Elster BCU 580 Technical Information Download Page 26

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BCU 580 · Edition 11.15

5 Valve proving system

The BCU 500..C1 is fitted with an integrated valve proving

system. This allows either the tightness of the gas solenoid

valves and the pipework between them to be checked (tight-

ness test) or the closed position of a solenoid valve (proof of

closure function) to be checked.
Once the test has been carried out successfully, the burner

enable signal is issued.
For details, see following chapter Tightness test and page 33

(Proof of closure function)

5 .1 Tightness test

The aim of the tightness control is to identify an inadmissible

leak on one of the gas solenoid valves and to prevent burner

start. Gas solenoid valves V1 and V2 are tested as is the pipe-

work between the valves.

Vp1

European standards EN 746-2 and EN 676 stipulate tightness

controls for capacities over 1200 kW (NFPA 86: from 117 kW or

400,000 Btu/h).
The tightness control function satisfies the requirements of

EN 1643, EN 746-2, ISO 13577-2 and NFPA 86 for valve prov-

ing systems.

Summary of Contents for BCU 580

Page 1: ...nited by a pilot burner in intermittent or continuous operation Optionally with valve proving system Flexible range of applications due to parameterization possibilities PROFINET fieldbus connection using optional bus module Assume safety functions pursuant to EN 746 2 EC type tested and certified Safety functions up to SIL 3 DIN EN 62061 corresponding to PL e ISO EN 13849 Burner control units BCU...

Page 2: ... Opening time tL 30 5 1 5 Measurement time tM 30 5 2 Proof of closure function 33 5 2 1 Program sequence 33 6 BCSoft 34 7 Profinet 35 7 1 BCU and bus module BCM 36 7 2 GSD file for PLC configuration 37 7 2 1 Modules for cyclic data exchange 38 7 2 2 Indexes for acyclic communication 44 8 Program step status 45 9 Fault signalling 47 10 Parameters 50 10 1 Scanning the parameters 55 10 2 Flame contro...

Page 3: ...ectrical connection 99 12 3 1 OCU 99 12 3 2 Safety current inputs 100 12 3 3 UVD control 101 12 4 Actuators 102 12 4 1 IC 20 102 12 5 Parameter chip card 103 12 6 Protecting the pilot burner from overload 103 12 7 Calculating the safety time tSA 104 12 8 Fifth or switchable gas valve on BCU F3 105 13 Accessories 106 13 1 BCSoft 106 13 1 1 Opto adapter PCO 200 106 13 1 2 Bluetooth adapter PCO 300 1...

Page 4: ...uring operation tSB 120 19 6 Safety shut down 121 19 7 Fault lock out 121 19 8 Warning signal 121 19 9 Timeout 121 19 10 Lifting 121 19 11 Air valve 121 19 12 Diagnostic coverage DC 122 19 13 Operating mode 122 19 14 Safe failure fraction SFF 122 19 15 Probability of dangerous failure PFHD 122 19 16 Mean time to dangerous failure MTTFd 122 Feedback 123 Contact 123 Contents ...

Page 5: ...rol tasks The burner control unit has an interface via which an air valve or actuator IC 20 IC 40 or RBW can be controlled for staged or modulating burner capacity control The program status the unit parameters and the level of the flame signal can be read directly from the unit The burners or a connected control element can be activated manually using the integrated Manual mode for setting and di...

Page 6: ...control unit OCU is available as an option for the burner control units The OCU can be installed in the control cabinet door instead of standard control units The program status flame signal or fault messages can be read on the OCU For burner adjustment the operating points can be approached conveniently in Manual mode using the operator control unit The address for the fieldbus communication is s...

Page 7: ...BCU 580 Edition 11 15 7 Bogie hearth forging furnace in the metal lurgical industry Intermittent shuttle kiln in the ceramics industry Walking beam furnace with overhead firing Application ...

Page 8: ... automati cally after the main burner has started up When the main burner is switched off the pilot burner automatically switches on again This reduces the main burner start up time The UV sensor monitors the flame signal from pilot and main burners The BCU provides the cooling and purg ing processes Application BCU 580 C0F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 U V S 38 37 18 17 1 2 3 FCU 500...

