No.

CP-SP-1388E

BC-R25 Series
Burner Controller
User's Manual

Thank you for purchasing the BC-R25

Series. This manual contains information
for ensuring the correct use of the BC-R25
Series.
This manual should be read by those who
design and maintain equipment that uses
the BC-R25 Series.
It also provides necessary information
for installation, maintenance, and
troubleshooting. 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 Azbil Corporation.
In no event is Azbil Corporation liable to anyone for any indirect, special or
consequential damages as a result of using this product.

© 2015 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
this module.

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

WARNING
Use this device with combustion equipment that is started and stopped at least once in a 24-hour
period.
This device cannot be used with combustion equipment that operates continuously for 24 hours or
longer.
Before removing, mounting, or wiring the BC-R25 Series, be sure to turn off the power to the
BC-R25 Series and all connected devices. Failure to do so might cause electric shock.
If lockout occurs, reset it only after removing the cause. Also, do not enter reset input repeatedly.
Operating this product improperly could result in a serious combustion equipment accident.

Never input a reset command from a remote location. Because it is difficult to make a safety check
when far from the equipment, there is an increased risk of explosion.
This device is equipped with functions that are extremely important for the safe operation of combustion
equipment. Be sure to follow the instructions given in this manual.
Check the model number carefully and check that the sequence timing is as specified by the combustion
equipment manufacturer. Installing the wrong model can result in an explosion hazard.
Do not touch terminal 14 (F) immediately after the power has been turned off. Because the terminal retains
an electrical charge, there is a danger of electric shock.
Do not use the monitor output or alarm relay output as safety output.

This device has an operating life and should be replaced within that time. Continued use beyond the
lifespan may result in device failure.

Do not start regular operation of the equipment without first completing the adjustments and tests for this
device, as well as the tests specified by the equipment manufacturer.
Do not disassemble this device. Malfunction, device failure, or electric shock may result.

CAUTION
In order to use this product correctly, be sure to follow this manual, the manuals for any associated
devices, and the manuals for the combustion equipment. When designing a flame safeguard
control system, please consult with a representative of the azbil Group.
Installation, wiring, inspection, adjustment, maintenance, etc. should be carried out only by trained
and experienced technicians who have knowledge and technical skills related to this product and
associated equipment.
Be sure to use this device correctly, within the ranges specified in this user's manual. Otherwise
device failure or malfunction could result.

Avoid installing the device where it will be subject to conditions such as the following. Otherwise
device failure could result.
• Certain chemicals or corrosive gases
• High temperatures
• Splashing water or excessive humidity.
• Prolonged vibration

ii
 CAUTION
Wire this device in compliance with established norms, using the types of wire and wiring methods
specified in this manual. Otherwise there is a risk of device failure or malfunction.

Carry out maintenance and inspection correctly according to the methods, procedures,
replacement cycles, etc., specified in this manual.

When discarding this product, dispose of it as industrial waste, following local regulations.

Do not connect a load that exceeds the rating stated in the specifications to the control load
terminals (terminals 2–1, 2–6, 2–7, or 2–8), and do not short-circuit the load. Doing so will burn out
the internal fuse, making the device unusable. To comply with CE standards, it is necessary to take
measures to prevent the use of a device whose relay contacts can be damaged by a connected
load that exceeds the rating or by a load short-circuit. For this reason, this device uses an internal
fuse that cannot be replaced.

iii
Contents
Conventions Used in This Manual
Safety Precautions

Chapter 1. Overview
■■ Instructions for proper use………………………………………………………………… 1
■■ Precautions on facility design……………………………………………………………… 1
■■ Most important points for ensuring safety……………………………………………… 1
■■ Model number……………………………………………………………………………… 2
■■ Related equipment………………………………………………………………………… 3

Chapter 2. Installation, Wiring

■■ Installation method………………………………………………………………………… 5
■■ Cautions regarding installation…………………………………………………………… 6
■■ Installation orientation……………………………………………………………………… 6
■■ DIN rail mounting…………………………………………………………………………… 6
■■ Mounting in a panel………………………………………………………………………… 7
■■ Mounting/removing the device and sub-base (sold separately)……………………… 7
■■ Terminal numbers, front panel item names……………………………………………… 8
■■ Example of wiring connection with external device ……………………………………10

Chapter 3. Operation
■■ Names of parts………………………………………………………………………………13
■■ Operation……………………………………………………………………………………13
■■ Trial operation mode…………………………………………………………………………16
■■ Function selection mode (for POC and host communications (RS-485) address)………18
■■ Host communication settings using the Smart Loader Package (SLP-BCR)……………20

Chapter 4. Explanation of Operation

■■ Example of wiring connection with external device: Internal block diagram…………21
■■ Example sequence……………………………………………………………………………23
■■ Alarm and occurrence sequence……………………………………………………………37

Chapter 5. Trial Operation and Adjustment

■■ Preliminary inspection………………………………………………………………………38
■■ Inspection procedure………………………………………………………………………38
■■ Ignition spark response (UV sensor)………………………………………………………39
■■ Measurement of flame voltage……………………………………………………………40
■■ Pilot turn-down test…………………………………………………………………………42
■■ Safety shutoff check…………………………………………………………………………43

iv
Chapter 6. Maintenance and Inspection
■■ General maintenance and inspection………………………………………………………44
■■ Maintenance and inspection cycle…………………………………………………………44
■■ Alarm codes and details……………………………………………………………………45
■■ Failure inspection flow ………………………………………………………………………46

Chapter 7. Specifications
■■ External dimensions…………………………………………………………………………49

v
Chapter 1. Overview

BC-R25 burner controllers are designed for batch operation of combustion equipment (at least one start and stop
in a 24-hour period). The BC-R25 automatically executes ignition, flame monitoring, and fuel shutoff for ON/OFF-
controlled gas burners and oil burners. Its features include a 7-segment LED display that is useful for maintenance
and a test mode that is convenient for trial runs & adjustment. In addition, it is equipped with host communication
(RS-485) and Smart Loader Package compatibility, which make more detailed monitoring and troubleshooting
possible.
• 7-segment display for sequence codes and alarm codes.
• LED indicators show whether there is a flame signal and whether lock-out is present.
• The monitor outputs the operating status of the flame signal, ignition failure, flame failure and lock-out
interlock.
• Perform fault diagnosis for the internal control relay circuit.
• The product is designed so that it cannot be restarted in the case of lock-out due to ignition failure, false
flame or other causes, unless it is reset manually.
• The design complies with JIS C 9730-2-5 and JIS C 9730-1.
• The air-flow switch (OFF/ON) is checked before and after start check. (JIS B 8407)
• POC (proof of closure) function based on shutoff valve closure confirmation switch input.
• Host communication (RS-485) allowing remote observation of status
• DIN rail mounting and sub-base structure are provided for easy installation and replacement

„„ Instructions for proper use

• This device has functions that are extremely important for the safe operation
of combustion equipment. Therefore, use the device correctly, according to this
user's manual.
• The device must be installed, wired, maintained, inspected and adjusted by
experienced specialists who have gained knowledge and skills concerning
combustion equipment and combustion safety devices.

„„ Precautions on facility design

The facilities that use the combustion safety device must be designed taking into
careful consideration the following safety guidelines and the like.
If the system is designed to a foreign specification, refer to laws and standards in the
relevant country.
• “Technical Policy on Safety Standards for Combustion Equipment in Industrial
Furnaces,” by the Ministry of Health, Labour and Welfare
• "General Safety Code for Industrial Combustion Furnaces"- 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
• “Index of Safety Technology of Industrial Gas Combustion Equipment,” by Japan
Gas Association
• “Safty Guideline for Gas Boiler Combustion Equipment” by The Japan Gas
Association

„„ Most important points for ensuring safety

The design must take into consideration the following points to ensure safety.
1. Connect loads directly to the device.
2. Make sure that the start check circuit operates correctly at startup.
3. Do not make a manual operation circuit or other bypass circuit for any loads.
4. Use a redundant shutdown system for both main valve and pilot valve.

1
Chapter 1. Overview

„„ Model number
(Note: The dedicated sub-base and sideboard are not provided with the BC-R25 series controller. Order them
separately.)

zz Direct ignition type

I II III IV V VI VII Example: BC-R25B1J0500
I II III IV V VI VII Description
Base Commu- Flame Power Function Timing Additional
model nications detector supply code Code functions
number function
BC-R Burner Controller
25 RS-485, with Smart Loader Package function
B Flame rod (Ionization)
C UV sensor (AUD100/110)
1 100 Vac
2 200 Vac
6 220 Vac
J Direct ignition type
050 Pre-purge time 35 s
086 Pre-purge time 45 s
122 Pre-purge time 60 s
158 Pre-purge time 3 min
0 None
D With inspection record (with data)

zz Interrupted pilot type

I II III IV V VI VII Example: BC-R25B1G0500
I II III IV V VI VII Description
Base Commu- Flame Power Function Timing Additional
model nications detector supply code Code functions
number function
BC-R Burner Controller
25 RS-485, with Smart Loader Package function
B Flame rod (Ionization)
C UV sensor (AUD100/110)
1 100 Vac
2 200 Vac
6 220 Vac
G Interrupted pilot type
050 Pre-purge time 35 s
086 Pre-purge time 45 s
122 Pre-purge time 60 s
158 Pre-purge time 3 min
0 None
D With inspection record (with data)

2
 Chapter 1. Overview

„„ Related equipment
zz Compatible flame detector (sold separately)
• Flame detector UV sensor
Model number Name Notes
AUD15C1000 Advanced UV sensor Use a dedicated socket for the AUD100C/110C/120C
Tube unit
AUD100C100 _ Advanced UV flame detector (Lead wire model AUD15C1000, sold separately
without AUD15C)
AUD100C1000-A15 Advanced UV flame detector (Lead wire model AUD15C1000 in package
with AUD15C)
AUD110C100 _ Advanced UV flame detector (Terminal block AUD15C1000, sold separately
model without AUD15C)
AUD110C1000-A15 Advanced UV flame detector (Terminal block AUD15C1000 in package
model with AUD15C)
AUD120C120 _ Advanced UV flame detector (1/2-inch Without G1/2 adapter, AUD15C1000, sold separately
mounting model)
AUD120C121 _ With G1/2 adapter, AUD15C1000, sold separately
_: ‌0: standard product. D: with inspection record (with data).
T: tropicalization (AUD110C only).
B: inspection record (with data) and tropicalization (AUD110C only).

