No. CP-SS-1885E BC-R10 Series Burner Controllers Summary BC-R10 Series burner controllers are combustion safety controllers specifically designed for batch operation (systems which start and stop at least once within 24 hours). They ensure safety by automatically controlling the ignition, combustion monitoring, and fuel shutoff of oil burners. BC-R10 burner controllers can be used with AFD100/110 series visible light flame detectors. They are also equipped with a 7-segment display that can be used in maintenance, a trial operation mode that is convenient for trial operation and adjustment, and other features. Features Compliant with JIS standards Safe construction of combustion systems and equipment - Uses prepurge and ignition timing in compliance with JIS B 8407:2012 (forced-air burners) and JIS B 8415:2008 (combustion equipment in compliance with the safety principles for industrial incinerators) JIS-compliant burner controller safety design - Safety design in compliance with JIS C 9730 (automatic electrical controls for household and similar use) - EN 298 compliance (certification pending) Easy mounting and replacement DIN rail mounting - Easily mountable in the same way as other control devices and control relays Uses a sub-base structure - Structure separates the sub-base from the main unit It is possible to change only the main unit, leaving the wired-in sub-base in place Precautions on equipment instrumentation Extensive communications with external devices Equipped with a 7-segment display - 7-segment display for sequence codes and warning codes - Press the DISP switch to display the flame voltage. External status output - States such as ignition failure, flame failure, and combustion detected are output digitally (and used as panel displays) Warning reset by contact input (1) The equipment used in the combustion safety system was designed with careful consideration of laws, standards, safety guidelines, and the like. If the system is designed to a foreign specification, refer to laws and standards in the relevant country. Main Safety Standards in Japan - Technical Policy on Safety Standards for Equipment in Industrial Furnaces: Ministry of Health, Labour and Welfare - equipment in compliance with the safety principles for industrial incinerators - JIS B 8415 - Forced Draught Burners - Part 1: Gas Burners - JIS B 8407-1 - Forced Draught Burners - Part 2: Oil Burners - JIS B 8407-2 - The index of safety technology of industrial gas combustion equipment: Japan Gas Association - Index of safety technology of gas boiler combustion facilities: Japan Gas Association (2) This device monitors for failures in the relay contacts used for combustion load (IG, PV, MV) output. An E09 error is output if a voltage occurs at a load terminal, due to a ground fault or wiring error, when this device is not outputting a load. If an E09 error occurs when this device is installed, recheck the wiring and eliminate the factors causing the error. (3) If the wiring from this device exceeds the recommended length, prevent malfunction due to the effects of external noise by running wires from the control panel to the casing through a conduit, keeping a distance between power lines and input lines, and other measures. Check the operation of the system on installation. (4) A reset signal must always be input near the equipment (burner, etc.), not remotely. If a reset is input while it is not possible to confirm safety, there is the risk of explosion. 1
