which require high reliability
and safety
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Use of Azbil Corporation's products, including switches, which contain electronic components, over a prolonged period
may degrade insulation or increase contact-resistance and may result in heat generation or any other similar problem
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Although acceleration of the above situation varies depending on the conditions or environment of use of the products,
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5. Recommendation for renewal

Mechanical components, such as relays and switches, used for Azbil Corporation's products will reach the end of their life
due to wear by repetitious open/close operations.
In addition, electronic components such as electrolytic capacitors will reach the end of their life due to aged deterioration
based on the conditions or environment in which such electronic components are used.
Although acceleration of the above situation varies depending on the conditions or environment of use, the number of
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unless otherwise specified in specifications or instruction manuals.
Field instruments (sensors such as pressure/flow/level sensors, regulating valves, etc.) will reach the end of their life due to
aged deterioration of parts.
For those parts that will reach the end of their life due to aged deterioration, recommended replacement cycles are
prescribed. You are required to replace parts based on such recommended replacement cycles.

6. Other precautions
Prior to your use of Azbil Corporation's products, you are required to understand and comply with specifications (e.g.,
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7. Changes to specifications
Please note that the descriptions contained in any documents provided by Azbil Corporation are subject to change
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For inquires or information on specifications as you may need to check, please contact our branch offices or sales offices,
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8. Discontinuance of the supply of products/parts

Please note that the production of any Azbil Corporation's products may be discontinued without notice.
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For field instruments, we may not be able to undertake parts replacement for similar reasons.
 Specifications are subject to change without notice. (09)

1-12-2 Kawana, Fujisawa

Kanagawa 251-8522 Japan
URL: http://www.azbil.com
14th edition: Apr. 2013 ( F )