• Flame rod
Model number Name Notes
C7007A Flame rod holder
C7008A Flame rod assembly

zz Optional parts (sold separately)

Model number Product name Notes
BC-R05A100 Dedicated sub-base for BC-R Required for all products in the BC-R25 series
81447514-001 Connector for front wiring Contains one
Weidmueller model number : BL3.5/11F
Compatible wire: 0.2–1.5 mm2 (28–14 AWG)
81447514-002 Connector for front wiring Contains one
(for right-side wiring) Weidmueller model number : BL3.5/11/270F
Compatible wire: 0.2–1.5 mm2 (28–14 AWG)
81447515-001 Side boards (2) Contains two
Not included in the sub-base
SLP-BCRJ71 Smart Loader Package Compatible with BC-R25 (with communications
(no cable) functions)
81441177-001 USB loader cable
FSP136A100 Analog flame meter
81447519-001 Jack cover Contains one
81447531-001 Front connector cover Mounting screw supplied

3
Chapter 2. Installation, Wiring

WARNING
Never input a reset command from a remote location. Because it is difficult to make a safety check
when far from the equipment, there is an increased risk of explosion.
This device is equipped with functions that are extremely important for the safe operation of
combustion equipment. Be sure to follow the instructions given in this manual.
Check the model number carefully and check that the sequence timing is as specified by the
combustion equipment manufacturer. Installing the wrong model can result in an explosion hazard.
Connect the load (ignition transformer, solenoid valve, etc.) directly to the output terminals of this
device.
If it is not directly connected, combustion safety cannot be ensured.

CAUTION
A ground-fault detection circuit is included in this device. Even if the power supply does not have
high and low potential sides, if a ground fault occurs due to insulation failure of a load such as an
ignition transformer, pilot valve, or main valve, this device will detect the ground fault and safely
shut off and lock out the equipment.
When mounting and wiring, be sure to follow this user's manual or the instruction manuals provided
by the equipment or system manufacturer.
Carry out the wiring work in conformity with the specified standards.

Connect the power supply last to prevent electric shock or damage. Otherwise touching terminals
by mistake may cause electric shock or may damage the device.
Make sure that loads connected to the terminals do not exceed the rating indicated in the
specifications.
Supply power at the voltage and frequency indicated on the model number label of the device.

In keeping with technical standards for electrical equipment, the burner frame must be connected
to an earth ground by a wire having a resistance of less than 100 Ω.
Run the high-voltage ignition transformer cable separately and keep it at least 30 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 can generate high-frequency radio waves, causing malfunction.
The ignition transformer ground lead should be connected directly to the burner itself or to a
metallic part electrically connected to the burner.
Be sure to check that the wiring is correct before you turn the power ON. Incorrect wiring can cause
damage or malfunction.
If the wires from this device exceed the recommended length, to prevent malfunction due to
external electrical noise, keep power wiring away from the wires running from the control panel to
the burner controller. After wiring, check that the equipment is operating properly.
Be sure to connect non-voltage contacts to the inputs of this device (terminals 16 to 29).

After the power has been turned ON, leave sufficient time before checking the output. This device
does not operate for about 8 seconds after the power has been turned ON.

4
 Chapter 2. Installation, Wiring

CAUTION
The reset input (terminal 24) must be used by this device only. It cannot be shared with any other
BC-R unit.
Output common terminals 4 and 5, and input common terminals 16 and 17 cannot be shared with
any other BC-R unit.
Do not design instrumentation that shuts off the power to this device as soon as alarm output is
generated. Doing so can corrupt this device's operation history records.
To prevent malfunction due to external electrical noise, do not operate the device with the loader
cable except for trial runs, maintenance, and troubleshooting.
If there is an inverter or the like that generates strong electrical noise near this device, take noise-
suppression measures, referring to the user's manual for the noise-generating equipment.

„„ Installation method

WARNING
Ensure you turn off the power of this device and all auxiliary devices when mounting, removing or
connecting the wires of this device. There is a risk of electrical shock.

CAUTION
Mounting, wiring, maintenance, inspection, calibration, etc. should be carried out by a professional
with technical training in combustion systems and flame safeguard control devices.
Do not install where exposed to any of the following:
• Certain chemicals or corrosive gases (ammonia, sulfur, chlorine, ethylene compounds, acids, etc.)
• Dripping water or excessive humidity
• High temperatures
• Sustained long-term vibration
For mounting and wiring, follow the instructions in this user's manual or in the combustion
equipment manufacturer's manual.
A fuse is built into the control load line of this device. Do not short-circuit the load, or the fuse will
melt. If the fuse has melted, replace the device.
When using the device as a burner control system, install it to a control panel that supports IP40 or
more. If IP40 is required for this single device, also use a side board (sold separately). The protection
structure of the device is equivalent to IP10.

5
Chapter 2. Installation, Wiring

„„ Cautions regarding installation

• Take space 50 mm above and below, 50 mm to the left and right, and 80 mm 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.

Front
50 mm 50 mm

50 mm 50 mm 80 mm
BC-R main
device

50 mm 50 mm

Wiring, ducts, etc.

•T
 his device must be grounded within a grounded and conductive control panel to
ensure safety.
•D
 o not pull the wiring while it is attached to the device. Doing so can cause
failures of the connectors or the device itself.

„„ Installation orientation
Attach the device in the orientation shown below.

Display area
BC-R main
BC-R main device
device

Do not install it in the orientations illustrated below.

BC-R main
device

„„ DIN rail mounting

(1) Pull down the sub-base's DIN rail clamp.
(2) Attach to the DIN rail while checking above and below the sub-base.
(3) Push up the DIN rail clamp to attach the sub-base to the DIN rail.

Attach sub-base to DIN rail

Pull the DIN rail clamp Push the DIN rail clamp
downwards upwards to fix in place

6
 Chapter 2. Installation, Wiring

„„ Mounting in a panel
(1) Drill two M4 screw holes into the panel.
M4 (Unit: mm)
62.5 (2 locations)

(2) Use screws to mount the sub-base on the panel.

(Maximum tightening torque: 1.2 N∙m)

CAUTION
Turn the power off before mounting the device on the sub-base. Otherwise, device failure may
occur.

„„ Mounting/removing the device and sub-base (sold separately)

(Mounting)
(1) Align the indentation in the center of the top of the device
with the projection on the sub-base.

(2) Once aligned as in (1), push straight downwards slowly.

(3) Tighten the device's retaining screws to secure it in the sub-

base. (Maximum tightening torque: 0.5 N·m)

(Removal)
(1) Remove the retaining screws from the device.
(2) Pull it out horizontally while holding down the sub-base.

7
Chapter 2. Installation, Wiring

„„ Terminal numbers, front panel item names

Front Sub-base (sold separately)
Display

Reset switch
DISP switch

Front connector cover

(connector is behind cover)

Jack * DIN rail clamp

Terminal board
* Set the POC function as disabled
On BC-R25, also used as a Smart Loader Package jack

zz Terminal No.
Front connector terminals
No. Function No. Function
25 Flame voltage output (+) 31 Power supply for monitor output
26 Flame voltage output (-) 32 Monitor output, flame
27 Host communications (RS-485) DA 33 Monitor output, ignition failure
28 Host communications (RS-485) DB 34 Monitor output, flame failure
29 Host communications (RS-485) SG 35 Monitor output, lock-out interlock
30 NC - -

Sub-base terminals
No. Function No. Function
1 Blower motor output 13 Alarm output
(electromagnetic breaker)
2 AC power supply (L1) 14 Flame detector (F)
3 AC power supply (L2 (N)) 15 Flame detector (G)
4 Output common 1 16 Input common 1
5 Output common 2 17 Input common 2
6 Ignition transformer output 18 NC
7 Pilot valve output 19 NC
8 Main valve output 20 Start input
9 NC 21 Air-flow switch input
10 NC 22 Lock-out interlock input
11 NC 23 POC (proof of closure) input
12 NC 24 Contact reset input

8
 Chapter 2. Installation, Wiring

zz Connector for front wiring (81447514-001) terminal layout

Mounting screw

25

Wiring
Wiring fastener screw

35

Mounting screw

zz Connector for front wiring (for right side wiring) (81447514-002) terminal layout

Mounting screw
25

Wiring
Wiring fastener screw

35

Mounting screw

9
Chapter 2. Installation, Wiring

„„ Example of wiring connection with external device

(Terminals 1 to 24: sub-base. Terminals 25 to 35: front connector.)
zz Interrupted pilot type
L1 L2 (N)

Blower motor K10

(electromagnetic K6
1 13 Alarm
breaker)
10A F
2 Flame 14 Flame
Power supply circuit detector detector
circuit G
3 24 Vdc 15
K1
4 K2 16 +
Input common
Output common
+
5 17
K5
Ignition transformer 6 NC 18
K3 Input
Pilot valve 7 Combustion NC 19
circuit
K4 safety
Main valve 8 (24 Vdc) 20 Start
control
9 NC circuit 21 Air-flow switch

10 NC 22 Lock-out interlock

11 NC 23 POC (proof of closure)

12 NC 24 Contact reset

Flame 25 FV+
voltage
Display circuit 26 FV-
27 DA
Terminal layout of
RS-485

connector for FLAME 28 DB

front wiring ALARM 29 SG
Power supply for monitor output
NC 30 (100/200 Vac or 24 Vdc)
DISP Reset 31 Power supply
switch switch
32 Flame
Monitor
output 33 Ignition failure
circuit
Loader 34 Flame failure
jack *1
35 Lock-out interlock

10
 Chapter 2. Installation, Wiring

zz Direct ignition type

L1 L2 (N)

Blower motor K10 K6

(electromagnetic 1 13 Alarm
breaker) 10A F
2 Flame 14 Flame
Power supply circuit detector detector
circuit G
3 24 Vdc 15
K1
4 K2 16 +
Input common
Output common +
5 17
K5
Ignition transformer 6 NC 18
K3
Main valve (Lo solenoid valve) 7 Combustion NC 19
*1 Input
K4 safety
Main valve (Hi solenoid valve) 8 control circuit 20 Start
*1 (24 Vdc)
circuit
9 NC 21 Air-flow switch

10 NC 22 Lock-out interlock

11 NC 23 POC (proof of closure)

12 NC 24 Contact reset

Flame 25 FV+
voltage
Display circuit 26 FV-
27 DA
Terminal layout of
connector for FLAME RS-485 28 DB
front wiring
ALARM 29 SG
Power supply for monitor output
NC 30 (100/200 Vac or 24 Vdc)
DISP Reset 31 Power supply
switch switch
32 Flame
Monitor
output 33 Ignition failure
circuit
Loader 34 Flame failure
jack
35 Lock-out interlock

Notes
• Use contact reset (terminal 24) input in isolation. It cannot be used in
conjunction with other BC-R contact reset inputs.
• Output common (terminals 4, 5) and input common (terminal 16, 17)
cannot be used in conjunction with other BC-R.