Specifications Application Item Compatible flame detector Batch-operated combustion systems burning oil Visible light flame detector AFD100/110 series Sequence Sequence timing Please refer to the model number composition table. Electrical specifications Transportation and storage conditions Operating conditions General specifications Flame response timing Warning detection timing monitoring Operation at ignition failure Operation at flame failure Rated power supply Allowable power supply voltage Voltage resistance Voltage resistance Please refer to the model number composition table. Description 1 s or longer (main unit reset switch or contact reset input) False flame (1) *1 (2) *1 Interlock error 5 s 1 s 180 s 1 s max Please refer to the model number composition table. Please refer to the model number composition table. 100 Vac or 230 Vac, 50 Hz or 60 Hz 85 to 110 % of rated power supply 10 W or less 1500 Vac for 1 min, or 1800 Vac for 1 s Between each terminal and ground (the DIN rail clamp), except for combustion sensor connection terminals (terminals 14, 15) Insulation resistance At least 50 MΩ, 500 Vdc megger Between each terminal and ground (the DIN rail clamp), except for combustion sensor connection terminals (terminals 14, 15) Contact rating Blower motor Warning (electromagnetic breaker) 100 VA 300 VA 200 VA 200 VA 75 VA s 4, maximum 30 ma each When ignition is detected: 1.3 Vdc or less detection level When detected as extinguished: 0.5 Vdc or over Flame voltage output Flame voltage output range: 0.2 to 4.8 Vdc Startup, lockout interlock, contact reset, airflow switch * Each input is a non-voltage contact input, with allowable contact resistance up to 500 Ω Lifespan 10 years when used for eight hours per day, or 100,000 start/stop cycles (at 25 C, constant temperature, rated voltage) Ambient temperature -20 to +70 C Ambient humidity 5 to 95 % RH (no condensation) Vibration 0 to 9.8 m/s 2 (10 to 150 Hz, 1 octave/minute, 10 cycles, in each of XYZ directions) Shock 0 to 300 m/s 2 Packaged drop test 60 cm drop height (free drop onto 1 corner, 3 edges, 6 sides) Ambient temperature -20 to +60 C Ambient humidity 10 to 90 % RH (no condensation) Vibration 0 to 3.2 m/s 2 (10 to 150 Hz, 1 octave/minute, 10 cycles, in each of XYZ directions) Shock 0 to 9.8 m/s 2 Mounting angle Reference plane +/-10 Dust 0.3 mg/m 3 or less Protective structure IP40 (with a sideboard (81447515-001) attached to the sub-base (BC-R05)) IP10 (sub-base (BC-R05) only) Excess voltage II category Pollution degree PD2 Case color Black Case material Denatured PPE resin (UL 94-V0 PTI material group IIIa) Structure Sub-base and main unit Mounted orientation Vertical or horizontal However, for horizontal attachment, 7 segment display can only be mounted so that it faces directly overhead (DIN rail mounting or direct mounting through base screw holes) Dimensions W95 H105 D110mm Weight Approximately 600 g (incl. sub-base) Wiring types and max. wiring - Start, airflow switch, lockout interlock length Copper IV wire with 600 V vinyl insulation, 1.25 mm 2, recommended condition: 20 m or less, maximum wiring length: 100 m - Contact reset Copper IV wire with 600 V vinyl insulation, 1.25 mm 2, maximum wiring length: 10 m - AFD100 Series (F, G) Copper IV wire with 600 V vinyl insulation, 1.25 mm 2, maximum wiring length: 100 m - Signal line for flame voltage output IV wire, 0.75 mm 2 or larger, max. wiring length 10 m *1 monitoring model only 2
Model number composition (Note: The dedicated sub-base and sideboard are not provided with the BC-R10 series controller. Order them separately.) Model Number BC-R10A7G004_ observation Pre-purge type Pre-ignition *3 Pre-purge time Ignition trial time Postignition *2 Operation at flame failure 4.5±0.5 s 11±1.5 s 2 s max BC-R10A7H003_ Pre-ignition *3 4.5±0.5 s 11±1.5 s Recycling *4 1 s max BC-R10A7H005_ Yes Pre-ignition *3 4.5±0.5 s 15±1.5 s Recycling *4 1 s max BC-R10A7J002_ Pre-purge 4.5±0.5 s 7±1 s 2 s max BC-R10A7K007_ Pre-purge 7±1 s 7±1 s Recycling *4 1 s max 20±2 s BC-R10A7L004_ Pre-ignition *3 4.5±0.5 s 11±1.5 s 2 s max BC-R10A7M003_ Pre-ignition *3 4.5±0.5 s 11±1.5 s Recycling *4 1 s max BC-R10A7M005_ No *1 Pre-ignition *3 4.5±0.5 s 15±1.5 s Recycling *4 1 s max BC-R10A7N002_ Pre-purge 4.5±0.5 s 7±1 s 2 s max BC-R10A7P007_ Pre-purge 7±1 s 7±1 s Recycling *4 1 s max _ 0 : No additional function D : With inspection record (with data) Flame failure Post-purge response time time *1 It must be used for burners that are configured for use without an airflow rate detector, as specified in JIS B 8407-2, Forced Draught Burners, Part 2: Oil Burners. *2 It proceeds to post-ignition after the end of ignition trial. *3 The ignition transformer is ON