*1 Content in ( ) describes the situation when three-position (Off-Lo-Hi)

control is used. If other than three-position control is used, connect to
main valve (terminal 7).

11
Chapter 2. Installation, Wiring

zz Wiring to a flame detector (UV sensor)

• AUD100C+AUD15C

Blue
Terminal 14 (F)
White *
Terminal 15 (G)

• AUD110C+AUD15C
Terminal

F Terminal 14 (F)
*
G Terminal 15 (G)

• AUD120C+AUD15C

Blue
Terminal 14 (F)
White *
Terminal 15 (G)
AUD120C
AUD120C

* If connection of the blue and white lead wires is reversed, or if the connections
to terminals F and G are reversed, the AUD15C tube unit may be damaged.

zz Wiring to a rectification flame rod

Terminal 14 (F)

(Flame)
Terminal 15 (G)

zz Example countermeasures against power surges caused by lightning

When using a line surge suppressor as a countermeasure against power surges caused
by lightning, connect it between Terminal 3 and the ground, as shown below.
The mounting brackets of the surge suppressor are crimp-on at the grounded side
and inside and in conducting state.
Therefore, they can be grounded by simply attaching them to a grounded metal
part such as the device cabinet.
When wiring to the power supply, use a lead wire of 0.75mm2 (diameter: 0.18, strand
count: 30) or more, which complies with JIS C 3306. Attach #187 Faston receptacle at
one end and make the wire length as short as possible when connecting it.

High-voltage side (L1)

Burner Controller

Burner Controller

2 2
to Power supply to Power supply

3 3

Low-voltage side (L2(N))

Surge absorber Line surge absorber

83968019-001
Faston terminal side (187 series)

Mounting bracket side

(grounded side)

12
Chapter 3. Operation

„„ Names of parts
7-segment LED (green) BC-R fastening screw
When normal: Sequence code/Flame voltage
When an error occurs: Alarm code/Flame voltage

DISP switch Reset switch

Switch to change as follows: Switch to cancel lock-out
Flame voltage/Sequence code or (Press and hold for approximately 1s)
Flame voltage/Alarm code

Flame LED (green) ALARM LED (red)

On during flame signal is detected. Lit during lock-out.
Off when flame signal is not detected. Off when there is no lock-out.

Loader jack Front connector

POC function selection Flame voltage output (0-5 V)
Smart Loader jack (BC-R25) Monitor output (semiconductor relay output)
Host communications (RS-485)
BC-R fastening screw
ID display

When a lock-out occurs, a alarm code is displayed automatically.

When an alarm occurs, the sequence code and alarm code issued when the lock-out
occurred are displayed alternately.

ID display
Item Notation
• Product number BC-R25xxxxxxx
• Voltage AC xxx V
• Flame detector (UV sensor) UV
(Flame rod) Ionization
• Timing display Pre-purge time PPT xx s
Ignition trial IGT xx s
Trial time
Flame failure response time FFRT xx s

„„ Operation
zz Operation switch
During normal operation
The 7-segment display shows a sequence code.
Every time the DISP switch is pressed, the display is changed between the sequence
code and flame voltage alternately.

Sequence codes
Code Interrupted pilot type Direct ignition type
P1 Start check
P2 Pre-purge
P4 Ignition trial Ignition trial
P5 Pilot stabilization Hi-valve ignition standby
P6 Main trial Hi-valve ignition
P8 RUN
P9 Post-purge
−− Controlled shutdown

13
Chapter 3. Operation

When an error occurs

The 7-segment display shows a alarm code and the sequence code for which the
alarm was issued alternately.
Every time the DISP switch is pressed, the display is changed between a alarm code
and the sequence code for which the alarm was issued alternately as well as the
flame voltage.

Alarm codes
Alarm codes Sub-code Description
E0 None interlock error
E1 False flame
E2 Air-flow switch error (1)
E3 Air-flow switch error (2)
E6 Ignition failure
E7 Flame failure
E8 POC (proof of closure) error *
E9 02 Switch input
E9 03 Internal relay feedback (K1)
E9 04 Terminal 4 and 5 voltage discrepancy (K2)
E9 05 Terminal 7 voltage discrepancy (PV)
E9 06 Terminal 8 voltage discrepancy (MV)
E9 07 Terminal 6 voltage discrepancy (IG)
E9 08 Alarm activation at power ON
E9 50 or more Device error

* Replace the burner controller, and if there is a alarm code E8, POC may have
been set by the equipment manufacturer as disabled.
In this case, check the equipment specification, and refer to “Function Setup
Mode” on P. 18 if necessary.

Examples of sequence codes and alarm codes (Alarm code: E0-E8)

Switches every 0.8 s

Examples of sequence codes and alarm codes (Alarm code: E9 + sub-code (2 digits))

(Sub-code)

Switches every 0.8 s

14
 Chapter 3. Operation

zz Reset switch *
Lock-out is canceled when the reset switch is pressed and held for 1 s.
* After the lock-out is canceled, a stabilization time of approximately 5 seconds
should be maintained.
During the stabilization time, no start input can be accepted.
• During postpurge, reset is not possible.

15
Chapter 3. Operation

„„ Trial operation mode

WARNING
Loads(the blower, ignition transformer, valves, etc.) operate in trial operation mode.
They should be operated by a person with expert knowledge and an understanding of the functions.
There is a risk of a major accident.

[1] Press and hold the DISP switch for approximately 5s or more
Transition to trial operation mode

during the stop sequence (when the start input is Off).

The 7-segment display changes to [ C 1 ] and the system goes into
trial operation mode.
[1] [3] The central dot of the 7-segment display starts blinking (on a 1 s
[2]
[3] cycle).
[4]
[2] Each time the DISP switch is pressed, the display cycles through
the sequence [→ C 1→C2→C3→C4→C5→C6 ].
Trial operation setup

Display Description
C1 Continuous pilot burn mode (only output from the main
valve 1 with direct ignition)
C2 Monitor output, flame
C3 Monitor output, ignition failure
C4 Monitor output, flame failure
C5 Monitor output, lock-out interlock
C6 Blower output

• Selecting trial operation mode

[3] Select a trial operation type using the DISP switch.
When C 1 is selected
1 Press the Reset button when C 1 is displayed.
The 7-segment display shows [--] blinking.
2 The combustion sequence starts when start input is received.
 t that stage, the sequence code blinks. (It is steadily lit in
A
normal mode.)
When C2-C6 is selected
1 Press the Reset button to enter selection mode.
The 7-segment display shows [ 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
Reset switch when in this state.

3 When the Reset switch is pressed to stop trial operation, the

display for selecting types of trial operation ([2] above) is
displayed.
Exit

16
 Chapter 3. Operation

[4] Press and hold the DISP switch for 5 s or more to end trial

Exit
operation mode.
Trial operation mode also ends in the following situations.
• Power OFF
• Alarm is issued during trial operation mode (in continuous pilot
burn mode).

1.1 Continuous pilot burn mode (C 1)

In the combustion sequence, only the pilot burns and main trial is not
performed.
A lock-out occurs if there is an error.
1.2 Forced flame monitor output (C2)
This function forces the monitor output to perform output to check the
operations of indicators and other components that are connected to the
monitor output terminal.
Forces the monitor output (flame) ON or OFF.
1.3 Forced ignition failure monitor output (C3)
This function forces the monitor output to perform output to check the
operations of indicators and other components that are connected to the
monitor output terminal.
Forces the monitor output (ignition failure) ON or OFF.
1.4 Forced flame failure monitor output (C4)
This function forces the monitor output to perform output to check the
operations of indicators and other components that are connected to the
monitor output terminal.
Forces the monitor output (flame failure) ON or OFF.
1.5 Forced lock-out interlock monitor output (C5)
This function forces the monitor output to perform output to check the
operations of indicators and other components that are connected to the
monitor output terminal.
Forces the monitor output (lock-out interlock) ON or OFF.
1.6 Blower motor (electromagnetic breaker) output On (C6)
This function enables the blower to output in order to check the air volume.

17
Chapter 3. Operation

„„ Function selection mode (for POC and host communications (RS-485) address)

CAUTION
If POC is selected, the lower right dot of the 7-segment display is lit, regardless of the operation mode.
If devices installed in the system are set without selecting POC (proof of closure), an E8 error is issued
when this device is replaced, unless the new device is set without POC (proof of closure) selection.

In regular modes other than function selection mode, remove the dedicated pin plug.
Transition to function setting mode

[1] Turn the power Off.

[2] Insert the dedicated pin plug into the loader jack connector.
[3] Turn on the power while holding the DISP switch down (approx.
[3]
[4] 10 seconds).
[5] [6]
[6] [7] The 7-segment display shows a blinking [H-], (with a blink cycle of
[7] [8] 0.4 seconds) and ALARM LED blinks (on a 1 s blink cycle).
[8] [9]
[9] [4] Release the DISP switch, then press and hold it again for at least 5 s.
[2][11]
The 7-segment display shows [H 1], and the mode switches to
function selection mode. (The ALARM LED continues to blink)
I f the 7-segment display flashes [O-/-O] for 2.5 s, the
transition to function selection mode has not succeeded. The
pin plug may not be inserted correctly.
Various settings

[5] Each time the DISP switch is pressed, the display cycles through
the sequence [ → H 1→H2→H3→H4 ].

Display Description
H1 POC (proof of closure) selection settings
H2 Communications address setting
H3 Baud rate setting
H4 Communications format setting

• POC (proof of closure) action selection setting

• Factory settings [6] Use the DISP switch to select 7-segment display [H 1].
Settings 1 Press the Reset button.
ON: POC function enabled The 7-segment display shows [H 1/OF ] or [ H 1/On].
2 When the DISP switch is pressed in this situation, the display
toggles between [H 1/OF ] and [ H 1/On], and the POC action
selection is changed between On and Off.
ON POC function enabled
OFF POC function disabled

3 A
 fter making the selection, press the Reset switch to confirm the
setting.
If On (with POC function enabled) is selected at this stage, the
display is [H 1.].
While the POC function is active, a dot appears in the lower
right area of the 7 segment display.
While the POC function is inactive, [H 1] is active, and no dot
appears in the lower right area of the 7 segment display.

18
 Chapter 3. Operation

Various settings
• Factory settings • Communications address setting (only on the BC-R25)
Settings [7] Use the DISP switch to select 7-segment display [H2].
1
1 Press the Reset button. (On the BC-R25, pressing this does not
change the display).
The 7-segment display shows [H2/xx ], where XX is the address
value.
2 When the DISP switch is pressed in this situation, the display
toggles between [→ H2/ 1→ H2/2→H2/3 ......... H2/32 ].
Make the address selection.
3 
After making the selection, press the Reset switch to confirm.
At this stage, the display is [H2].

• Factory settings • Baud rate setting (only on the BC-R25)

Settings [8] Use the DISP switch to select 7-segment display [H3].
3: 19600 bps 1 Press the Reset button. (On the BC-R25, pressing this does not
change the display.)
The 7-segment display shows [H3/xx ], where XX is 1-3 1:
1: 4800 bps
2: 9600 bps
3: 19200 bps
2 When the DISP switch is pressed in this situation, the display
cycles through [→ H3/ 1→H3/2→H3/3 ].
Make the baud rate selection.
3 After making the selection, press the Reset switch to confirm.
At this stage, the display is [H3].
• Factory settings • Communications format setting (only on the BC-R25)
Settings [9] Use the DISP switch to select 7-segment display [H4].
1: Even parity
1 stop bit 1 Press the Reset button. (On the BC-R25, pressing this does not
change the display).
The 7-segment display shows [H4/xx ], where XX is 1-4
1: Even parity, 1 stop bit
2: Even parity, 2 stop bits
3: Odd parity, 1 stop bit
4: Odd parity, 2 stop bits
2 When the DISP switch is pressed in this situation, the display
cycles through [→ H4/ 1→H4/2→H4/3 ].
Select the communications format.
3 After making the selection, press the Reset switch to confirm.
At this stage, the display is [H4].

[10] Turn the power Off.

Exit

[11] Remove the pin plug.

19
Chapter 3. Operation

„„ Host communication settings using the Smart Loader Package (SLP-BCR)

Function setting mode [H2], [H3] and [H4] (host communication (RS-485) setting)
can also be set using the smart loader package.

[1] Turn off the power of the product.

[2] Remove the wiring of RS-485.
Insert one end of the USB loader cable into the loader jack of the
product, and then insert the other end into a USB port of the PC.
[3] Turn on the power of the product.
[4] Start SLP-BCR and set host communication.
(Do not turn off the power for 5 seconds after pressing the [Set]
button, as data is being written.)
[5] Turn off the power of the product.
Remove the USB loader cable.
Connect RS-485.
[6] Turn on the power of the product.
[7] Start communications with the host device.

20
Chapter 4. Explanation of Operation

CAUTION
Even if the start input is turned on, this device does not begin operation until approximately 8
seconds after power supply being turned on.
Therefore, give sufficient time after turning on the power, then check the output of the device.

As the start input uses a 24 Vdc input circuit, it takes approximately 1 second to confirm it.

„„ Example of wiring connection with external device: Internal block diagram

(Terminals 1 to 24: sub-base. Terminals 25 to 35: front connector.)
zz Interrupted pilot type
L1 L2 (N)

Blower motor K10 K6

(electromagnetic 1 13 Alarm
breaker) 10A F
2 Flame 14 Flame
Power supply circuit detector detector
circuit G
3 24 Vdc 15
K1
4 K2 16 +
Input common
Output common
+
5 17
K5
Ignition transformer 6 NC 18
K3 Input
Pilot valve 7 Combustion NC 19
circuit
Main valve K4 safety 20 Start
8 (24 Vdc)
control
9 NC circuit 21 Air-flow switch

10 NC 22 Lock-out interlock

11 NC 23 POC (proof of closure)

12 NC 24 Contact reset

Flame 25 FV+
voltage
Display circuit 26 FV-
27 DA
RS-485

Terminal layout of
connector for FLAME 28 DB
front wiring
ALARM 29 SG
Power supply for monitor output
NC 30 (100/200 Vac or 24 Vdc)
DISP Reset 31 Power supply
switch switch
32 Flame
Monitor
output 33 Ignition failure
circuit
Loader 34 Flame failure
jack
35 Lock-out interlock

21
Chapter 4. Explanation of Operation

zz Direct ignition type

L1 L2 (N)

Blower motor K10 K6

(electromagnetic 1 13 Alarm
breaker) 10A F
2 Flame 14 Flame
detector
Power supply circuit circuit G detector
3 24 Vdc 15
K1
4 K2 16 +
Input common
Output common +
5 17
K5
Ignition transformer 6 NC 18
K3 Combustion
Main valve (Lo solenoid valve) 7 NC 19
*1 safety Input
Main valve (Hi solenoid valve) K4 circuit 20 Start
8 control
*1
circuit (24 Vdc)
9 NC 21 Air-flow switch

10 NC 22 Lock-out interlock

11 NC 23 POC (proof of closure)

12 NC 24 Contact reset

Flame 25 FV+
voltage
Display circuit 26 FV-
27 DA
Terminal layout of
RS-485

connector for FLAME 28 DB

front wiring
ALARM 29 SG
Power supply for monitor output
NC 30 (100/200 Vac or 24 Vdc)
DISP Reset 31 Power supply
switch switch
32 Flame
Monitor
output 33 Ignition failure
circuit
Loader 34 Flame failure
jack
35 Lock-out interlock

*1 Content in ( ) describes the situation when three-position (Off-Lo-Hi) control

is used. If other than three-position control is used, connect to main valve
(terminal 7).

Handling Precautions
• POC (proof of closure) is checked in synchronization with the operation of the
main valve for the interrupted pilot type, or the operation of the Lo solenoid
valve (main valve) for the direct ignition type.

22
 Chapter 4. Explanation of Operation

„„ Example sequence
zz Normal operation
• Interrupted pilot type

n
io
at
al

liz
ck

ge
tri
e

bi

RU al
he

rg

ur
ta
n

tri
pu

tio

-p
tc

ts

n
op

op
N

st
e-
ar

ni

lo

ai

Po
Pr
St

St

St
M
Ig

Pi
[7-segment display] -- P1 P2 P4 P5 P6 P8 P9 --
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Loc-kout interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s
Ignition trial time Main trial
Pilot stabilization time

Input Action Sequence

codes
Start When the start input is turned ON, the internal circuits are checked, and also checks are done to make sure that P1
input ON lock-out interlock is ON (normal), that the shutoff valve proof of closure switch is ON (POC function enabled),
and that the air-flow switch is OFF. K10 is turned ON and the blower motor is turned ON.
The air-flow switch remains ON with the pre-purge timing. P2
After the pre-purge time has elapsed, K3 and K5 are turned ON to perform the output of the ignition transformer P4
and pilot valve.
When the ignition trail time has elapsed, K5 is turned OFF and the ignition transformer is turned OFF. P5
K4 is turned ON and the main valve is turned ON. Within 3 seconds after the main valve is turned ON a check is P6
done to make sure that the shutoff valve proof of closure switch is OFF (POC function enabled).
Once the main trail is completed, K3 is turned OFF and the pilot valve is turned OFF. RUN sequence continues in P8
this state until the start input is turned OFF.
Start When the start input is turned OFF, K1, K2, and K4 are turned OFF and the main valve is turned OFF. K10 remains P9
input OFF turned ON to keep the blower ON.
After the post-purge time has elapsed, K10 is turned OFF, the blower motor is turned OFF, and the system stands -
by until the next start input is turned ON.
Also, when the start input is OFF, lock-out interlock, shutoff valve proof of closure check, and lock-out due to
false flame are not performed. However, the flame of monitor output is generated if the flame detector detects
a flame.

23
Chapter 4. Explanation of Operation

zz Normal operation
• Direct ignition type

y
db
an
st
n

n
tio

tio
i

i
l

gn

gn
a
ck

ge
tri
e

i
he

rg

ur
ve

ve
n
pu

tio

-p
tc

al

al
op

op
N

st
-v

-v
e-
ar

ni

RU

Po
Hi

Hi
Pr
St

St

St
Ig
[7-segment display] -- P1 P2 P4 P5 P6 P8 P9 --
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Main valve (Lo solenoid valve)*
Main valve (Hi solenoid valve)*
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s Main trial time Hi-valve ignition time
Hi-valve ignition standby time

* Content in ( ) describes the situation when three-position (Off-Lo-Hi) control is used.

If other than three-position control is used, only look at the main valve (Lo solenoid valve)

Input Operation Sequence

codes
Start When the start input is turned ON, the internal circuits are checked, and also checks are done to make sure that P1
input ON lock-out interlock is ON (normal), that the shutoff valve proof of closure switch is ON (POC function enabled),
and that the air-flow switch is OFF. K10 is turned ON and the blower motor is turned ON.
The air-flow switch remains ON with the pre-purge timing. P2
After the pre-purge timing is completed, K3 and K5 are turned ON to perform the output of the ignition P4
transformer and main valve (Lo solenoid valve).
Within 3 seconds after the main valve is turned ON a check is done to make sure that the shutoff valve proof of
closure switch is OFF (POC function enabled).
When the ignition trail time is reached, K5 is turned OFF and the ignition transformer is turned OFF. P5
K4 is turned ON and Hi solenoid valve is turned ON. P6
Even after the completion of Hi solenoid valve ignition, K3 and K4 are turned ON, and both Lo solenoid valve P8
and Hi solenoid valve remain turned ON. RUN sequence continues in this state until the start input is turned OFF.
Start When the start input is turned OFF, K1, K2, and K4 are turned OFF and the main valve is turned OFF. K10 remains P9
input OFF turned ON to keep the blower ON.
After the post-purge time has elapsed, K10 is turned OFF, the blower motor is turned OFF, and the system stands -
by until the next start input is turned ON.
Also, when the start input is OFF, lock-out interlock, shutoff valve proof of closure check, and lock-out due to
false flame are not performed. However, the flame of monitor output is generated if the flame detector detects
a flame.

24
 Chapter 4. Explanation of Operation

zz No ignition
• Interrupted pilot type

al
ck

ge
tri
e
he

rg

ur
n
pu

tio

-p
tc
op

st
e-
ar

ni

Po
Pr
St

St

Ig
[7-segment display] -- P1 P2 P4 P4/E6
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s
Ignition trial time

Input Action Sequence

codes
Start When the start input is turned ON, the internal circuits are checked, and also checks are done to make sure that P1
input ON lock-out interlock is ON (normal), that the shutoff valve proof of closure switch is ON (POC function enabled),
and that the air-flow switch is OFF. K10 is turned ON and the blower motor is turned ON.
The air-flow switch remains ON with the pre-purge timing. P2
After the pre-purge timing is completed, K3 and K5 are turned ON to perform the output of the ignition P4
transformer and pilot valve.
If flame is not detected before the ignition trail time elapses, K5 is turned OFF, K6 is turned ON, and lock-out P4/E6
occurs.
With regards to monitor output, ignition failure output is generated. In that case, K10 remains ON and the
blower motor continues to operate until post-purge is complete. After the post-purge time elapses, K10 is
turned OFF and the blower motor is turned OFF.
During post-purge (at tie time of alarm), reset operation is not accepted.