during pre-purge. *4 When flame failure occurs, after the flame failure response time,the recycling model proceed to pre-purge after 5 s of inter-waiting time and 2 s of start check time elapse. Recycling is done once. If there is second time of flame failure, it proceeds to lock-out. 0 s Compatible flame detector (sold separately) Visible light flame detector Model number Name Notes AFD100A0700 Visible light flame detector Light reception direction: front, top-view type AFD100B0700 AFD110A0000 Light reception direction: side, side-view type G3/4-inch flange mounting type Options (sold separately) Model number Name Notes BC-R05A100 Dedicated BC-R sub-base Required for all products in the BC-R10 series 81447514-001 Connector for front wiring Weidmueller BL3.5/11F Compatible wire: 0.2-1.5 mm 2 (AWG28-14) 81447514-002 Connector for front wiring (for right side wiring) Weidmueller BL3.5/11/270F Compatible wire: 0.2-1.5 mm 2 (AWG28-14) 81447515-001 Side boards Contains two. Not included in the sub-base. FSP136A100 Analog flame meter 81447519-001 Jack cover Includes mounting screw 81447531-001 Front connector cover Packaged with mounting screws (Included with the controller.) BC-R models that replace R4424 and older models Current/old model R4424C104-A, R4424C104-1, R4313C1007-5 R4424C204-A, R4424C204-1, R4313C1015-5 R4424D1001-A, R4424C1001-1, R4313D1005 R4424D1019-A, R4424C1019-1, R4313D1013 R4424D121-A, R4424C121-1, R4313B1009 R4424D221-A, R4424C221-1, R4313B1017 R4424E104-A, R4424C104-1, R4313E1002 R4424E204-A, R4424C204-1, R4313E1010 Rated power supply 100 Vac 200 Vac 100 Vac 200 Vac 100Vac 200 Vac 100 Vac 200 Vac Operation at flame failure Recycling Recycling Pre-purge type Pre-purge Pre-ignition Pre-purge Pre-ignition Pre-purge Pre-purge Replacement BC-R model BC-R10A7P0070 (BC-R10A7K0070) * BC-R10A7L0040 (BC-R10A7G0040) * BC-R10A7M0050 (BC-R10A7H0050) * BC-R10A7N0020 (BC-R10A7J0020) * * Note: monitoring is available for models in parentheses. Sequence timing and tolerances of the replacement may differ from those of the replaced model. For details, see the individual speciations sheet. 3
Terminal numbers, front panel item names Front Display Sub-base (sold separately) switch Display switch Front connector cover (connector is behind cover) Jack * * Used for inspection and adjustment during production. Not for Smart Loader Package use. DIN rail clamp Terminal board Terminal numbers Front connector terminals No. Function No. Function 25 Flame voltage output (+) 31 for monitor output 26 Flame voltage output (-) 32, combustion 27 NC 33, ignition failure 28 NC 34, flame failure 29 NC 35, lockout 30 NC interlock input Sub-base terminals No. Function No. Function 1 Blower motor output (electromagnetic breaker) 13 2 AC power supply (L1) 14 Flame detector (F) 3 AC power supply (L2 (N)) 15 Flame detector (G) 4 common 1 16 common 1 5 common 2 17 common 2 6 output 18 NC 7 ) 19 NC 8 ) 20 9 NC 21 input *1 10 NC 22 input 11 NC 23 NC 12 NC 24 Contact reset input *1 Only for models with airflow switch observation. 4
7-segment display, LED display, switches If this device detects a flame failure etc., it isolates the load and applies a lockout. During lockout, the relevant diagnostic function code is displayed on the 7-segment display. Part Name 7-segment LED (green) When normal: sequence code/ flame voltage When an error occurs: Warning code/ flame voltage Switch Flame voltage/ sequence code Flame voltage/ warning code display switch Flame LED (green) Lit when flame signal is detected. Off when flame signal is off. Loader jack Used for inspection and adjustment during production. Not for Smart Loader Package use. BC-R main unit fastening screw switch Switch to cancel lockout (Press and hold for approximately 1s) ALARM LED (red) Lit during lockout. Off when there is no lockout. Front connector Flame voltage output (0-5V) (semiconductor relay output) BC-R main unit fastening screw Warning codes Display Name Meaning E0 Interlock error E 1 False flame signal was detected for 5s during start check and prepurge E2 error 1 *1 The airflow switch turned Off