25
Chapter 4. Explanation of Operation

zz No ignition
• Direct ignition type

al
ck

ge
tri
e
he

rg

ur
n
pu

tio

-p
tc
op

st
e-
ar

ni

Po
Pr
St

St

Ig
[7-segment display] -- P1 P2 P4 P4/E6
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Main valve (Lo solenoid valve)*
Main valve (Hi solenoid valve)*
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s
Ignition trial time

* Content in ( ) describes the situation when three-position (Off-Lo-Hi) control is used.

If other than three-position control is used, only look at the main valve (Lo solenoid valve)

Input Action Sequence

codes
Start When the start input is turned ON, the internal circuits are checked, and also checks are done to make sure that P1
input ON lock-out interlock is ON (normal), that the shutoff valve proof of closure switch is ON (POC function enabled),
and that the air-flow switch is OFF. K10 is turned ON and the blower motor is turned ON.
The air-flow switch remains ON with the pre-purge timing. P2
After the pre-purge timing is completed, K3 and K5 are turned ON to perform the output of the ignition P4
transformer and main valve (Lo solenoid valve).
Within 3 seconds after the main valve is turned ON, check to make sure that the shutoff valve closure check
switch is OFF (POC function enabled).
If flame is not detected at the completion of the ignition trail time, K6 is turned ON and a lock-out occurs. P4/E6
Monitor output performs the output of an ignition failure.
In that case, K10 remains turned ON and the blower motor continues the operation until post-purge is
completed. After the post-purge timing is completed, K10 is turned OFF and the blower motor is turned OFF.
During post-purge (at the time of alarm), reset operation is not accepted.

26
 Chapter 4. Explanation of Operation

zz Flame failure
• Interrupted pilot type

n
io
at

-p re
al

liz
ck

ge
st ilu
tri
e

bi

RU ial
he

rg

ur
Po e fa
ta
n

tr
pu

tio
tc

ts

m
op

N
e-
ar

ni

lo

ai

Fla
Pr
St

St

M
Ig

Pi
[7-segment display letter] -- P1 P2 P4 P5 P6 P8 P8/E7
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output
Flame response
Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s
Ignition trial time Pilot Main trial time
stabilization time

Input Action Sequence

codes
Start The start input is turned ON, a start check and ignition operation are performed, and then RUN sequence is P8
input ON performed.
If the flame is extinguished during RUN sequence for some reason, the loss of flame is detected after the flame P8/E7
failure response time, and then K1, K2, and K4 are turned OFF, the main valve output is turned OFF, K6 is turned
ON, and lock-out occurs.
With regard to monitor output, flame failure output is generated. In that case, K10 remains ON and the blower
motor continues to operate until post-purge is complete. After the post-purge time has elapsed, K10 is turned
OFF and the blower motor is turned OFF.
During post-purge (at the time of alarm), reset operation is not accepted.

27
Chapter 4. Explanation of Operation

zz Flame failure
• Direct ignition type

by
nd
sta

n
tio
on

ur e
ni
iti
al

-p ur
ck

ge
ign

ig
tri
e

st ail
he

rg

ve
n

lve

Po e f
pu

tio
tc

al

m
-va
op

N
-v
e-
ar

ni

RU

Fla
Hi
Pr
St

St

Hi
Ig
[7-segment display letter] -- P1 P2 P4 P5 P6 P8 P8/E7
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Main valve (Lo solenoid valve)*
Main valve (Hi solenoid valve)*
Alarm output
Monitor output
Flame response
Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s
Ignition trial time Hi-valve ignition time
Hi-valve ignition
standby time

* Content in ( ) describes the situation when three-position (Off-Lo-Hi) control is used.

If other than three-position control is used, only look at the main valve (Lo solenoid valve)

Input Action Sequence

codes
Start The start input is turned ON, a start check and ignition operation are performed, and then RUN sequence is P8
input ON performed.
If the flame is extinguished during RUN sequence for some reason, the loss of flame is detected after the flame P8/E7
failure response time, and then K1, K2, and K4 are turned OFF, the main valve output is turned OFF, K6 is turned
ON, and lock-out occurs.
With regard to monitor output, flame failure output is generated. In that case, K10 remains ON and the blower
motor continues to operate until post-purge is complete. After the post-purge time has elapsed, K10 is turned
OFF and the blower motor is turned OFF.
During post-purge (at the time of alarm), reset operation is not accepted.

28
 Chapter 4. Explanation of Operation

zz Start input during post-purge

• Interrupted pilot type
Transition to pre-purge without checking that the air-flow switch is Off or stopping the blower.

n
io
at
l

l
a

a
ge
liz
tri

tri
e

e
k

l
ec

bi

a
rg

rg
ur
n

n
tri
sta
ch

pu

pu
tio

tio
-p
n
op

N
rt

st
ot
e-

e-
ni

ni
ai

RU
a

Po
Pil
Pr

Pr
St

M
Ig

Ig
St
[7-segment display] -- P1 P2 P4 P5 P6 P8 P9 P2 P4
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time Pre-purge time

Start check time Approx. 2 s
Ignition trial time
Ignition trial time Pilot Main trial time
stabilization time

Input Action Sequence

codes
Start The start input is turned ON, a start check and ignition operation are performed, and then RUN sequence is P8
input ON performed.
Start When the start input is turned OFF, K1, K2 and K4 are turned OFF and the main valve is turned OFF. K10 remains P9
input OFF turned ON to keep the blower ON.
Start If the start input is turned ON during post-purge, K10 remains ON. The air-flow switch remains ON with the P2
input ON pre-purge timing. (Transition to the purge sequence occurs without checking that the air-flow switch is OFF and
without stopping the blower motor.)

29
Chapter 4. Explanation of Operation

zz Start input during post-purge

• Direct ignition type
Transition to pre-purge without checking that the air-flow switch is Off or stopping the blower.

y
db
an
st
n

n
tio

tio
i

i
l

l
gn

gn
a

a
ck

ge
tri

tri
e

e
i

i
he

rg

rg
ur
ve

ve
n

n
pu

pu
tio

tio
-p
tc

al

al
op

st
-v

-v
e-

e-
ar

ni

ni
RU

Po
Hi

Hi
Pr

Pr
St

St

Ig

Ig
[7-segment display] -- P1 P2 P4 P5 P6 P8 P9 P2 P4
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Main valve (Lo solenoid valve)*
Main valve (Hi solenoid valve)*
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time Pre-purge time

Start check time
Approximately 2 s Ignition trial time
Ignition trial time Hi-valve ignition time
Hi-valve ignition
standby time

* Content in ( ) describes the situation when three-position (Off-Lo-Hi) control is used.

If other than three-position control is used, only look at the main valve (Lo solenoid valve)

Input Action Sequence

codes
Start The start input is turned ON, a start check and ignition operation are performed, and then RUN sequence is P8
input ON performed.
Start When the start input is turned OFF, K1, K2 and K4 are turned OFF and the main valve is turned OFF. K10 remains P9
input OFF turned ON to keep the blower ON.
Start If the start input is turned ON during post-purge, K10 remains ON. The air-flow switch remains ON with the P2
input ON pre-purge timing. (Transition to the purge sequence occurs without checking that the air-flow switch is OFF and
without stopping the blower motor.)

30
 Chapter 4. Explanation of Operation

zz Interlock error
• Interrupted pilot type

n
io
at
l

iliz
a
ck

ge
tri
e

l
b
he

a
rg

ur
ta
n

tri
pu

tio

-p
tc

ts

t
n

se
op

st
e-
ar

ni

lo

ai

RU

Po

Re
Pr
St

St

M
Ig

Pi
[7-segment display] -- P1 P2 P4 P5 P6 P8 P8/E0 --
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time, approx. 2 s

Ignition trial time Pilot Main trial time
stabilization time

Input Action Sequence

codes
Start input The start input is turned ON, a start check and ignition operation are performed, and then RUN sequence is P8
ON performed.
Lock-out If the lock-out interlock is turned OFF during RUN sequence, K1, K2, and K4 are turned OFF, main valve P8/E0
interlock OFF output is turned OFF, K6 is turned ON, and lock-out occurs.
With regard to monitor output, lock-out interlock output is generated. In that case, K10 remains ON and the
blower motor continues to operate until post-purge is complete. After the post-purge time has elapsed, K10
is turned OFF and the blower motor is turned OFF. During post-purge (at the time of alarm), reset operation
is not accepted.

(The above sequence chart shows an example of turning off the start input during post-purge.)
Contact reset After the post-purge time has elapsed, if the reset switch is pressed and held for approximately 1 second, -
or the lock-out state is cleared and K6 is turned OFF.
device reset
switch: ON

31
Chapter 4. Explanation of Operation

zz Interlock error
• Direct ignition type

y
db
an
st
n

n
tio

tio
i

i
l

gn

gn
a
ck

ge
tri
e

i
he

rg

ur
ve

ve
n
pu

tio

-p
tc

al

al

t
se
op

st
-v

-v
e-
ar

ni

RU

Po

Re
Hi

Hi
Pr
St

St

Ig
[7-segment display] -- P1 P2 P4 P5 P6 P8 P8/E0 --
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Main valve (Lo solenoid valve)*
Main valve (Hi solenoid valve)*
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge time Post-purge time

Start check time
Approximately 2 s
Ignition trial time Hi-valve ignition Hi-valve ignition time
standby time

* Content in ( ) describes the situation when three-position (Off-Lo-Hi) control is used.

If other than three-position control is used, only look at the main valve (Lo solenoid valve)

Input Action Sequence

codes
Start input The start input is turned ON, a start check and ignition operation are performed, and then RUN sequence is P8
ON performed.
Lock-out If the lock-out interlock is turned OFF during normal combustion, K1, K2, and K4 are turned OFF, main valve P8/E0
interlock OFF output is turned OFF, K6 is turned ON, and lock-out occurs.
With regard to monitor output, lock-out interlock output is generated. In that case, K10 remains ON and the
blower motor continues to operate until post-purge is complete. After the post-purge time has elapsed, K10
is turned OFF and the blower motor is turned OFF. During post-purge (at the time of alarm), reset operation
is not accepted.

(The above sequence chart shows an example of turning off the start input during post-purge.)
Contact reset After the post-purge time has elapsed, if the reset switch is pressed and held for approximately 1 second, -
or the lock-out state is cleared and K6 is turned OFF.
device reset
switch: ON

32
 Chapter 4. Explanation of Operation

zz False flame occurred during pre-purge (interrupted pilot type / direct ignition type)

ck

e
he

ut
rg
pu

o
tc

k-
op

e-
ar

c
Lo
Pr
St

St
[7-segment display] -- P1 P2 P2/E1
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Pre-purge
Start check time
time
Approximately 2 s

Input Action Sequence

codes
Start When the start input is turned ON, the internal circuits are checked, and also checks are done to make sure that P1
input ON lock-out interlock is ON (normal), that the shutoff valve proof of closure switch is ON (POC function enabled),
and that the air-flow switch is OFF.
The air-flow switch ON check is performed. P2
A false flame is detected during the pre-purge sequence. After the false flame state continues for 5 seconds, K6 P2/E 1
is turned ON and lock-out occurs.

33
Chapter 4. Explanation of Operation

zz False flame occurred before the start input. Then, the start input was turned ON (interrupted pilot
type/direct ignition type)

-k k
c
he

t
ou
tc
op

ar

c
Lo
St

St
[7-segment display] -- P1 P1/E1
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Start check time

Approximately 2 s

Input Action Sequence

codes
After the During the stop sequence, a false flame is detected. -
power is
turned ON, a
false flame is
detected.
Start input After the start input is turned ON, the false flame is monitored. The start check part of the sequence P1
ON continues.
After the false flame state continues for 5 seconds, K6 is turned ON and lock-out occurs. P 1/E 1

34
 Chapter 4. Explanation of Operation

zz The air-flow switch was not turned ON during pre-purge (interrupted pilot type/direct ignition type)

ck

e
he

ut
rg
pu

o
tc

k-
op

e-
ar

c
Lo
Pr
St

St
[7-segment display] -- P1 P2 P2/E3
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock

Start check time, approx. 2 s Approximately 3 min

Input Action Sequence

codes
Start When the start input is turned ON, the internal circuits are checked, and also checks are done to make sure that P1
input ON lock-out interlock is ON (normal), that the shutoff valve proof of closure switch is ON (POC function enabled),
and that the air-flow switch is OFF.
The air-flow switch ON check is performed. P2
If the air-flow switch is not turned ON within 3 minutes, K6 is turned ON and lock-out occurs. At the same time P2/E3
that lock-out occurs, K10 is turned OFF and the blower motor is turned OFF.

35
Chapter 4. Explanation of Operation

zz Lock-out interlock Off (open) at start input (interrupted pilot type/direct ignition type)

k
Lo hec
ut
-o
tc
op

ck
ar
St

St
[7-segment display] - - P1 P1/E0
Input

Power supply
Start input
Air-flow switch
POC (proof of closure)
Lock-out interlock
Flame signal
Reset
Output

Blower motor (electromagnetic breaker)

Ignition transformer
Pilot valve
Main valve
Alarm output
Monitor output

Flame
Flame failure
Ignition failure
Lock-out interlock
Start check time
Approximately 2 s

Input Action Sequence

codes
Start Check the internal circuit when the start input is turned ON, and also check to make sure that lock-out interlock P1
input ON is ON (normal), the shutoff valve closure check switch is ON (POC function enabled) and the air-flow switch is
OFF.
If lock-out interlock ON (normal) cannot be confirmed, K6 is turned ON and lock-out occurs. P 1/E0
Monitor output lock-out interlock is turned ON.

36
 Chapter 4. Explanation of Operation

„„ Alarm and occurrence sequence

Name Symbol Interlock False flame Air-flow Air-flow Ignition Flame POC
Error switch switch failure failure (proof of
error (1) error (2) closure)
error
E0 E1 E2 E3 / EA E6 E7 E8
Stop −−
Start check P1
Pre-purge P2
Ignition trial P4
Pilot stabilization / P5
Hi-valve ignition standby
Main trial / Hi-valve ignition P6

RUN P8
Post-purge P9

Explanation of symbols in the table

Blank: Not monitored
: Monitored

37
Chapter 5. Trial Operation and Adjustment

WARNING
Make sure that the ignition times for the pilot and main burners do not exceed the ignition
times specified by the burner or device manufacturer. Excessive ignition times may cause fuel to
accumulate in the combustion chamber and form an explosive fuel-air mixture, which can result in
a serious explosion hazard.
Terminal 14 (F) retains an electrical charge even after the power is turned off. Do not touch terminal
F even after turning the power off. Failure to do so may result in an electric shock.

Do not operate this device without first completing calibration, testing, and combustion equipment
manufacturer's tests.

If lock-out occurs, make sure to execute a pre-purge before restarting. If unburned gas is not
expelled from the combustion chamber and flue, there is a risk of an explosion during ignition.

CAUTION
Mounting, wiring, maintenance, inspection, calibration, etc. should be carried out by a professional
with technical training in combustion systems and combustion safety devices.
The pilot turn-down test should be carried out by an experienced specialist possessing knowledge
and skills pertaining to combustion equipment and combustion safety.

„„ Preliminary inspection
(1) The temperature and humidity are within the ranges specified for operating
conditions.
(2) There are no errors in wiring and terminal screws are not loose.
(3) The flame detector is installed correctly. (For the installation location,
orientation, and other details, see the user's manual for the flame detector.)
(4) The burner is adjusted correctly.
(5) There are no obstructions, covers, or other items in the combustion air intake or
exhaust outlet.
(6) The power supply voltage and frequency are the same as those shown on the
device.

„„ Inspection procedure
For safe operation of the combustion equipment, inspect the following items
carefully and make appropriate adjustments.

38
 Chapter 5. Trial Operation and Adjustment

„„ Ignition spark response (UV sensor)

WARNING
Ensure that the UV sensor does not detect ultraviolet rays other than those from the burner.
If the UV sensor responds to other ultraviolet radiation, fuel will continue to be supplied even if the
burner flame is off, potentially causing an explosion.

Before doing the spark response test, always make sure that all manual fuel valves are closed.

(1) Close the manual valves in the piping for the pilot and main burners.
(2) Begin operation and measure the flame voltage during the ignition trail
sequence to check for any effect from the ignition spark.
(3) If the spark has an effect, such as causing the FLAME LED to light up, refer to
the user's manual for the equipment and make adjustments in the following way.
• Move the UV sensor or the ignition spark rod so that the spark does not affect
the flame voltage.
• Attach a shield that prevents the spark's ultraviolet radiation from entering
the optical path of the UV sensor. Adjust so that the spark's effect on the
flame signal is 0.4 Vdc or less.
• In the case of a solid-state power semi-terminal drive igniter (S7200AxxxGHx
or S720AxxxGHx), swap the polarity of the power to the igniter. When this
device is used in combination with a half-wave drive igniter, changing the
polarity of the power can prevent the the UV sensor's detection of the spark.

Handling Precautions
• Ensure that the UV sensor does not detect ultraviolet rays other than those
from the burner flame.

Sources of ultraviolet radiation (other than the burner flame) that can activate the
UV sensor include the following.
Examples:
Ultraviolet ray sources 1371 °C or hotter red-hot furnace wall (within 50 cm from wall)
Ignition transformer, welding arc spark
Gas laser
Sun lamp
Germicidal lamp, ultraviolet lamp, fluorescent lamp
Strong flashlight (towards UV phototube)
Gamma ray and X-ray X-ray analyzer, gamma ray analyzer/measurer
sources Electron microscope
X-ray machine
High-voltage vacuum switch
High-voltage capacitor
Radioactive isotope
Any other ultraviolet, gamma, or X-ray source

39
Chapter 5. Trial Operation and Adjustment

„„ Measurement of flame voltage

This device shows the flame voltage on the 7-segment display. It can be checked by
changing the display using the DISP switch on the front of the device.
Checking the flame voltage is the best way to determine whether or not the location
of the flame detector is appropriate.
It should be checked during installation and servicing.
Checking it once per month or more can prevent shutdowns due to insufficient flame
voltage.
Start the device and measure the voltage under various conditions, such as at
startup and during normal operation.
Check to make sure that the flame voltage remains stable at 2.0 Vdc or more. The
recommended flame voltage is 2.0 Vdc or more and it must be stable.
* If this stable voltage cannot be achieved, the problem may be caused by one or
more of the following. In such a case, do a thorough inspection.
(1) The power supply voltage or frequency is not correct.
(2) The air supply pressure or air-fuel ratio is not correct.
(3) The flame detector is not correctly wired.
• Open circuit
• Short circuit
• High-resistance short circuit of the lead wires due to the temperature or dirt
(4) Incorrect flame monitoring direction (BC-R25C)
(5) Dirty flame sensor surface (BC-R25C).
(6) AUD15C tube unit deterioration (BC-R25C).
(7) Incorrect flame rod installation (BC-R25B).
• Area in contact with flame is insufficient.
• Position of flame rod in flame is incorrect.
• The flame rod insulator is at a high temperature (315 °C).
• Flame rod is affected by ignition transformer.
If the ignition transformer is placed close to Terminal F of the flame rod,
electrons in the flame are absorbed into the ignition transformer, and as a
result, sufficient flame voltage cannot be achieved.

(Ref.) Correlation of flame output with that of older model

• BC-R25C (AUD100/110/120) • BC-R25B (flame rod)
R4750C Current−BC-R Voltage Conversion R4750B Current−BC-R Voltage Conversion
5 5

4 4
Flame voltage [V]

Flame voltage [V]

3 3

2 2

1 1

0 0
0 1 2 3 4 5 6 0 1 2 3 4 5 6
Flame current [μA] Flame current [μA]

40
 Chapter 5. Trial Operation and Adjustment

zz Measurement method for flame voltage

The voltage can be checked on the 7-segment display or by connecting a flame
meter to terminals 25 and 26 of the front connector.

Analog flame meter

Flame voltage display
FSP136A100

25

26

* Connector for front wiring (81447514-001/002)

is required to connect FSP136A100 to BC-R25 series.

Handling Precautions
• For flame voltage output signal wires, use wire with indoor PVC insulation ("IV
wire," JIS C3307) 0.75 mm2. Wiring length cannot be more than 10 m.
• The input impedance of a measuring instrument used with this device must
be 100 kΩ or more.