during combustion E3 error 2 *1 The airflow switch stayed On for 3 minutes during start check The airflow switch did not turn On for 3 minutes after the start of prepurge E6 Ignition failure Ignition could not be detected with main trial E7 Flame failure The flame signal disappeared in the sequence after main trial E9 + Sub-code (2 digits) Device error Voltage error detected in output from the ignition transformer, ), or Hi solenoid valve), etc. *1 Only for models with airflow switch observation. Sequence codes Display Status content P 1 P2 Pre-purge P4 Iignition trial P5 Post ignition P8 Run Pr Inter-waiting -- Controlled shutdown Examples of sequence codes and warning codes Warning code: E1 to E7 Warning code: E9 + sub-code (2 digits) Switches every 0.8s (Sub-code) Switches every 0.8s 5
Internal block circuit, external connection terminals (1-24 on sub-base, 25-35 on front connector) L1 L2(N) Blower motor (Electromagnetic breaker) common 1 2 3 4 5 6 7 8 9 K10 10A circuit K2 K5 K3 K4 NC K1 DC24V safety control circuit K6 Flame detector circuit circuit (24Vdc) 13 F 14 G 15 + 16 + 17 NC 18 NC 19 20 21 Warning Flame detector common Start *2 10 NC 22 11 NC NC 23 12 NC 24 Contact reset Display FLAME ALARM Flame voltage circuit 25 26 NC 27 NC 28 NC 29 FV+ FV- DISP switch Loader jack *1 switch Monitor output circuit NC 30 31 32 33 34 35 Interlock for monitor output (100/200 Vac or 24 Vdc) Note - Use reset (terminal 24) input in isolation. It cannot be used in conjunction with other BC-R contact reset inputs. - common (terminals 4, 5) and input common (terminal 16, 17) cannot be used in conjunction with other BC-R. *1 The loader jack is used for inspection and adjustment during production. *2 Only for models with airflow switch observation 6
External Dimensions BC-R10 Burner Controller (Unit: mm) 61 95 110 105 27 17 Sub-base (sold separately) BC-R main unit fastening screw Connector for front wiring Sub-base (sold separately) BC-R main unit fastening screw A DIN rail clamp Model number A 81447514-001 10.6 81447514-002 14.6 Sub-base BC-R05A100 (sold separately) 61 105 27 17 Knockout hole 16 Knockout hole 64 M3.5 (terminal screw) ø12 knockout hole ø12 knockout hole Sub-base mounting hole Sub-base mounting hole 95 62.5 DIN rail clamp 7
Sideboard 81447515-001 (sold separately) (Unit: mm) Sub-base 30.7 Sub-base ø19 knockout hole 46.6 73.5 Sideboard Sideboard ø19 knockout hole 23.9 Precautions on installation (1) Allow 50mm above and below, 50mm to the left and right, and 80mm to the front as space for removal, wiring, and maintenance. Also, do not install this device close to electric power devices or other sources of heat. 50mm Front 50mm 50mm 50mm 80mm 50mm 50mm Wiring, ducts, etc. (2) This device must be grounded within a grounded and conductive control panel to ensure safety. (3) Do not pull the wiring while it is attached to the device. Doing so can cause failure of the connectors or the unit itself. Installation orientation Install the device in the orientation shown below. Display area BC-R Main unit OK BC-R Main unit OK Do not install it in the orientations illustrated below. BC-R Main unit Mounting in a Panel [1] Drill two M4 screw holes into the panel. [2] Use screws to mount the sub-base on the panel. (Maximum tightening torque: 1.2 N m) 62.5 M4 (2 locations) (Unit: mm) 8
Operation Sequence 1-1. Normal Operation (Pre-purge with airflow switch) signal Prepurge Post ignition Steady combustion -- P1 P2 P4 P5 P8 -- time time Post ignition time 1-2. Normal Operation (Pre-purge without airflow switch) signal Prepurge Post ignition Steady combustion -- P1 P2 P4 P5 P8 -- time time Post ignition time 9
1-3. Normal Operation (Pre-ignition pre-purge with airflow switch) signal Pre-ignition Pre-purge Post ignition Steady combustion -- P1 P2 P4 P5 P8 -- time time Post ignition time 1-4. Normal Operation (Pre-ignition pre-purge without airflow switch) signal Pre-ignition Pre-purge Post ignition Steady combustion -- P1 P2 P4 P5 P8 -- time time Post ignition time 10
2. (Pre-purge with airflow switch) signal Prepurge -- P1 P2 P4 P4/E6 time time 11