41
Chapter 5. Trial Operation and Adjustment

„„ Pilot turn-down test

WARNING
Make sure that the pilot turn-down test is done properly.
If the flame detector is able to detect a pilot flame that is too small to ignite the main burner, and if
there is a flame failure of the main burner, this device will not be able to recognize the flame failure.
As a result, fuel will continue to be supplied, resulting in an explosion hazard.

Before doing the pilot turn-down test, always make sure that all manual fuel valves are closed.

If the pilot turn-down test must be repeated, stop the combustion equipment completely each time
and discharge all of the unburned gas and oil from the fuel chamber and flue. Failure to discharge
unburned gas may result in an explosion hazard.
After completing the pilot turn-down test, turn off the power switch to turn off the power supply.
Make sure to return all test jumpers and limit or controller settings to their original values.
Resuming normal operation without returning the settings to their original values, etc., may
damage the equipment or cause a gas leak or explosion.

CAUTION
The pilot turn-down test should be carried out by an experienced specialist possessing knowledge
and skills pertaining to combustion equipment and combustion safety.

The purpose of this test is to determine the smallest possible pilot flame that will
reliably ignite the main burner.
Before and after this test, make sure to measure the flame voltage and confirm that
it is 2.0 V or more. This device has a trial operation mode. If pilot turn-down is
selected in the trial operation mode, the device does not proceed to RUN sequence,
but instead continues with pilot combustion. When the trial operation mode is
used, the pilot turn-down test can be executed by turning on and off the start input.
For instructions on starting trial operation mode, see chapter 3.
(1) Turn off the power switch and stop all the equipment.
(2) Close the main valve (by removing one side of the wiring to the main valve or by
closing the manual cock) to cut off the gas to the main burner. The pilot valve
remains in its normal state.
(3) Turn on the power switch. If the start input is on, the ignition sequence begins
after the pre-purge, as soon as the pilot valve is opened.
(4) After the pilot burner ignites, turn the pilot valve (manual cock) down until
the burner controller extinguishes the flame. Mark the position of the manual
cock at the time when the flame is extinguished. Then, press the reset switch
to reset the error and restart it. Turn the manual cock back until just before the
previously marked position (so that more gas is output).

Key Point
When the trial operation mode is used, the pilot burner combustion
continues and there is no limitation on the ignition trail time. Therefore, it is
easy to check.

42
 Chapter 5. Trial Operation and Adjustment

(5) Turn off the power switch, return the main valve to the normal state and then
turn on the power switch again. After the pre-purge, pilot burner combustion
begins and then main burner combustion begins.
If the main burner does not ignite, turn off the power switch immediately.
The pilot flame is too small, so it must be increased. In that case, correct the
installation location of the flame detector so that the monitoring angle of the
flame detector is slightly away from the pilot flame monitoring axis.

Handling Precautions
• If it is necessary to repeat the test, each time it is repeated be sure to stop all
the equipment first to prevent an explosion and then discharge all unburned
gas that has accumulated in the combustion chamber and exhaust flue.
• Also when executing the pilot turn-down test using the trial operation mode,
where there is a risk because the main valve is on, force the gas to be cut off
by using the manual cock or disconnecting the wiring.

(6) Change the gas pressure from the minimum to the maximum and repeat steps
(1) to (5) to check if the main burner ignites properly.

„„ Safety shutoff check

(1) Interlock check
While the burner is operating, simulate the operation of each interlock and
check if lock-out or shutdown occurs.
After checking, return the settings to their original values and restart the burner
to check that it ignites normally.
(2) Ignition trail failure check
Close the manual gas cock. Turn on the start input of the burner to begin
operation. After the pre-purge, an attempt is made to ignite the pilot burner.
Since the manual cock is closed, however, the pilot burner does not ignite and
lock-out occurs.
After confirming the above behavior, open the manual cock. Turn on the reset
switch, restart the burner and check if it ignites normally.
(3) Flame failure check
Close the manual gas cock while the burner is operating. After the flame failure
response time elapses, the pilot valve and main valve close and lock-out occurs.
After confirming the above behavior, open the manual cock. Turn on the reset
switch, restart the burner and check if it ignites normally.
(4) Power loss (power failure) check
Turn off the power switch during burner operation in order to stop combustion.
After waiting for a while, turn on the power switch again.
Then, turn on the start input, restart the burner and check if it ignites normally.

43
Chapter 6. Maintenance and Inspection

WARNING
Ensure you turn off the power of this device and all auxiliary devices when mounting, removing or
connecting the wires of this device. There is a risk of electrical shock.
Terminal 14 (F) retains an electrical charge even after the power is turned off. Do not touch terminal
14 (F) even after turning the power off. Doing so may result in an electric shock.

CAUTION
Mounting, wiring, maintenance, inspection, calibration, etc. should be carried out by a professional
with technical training in combustion systems and combustion safety devices.
If the device undergoes safety shutdown and restarts, do all of the inspection steps described in
chapter 5, "Trial Operation and Adjustment."
As part of the maintenance and inspection of the burner, make sure to do the pilot turn-down test.
Inspect the burner at least once a year.
Also, follow the instructions for periodic inspection that are given in the combustion equipment
manufacturer's manual.

When cleaning the burner, clean the flame detector also.

„„ General maintenance and inspection

• When replacing this device, do all of the checks and adjustments, including those
mentioned in the notices on page 1.
• Do not lubricate any part of this device.
• Remove any products of combustion that are stuck to the burner or other
equipment.

„„ Maintenance and inspection cycle

The maintenance and inspection cycle should take into consideration the device
type, ambient conditions of the installation location, the frequency of use, etc. The
following are approximate guidelines.
•C
 leaning the burner: once or more per year
After cleaning, make sure to do the pilot turn-down test.
• Burner shutdown check: once or more per month
• Flame voltage check: once or more per month

44
 Chapter 6. Maintenance and Inspection

„„ Alarm codes and details

When lock-out occurs, an alarm code is displayed automatically. When an alarm
occurs, the sequence number and alarm code issued when the lock-out occurred are
displayed alternately. Refer to chapter 4, “Relationship between Error Occurrence
and Sequence.”

Alarm code Sub-code Description Status

E0 None Interlock error Lock-out interlock operated
E1 False flame The flame signal is detected for 5 s during pre-purge
E2 Air-flow switch error (1) The air-flow switch turned off during combustion.
E3 Air-flow switch error [2] The air-flow switch stayed on for 3 minutes during the start check.
Air-flow switch error [2] The air-flow switch stayed off for 3 minutes during pre-purge.
E6 Ignition failure At the end of P4 (pilot ignition or main ignition), flame could not be detected.
E7 Flame failure In the sequence following P4 (pilot ignition or main ignition), the flame signal
disappeared.
E8 POC (proof of closure) error POC (proof of closure) switch was detected to be off (open) when the main valve was
closed.
POC (proof of closure) switch was detected to be on (closed) when the main valve was
open.
Note: To disable POC, see "Function selection mode" in chapter 3, "Operation."
E9 02 Switch input error The DISP switch, RESET switch or reset input stayed on for 60 seconds.
Note: Monitoring is continuous while power is supplied.
E9 03 Internal relay feedback (K1) Relay K1 failure (contact welding)
Note: I f this error recurs even after a manual reset, a device failure may have occurred.
E9 04 Terminal 4 and 5 voltage discrepancy Voltage from terminal L2 (power supply) is applied to terminals 4 and 5.
(K2) Note: C
 heck that all combustion load output common lines connected to terminals 6,
7, and 8 are wired to terminals 4 and 5.
E9 05 Terminal 7 voltage discrepancy (PV) At terminal 7, while pilot valve or main valve output was OFF, voltage was detected
for 30 seconds.
Note: This error can occur because of a ground fault, voltage supply to terminal 7 from
an external circuit (bypass circuit, etc.), or relay K3 failure (contact welding, etc.).
E9 06 Terminal 8 voltage discrepancy (MV) At terminal 8, while main valve output was OFF, voltage was detected for 30 seconds.
Note: This error can occur because of a ground fault, voltage supply to terminal 8 from
an external circuit (bypass circuit, etc.), or relay K4 failure (contact welding, etc.).
E9 07 Terminal 6 voltage discrepancy (IG) At terminal 6, while the ignition transformer output was OFF, voltage was detected for
30 seconds.
Note: This error can occur because of a ground fault, voltage supply to terminal 6 from
an external circuit (bypass circuit, etc.), or relay K5 failure (contact welding, etc.).
E9 08 Alarm generation when power is When the cause of lock-out cannot be identified
turned ON • Power was turned off before CPU error judgment after lock-out occurred
• Latch relay was set to lock-out due to vibration during transport or for other reasons
E9 50 to 7 1 Other problems Device failure or malfunction due to external electrical noise
* Check that there is no grounding failure, and that high-voltage cables and signal
wires do not run together.
If there is an inverter or the like that generates strong electrical noise near this
device, take noise-suppression measures, referring to the user's manual for the
noise-generating equipment.
Note: If this error recurs even after a manual reset, a device failure may have occurred.

• If the sequence cannot be specified, the sequence code displayed when lockout occurred may be shown as [– –]
(stopped).

45
Chapter 6. Maintenance and Inspection

„„ Failure inspection flow

WARNING
Before removing, mounting, or wiring the module, be sure to turn OFF the power to the module
and all connected devices. Failure to do so may result in an electric shock.

If there is any problem with the device, follow the inspection procedure below.

Turn start input OFF

and press reset switch. (See note)

N Error occurs during Y

Is voltage supplied
to terminals 2−3? prepurge.

- Inspect panel power

N
Y switch and fuse.
- Inspect wiring. Check air-flow switch air
Is power supply N and inspect for line breaks.
within allowable
voltage range?
Set voltage within the
Y
allowable range. N
Pilot burner ignites.

Did FLAME LED of N

this device turn OFF? Y
Is voltage applied betw. N
Disconnect the flame terminals 4–5 and 6–7?
Y detector wiring.
- Inspect wiring of this device.
Turn ON the start input. Y - Replace this device.

Did FLAME LED turn off? N - Inspect pilot, ignition

transformer, and wiring
- Ignition spark response test
Replace this device.
Y - Inspect burner

- Inspect burner (false flame).

- Inspect flame detector. Was FLAME LED of N
this device lit?
Is start input of this
device connected correctly? N
Y Is flame voltage N
Is “P1” on the 7-segment
display? 2 V or more?
- Inspect start input terminals
Y (20, 16 and 17) of this device. Y Flame simulator
- Inspect start input. FLAME LED is lit.
Replace this device.
Y
Does error occur soon N N
(See note) Main burner ignites. - Inspect burner.
after startup? - Inspect flame detector.

Y Is voltage applied N
between terminals
Y 4/5 and 8?
Close manual valve Replace this device.
to main burner. Y
Inspect air-flow, POC and - Inspect main valve.
lock-out interlock. - Inspect burner and wiring.
N
Extinguished.

Y - Check for leak from main valve.

- Inspect burner.

Alarm sounds. N

Y - Inspect alarm function.

- Inspect this device.

Normal

46
Chapter 7. Specifications

Item Description
Application Batch-operated combustion systems burning gas, oil, or gas/oil mixture
Compatible flame detector AUD100/110/120 series UV sensor, flame rod
Sequence Sequence timing Pre-purge Ignition trial Pilot stabilization Main trial Post-purge
(Hi-valve ignition (Hi-valve ignition)
standby) *1 *1
35 s, 45 s, 60 s, 3 min 4.5±0.5 s 8.5±1 s 4.5±0.5 s 20±2 s
(select by
model number)
Flame failure AUD100/110/120 series UV sensor Flame rod (Ionization)
response timing 2 s max (nominal 1.5 s) (when flame voltage is 3 V) 2 s max (nominal 1.5 s) (when flame voltage is 2V)
Reset timing 1 s or longer (reset switch or contact reset input)
Alarm detection False flame Air-flow switch Air-flow switch (2) Interlock error POC (proof of
timing (1) closure) error
5s 1 s max. 180 s 1 s max. 3s
Air-flow switch Available (performs observation of air-flow switch malfunction (1), (2))
observation
Operation at Lock-out
ignition failure
Operation at flame Lock-out
failure
Electrical Rated power 100 Vac or 200 Vac (depending on the model), 50 Hz or 60 Hz
specifications supply
Allowable power 85-110% of rated power supply
supply voltage
Power 10 W or less
consumption
Dielectric strength 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 50 MΩ min. with 500 Vdc megger
resistance Between each terminal and ground (the DIN rail clamp), except for combustion sensor connection
terminals (terminals 14, 15)
Contact rating Blower motor Ignition Pilot valve Main valve Alarm
(electromagnetic transformer (main valve Lo (main valve Hi
switch) solenoid valve)*1 solenoid valve) *1
100 VA 300 VA 200 VA 200 VA 75 VA
Monitor outputs*2 4, maximum 30 mA each
Flame detection AUD100/110/120 series UV sensor Flame rod (Ionization)
level Flame establishment: 1.5-4.5 Vdc Flame establishment: 1.5-4.5 Vdc
Flame-out detection: 0.2-0.6 Vdc Flame-out detection: 0.0-0.2 Vdc
Flame voltage Recommended flame voltage: Must be stable at 2 Recommended flame voltage: Must be stable at
output Vdc or above 2 Vdc or above
Flame voltage output range:0.2-4.5 Vdc Flame voltage output range: 0.0 - 4.5 Vdc
Input Start, lock-out interlock, contact reset, air-flow switch, POC (proof of closure)
Each input is a non-voltage contact input, with allowable contact resistance up to 500 Ω
Life 10 years when used for eight hours per day, or 100,000 start/stop cycles
(at 25 °C, room humidity, rated voltage)
Operating Ambient −20 to＋60℃
conditions temperature
Ambient humidity 10-90%RH (no condensation)
Vibration 0-3.2 m/s2 (10-150 Hz, 1 octave/minute, 10 cycles, in each of XYZ directions)
Shock 0-9.8m/s2
Mounting angle Reference plane +/-10°
Dust 0.3 mg/m3 or less

47
Chapter 7. Specifications

General Protection rating IP40 (with sideboards (81447515-001) attached to the sub-base (BC-R05))
specifications IP10 (sub-base (BC-R05) only)
Overvoltage II
category
Pollution degree PD2
Case color Black
Case material Denatured PPE resin (UL94-V0 PTI Material group IIIa)
Structure Sub-base and main device
Mounted Vertical or horizontal
orientation 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)
Standards JIS C 9730-2-5:2010 (Automatic Electrical Controls For Household And Similar Use -
Part 2-5: Particular Requirements For Automatic Electrical Burner Control Systems)
Compliant with JIS C 9730-1:2010 (Automatic Electrical Controls For Household And Similar Use -
Part 1: General Requirements)
Dimensions W95 × H105 × D110mm
Weight Approximately 600 g (incl. sub-base)
Wiring types and max. wiring • Start, air-flow switch, lock-out interlock, POC (proof of closure)
length Copper IV wire with 600V vinyl insulation, 1.25 mm2
Recommended condition: 20 m or less, maximum wiring length: 100m
• Contact reset
Copper IV wire with 600V vinyl insulation, 1.25 mm2, maximum wiring length: 10 m
• AUD100 Series (F, G)
Copper IV wire with 600V vinyl insulation, 1.25 mm2, maximum wiring length: 100m
• Flame rod (F, G)
RG-11U (JAN standard: US DoD compliant specification)
Or equivalent 5C2V, 7C2V (JIS standard)
Recommended condition: 20 m or less, maximum wiring length: 30 m
• RS-485 communications (3-wire system)
0.2-1.5mm2
Shielded twisted pair cable (recommended)
Maximum wiring length: 500m
• Flame voltage output signal circuit
IV wire 0.75 mm2 or larger, max. wiring length 10 m
*1 Item in ( ) is for the case of direct ignition.
*2 If an inductive load is used, connect a protection circuit such as an RC snubber to the load in parallel.

48
 Chapter 7. Specifications

„„ External dimensions
 (Unit: mm)
zz Body
64
17
27

Sub-base (sold separately)

BC-R
fastening screw
95 110
105

Connector for Sub-base

front wiring (sold separately)

BC-R fastening screw DIN rail clamp

A

Model number A
81447514-001 10.6
81447514-002 14.6

49
 Chapter 7. Specifications

 (Unit: mm)
zz Sub-base BC-R05A100 (sold separately)
61

17
27

Knockout hole 16 Knockout hole

64
M3.5 (terminal screw)

φ12 knockout hole φ12 knockout hole

105

Sub-base mounting hole Sub-base mounting hole

95
DIN rail clamp
62.5

zz Sideboard 81447515-001 (sold separately)

30.7
Sub-base
Sub-base
φ19 knockout hole
46.6

73.5

Sideboard
Sideboard φ19 knockout hole
23.9

50
Revision History of CP-SP-1388E
Printed Edn. Revised pages Description
Jan. 2015 1
Jun. 2015 2 ii, iii Warnings and cautions were partly revised in the Safety Precautions section.
4, 5 Warnings and cautions were partly revised in Chapter 2.
47, 48 "*" was changed to "*1."
47 "*2" was added to the end of "Monitor outputs."
48 A note was added as *2.
 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 (system 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 product has any failure attributable to azbil during the aforementioned warranty
period, Azbil Corporation 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 product
(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 product;
(3) Failure caused by any modification or repair made by any person other than Azbil Corporation or Azbil
Corporation's subcontractors;
(4) Failure caused by your use of Azbil Corporation's product in a manner not conforming to the intended usage of
that product;
(5) Failure that the state-of-the-art at the time of Azbil Corporation's shipment did not allow Azbil Corporation to
predict; or
(6) Failure that arose from any reason not attributable to Azbil Corporation, including, without limitation, acts of God,
disasters, and actions taken by a third party.
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 product 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 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 safety design such as fool-proof design, *1 and fail-safe
design*2 (anti-flame propagation design, etc.), whereby preventing any occurrence of physical injuries, fires,
significant damage, and so forth. Furthermore, fault avoidance, *3 fault tolerance,*4 or the like should be
incorporated so that the said Equipment can satisfy the level of reliability and safety required for your use.

*1. A design that is safe even if the user makes an error.

*2. A design that is safe even if the device fails.
*3. Avoidance of device failure by using highly reliable components, etc.
*4. The use of redundancy.

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.
The products are for industrial use. Do not allow general consumers to install or use any Azbil Corporation's product.
However, azbil products can be incorporated into products used by general consumers. If you intend to use a product for
that purpose, please contact one of our sales representatives.
In addition,
you are required to conduct a consultation with our sales representative and understand detail specifications, cautions
for operation, and so forth by reference to catalogs, specifications, instruction manual, etc. in case that you intend to use
azbil product 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, fault avoidance, fault tolerance, and other kinds of protection/safety circuit design on your own responsibility to
ensure 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
* Facilities/applications associated directly with billing
(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

4. Precautions against long-term use

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
causing such product or switch to develop safety hazards such as smoking, ignition, and electrification.
Although acceleration of the above situation varies depending on the conditions or environment of use of the products,
you are required not to use any Azbil Corporation's products for a period exceeding ten (10) years unless otherwise
stated in specifications or instruction manuals.

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
open/close operations of relays, etc. as prescribed in specifications or instruction manuals, or depending on the design
margin of your machine or equipment, you are required to renew any Azbil Corporation's products every 5 to 10 years
unless otherwise specified in specifications or instruction manuals.
System products, field instru ments (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.,
conditions and environment of use), precautions, warnings/cautions/notices as set forth in the technical documents
prepared for individual Azbil Corporation's products, such as catalogs, specifications, and instruction manuals to ensure
the quality, reliability, and safety of those products.

7. Changes to specifications
Please note that the descriptions contained in any documents provided by azbil are subject to change without notice for
improvement or for any other reason.
For inquires or information on specifications as you may need to check, please contact our branch offices or sales offices,
or your local sales agents.

8. Discontinuance of the supply of products/parts

Please note that the production of any Azbil Corporation's product may be discontinued without notice.
For repairable products, we will, in principle, undertake repairs for five (5) years after the discontinuance of those
products. In some cases, however, we cannot undertake such repairs for reasons, such as the absence of repair parts.
For system products, field instruments, we may not be able to undertake parts replacement for similar reasons.

9. Scope of services
Prices of Azbil Corporation's products do not include any charges for services such as engineer dispatch service.
Accordingly, a separate fee will be charged in any of the following cases:
(1) Installation, adjustment, guidance, and attendance at a test run
(2) Maintenance, inspection, adjustment, and repair
(3) Technical guidance and technical education
(4) Special test or special inspection of a product under the conditions specified by you
Please note that we cannot provide any services as set forth above in a nuclear energy controlled area (radiation
controlled area) or at a place where the level of exposure to radiation is equivalent to that in a nuclear energy controlled
area.

AAS-511A-014-05
 Specifications are subject to change without notice. (09)

1-12-2 Kawana, Fujisawa

Kanagawa 251-8522 Japan
URL: http://www.azbil.com 1st edition: Jan. 2015 (K)
2nd edition: Jun. 2015 (V)