3-1. (Non-recycling model) signal Prepurge Post ignition Steady combustion -- P1 P2 P4 P5 P8 P8/E7 Flame response Post ignition time time time 3-2. (Recycling model) signal Prepurge Post ignition Steady combustion Inter-waiting Prepurge -- P1 P2 P4 P5 P8 Pr P1 P2 P4 Flame response Post ignition time time time Inter-waiting time Approximately 5 s time 12
4. Interlock error(pre-purge model) signal Prepurge Steady combustion -- P1 P2 P4 P5 P8 P8/E0 -- time Post ignition time time 5. does not turn ON when pre-purge starts.(common to both pre-purge and preignition models) signal Prepurge -- P1 P2 P2/E3 time Approximately 3 m 13
6. False flame signal before startup -- P1 P1/E1 signal 5 s 7. False flame occurred during pre-ignition prepurge(pre-ignition model) (False flame occurrence time: less than 5 s) signal Pre-ignition Pre-purge False flame occurrence False flame extinguished Post ignition Steady combustion -- P1 P2 P4 P5 P8 -- Less than 5 s * Flame response time Post ignition time time * Note: If the false flame signal continues for five seconds or longer, lockout occurs. 14
Trial-run operation mode Warning In trial operation mode, loads (blower, ignition transformer, control motor, etc.) operate. They should be operated by a person with expert knowledge and an understanding of the functions. There is a risk of a major accident. Transition to trial operation mode [1] Press and hold the DISP switch for approximately 5 s or more during the stop sequence (when the start switch is Off). The 7-segment display changes to [ C2 ] and the system goes into trial operation mode. The central dot of the 7-segment display starts blinking (a 1 s cycle). [1] [2] [3] [4] [3] Trial operation setup [2] Each time the DISP switch is pressed, the display changes through the cycle [ C2 C3 C4 C5 C6 ] Display C2 C3 C4 C5 C6, flame, ignition failure, flame failure, lockout interlock Blower motor output Meaning n Trial-run operation mode selection [3] Select trial operation type using the DISP switch. When C2 ~ C6 is selected 1 Press the button to enter selection mode. The 7-segment display displays [ Cx/OF ]. 2 When the DISP switch is pressed in this situation, the display toggles between [ Cx/ OF ] and [ Cx/On ], and trial operation runs according to the On/Off selection. * C6 only becomes [ C6/On ]. To turn the blower off, press the switch when in this state. 3 When the switch is pressed to stop trial operation, the display for selecting types of trial operation ([2] above) is displayed. Exit [4] Press and hold the DISP switch for 5 s or more to end trial operation mode. Trial operation mode also ends in the following situations. The power supply is turned Off. 1.1 Forced output of the Flame monitor output ( c2 ) Allows checking of indicators etc. connected to the monitor output terminal. Turns the flame monitor output ON or OFF. 1.2 Forced ignition failure monitor output ( c3 ) Allows checking of indicators etc. connected to the monitor output terminal. Turns the ignition failure monitor output ON or OFF. 1.3 Forced flame failure monitor output ( c4 ) Allows checking of indicators etc. connected to the monitor output terminal. Turns the flame failure monitor output ON or OFF. 1.4 Forced lockout interlock monitor output ( c5 ) Allows checking of indicators etc. connected to the monitor output terminal. Turns the lockout interlock monitor output ON or OFF. 1.5 output On ( c6 ) This is a function to force blower motor (electromagnetic breaker) output and check the air volume. 15
Customer Specification Check Sheet, BC-R10 Series This sheet is for selecting the optimum BC-R10 Series product to suit the customer s specification. Use it to facilitate communications with our sales staff. Equipment name Equipment summary Flame detector used Visible light flame detector AFD100/110 sires Ignition method voltage 100 to 230 Vac Sequence Pre-purge Seconds or minutes Ignition standby Post-ignition Flame response s s s (Write whether or not there is input, the specification, etc.) input Contact reset input input MEMO 16 1st Edition: Issued in Mar. 2014 2nd Edition: Issued in July 2014