Page 9: ...urner has been detected Pilot and main burners can be operated simultaneously This reduces the time required by the main burner for starting up The BCU provides the cooling and purg ing processes Application Examples of application BCU 580 C0F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 38 37 18 17 1 2 3 FCU 500 Process control PCC 46 49 50 P HT A ϑ1 9 13 14 57 8 5 4 41 42 43 1 2 ϑ2 t 1 2 04 04 02 ...

Page 10: ...U issues the Enable sig nal for the maximum burner capacity Pilot and main burners can be operated simultaneously This reduces the time re quired by the main burner for starting up The BCU provides the cooling and purg ing processes Application Examples of application TZI TGI VAS VAS 1 VAG IC 40 BVA V1 V2 V3 V4 VAS 1 4 10 12 7 16 12 M µC BCU 580 C0F2 µC 38 37 18 17 1 2 3 FCU 500 Process control PC...

Page 11: ...en detected The control system controls the burner capacity via the but terfly valve for air after the operating state has been signalled Pilot and main burners can be operated simultaneously This reduces the time required by the main burner for starting up Application Examples of application V1 IC 20 BVA BCU 580 C0F1 µC 38 37 18 17 1 2 3 FCU 500 Process control PCC 46 49 50 P HT A ϑ1 13 14 57 TZI...

Page 12: ...tem is in High temperature mode HT When the HT input is activated the burner control units switch to High temperature mode They operate without evaluating the flame signal and their internal flame control is non functional If the furnace temperature falls below the spontaneous igni tion temperature 750 C the FCU disconnects the HT output from the electrical power supply As soon as the signal to th...

Page 13: ... BCM for starting resetting controlling the air valve purging the furnace or for cooling and heating during operation In the opposite direction it sends operating status the level of the flame signal and the current program status Control signals that are relevant for safety such as the safety interlocks purge and HT input are transferred independently of the bus communication by separate cables A...

Page 14: ...m convection in the furnace chamber even with regulated heating The pneumatic ratio control system con trols the gas pressure on the burner pro portionally to the air pressure and thus maintains a constant air gas ratio At the same time it acts as a low air pressure protection device The ignition and monitoring of the pilot main burners is ensured by burner con trol units BCU 580 The centrally che...

Page 15: ...o portionally to the air pressure and thus maintains a constant air gas ratio At the same time it acts as a low air pressure protection device The ignition and monitoring of the pilot main burners is ensured by burner con trol units BCU 580 The centrally checked safety functions such as pre purge tightness test flow detector and pressure switch check gas min gasmax airmin are provided by the FCU 5...

Page 16: ...06 95 EC EMC Directive 2004 108 EC FM approved Factory Mutual Research Class 7400 Process Control Valves Designed for applications pursuant to NFPA 85 and NFPA 86 www approvalguide com ANSI CSA approved American National Standards Institute Canadian Stand ards Association ANSI Z21 20 CSA C22 2 No 199 www csagroup org Class number 3335 01 and 3335 81 Eurasian Customs Union The product BCU 580 meets...

Page 17: ...converters see from page 71 Capacity control Electrical connection see page 98 Project planning infor mation Explanation of symbols see page 119 Legend N BCU 580 F1 µC 88 c c 0 V 24 V 24V DC 9 11 12 10 62 61 230V 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70 P69 P73 P72 P72 HT pu 2 GZL PZL P71 46 45 65 66 67 68 49 50 51 52 5 6 7 8 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 A 53 54 55 5...

Page 18: ...AC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 P P 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 2 1 I Luftmin Luft 0 6 IN 3 1 2 BCU 580 F2 Alternative flame control see page 20 Flame control Detailed connection diagrams for actuators and frequency converters see from page 71 Capacity control Electrical connection see page 98 Project planning infor mation Explanation of symbo...

Page 19: ...ction see page 98 Project planning infor mation Explanation of symbols see page 119 Legend Function Connection diagram N BCU 580 F3 µC 88 c c 0 V 24 V 24V DC 9 11 12 10 62 61 230V 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70 P69 P73 P72 P72 HT pu 2 GZL PZL P71 46 45 65 66 67 68 49 50 51 52 5 6 7 8 A 53 54 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 P 2 1 I Airmin Air 0 6 IN ...

Page 20: ...1 The 0 20 mA current output can be used to display the flame signal The cable to the control room must be screened The 0 20 mA current output is not required for normal operation Depending on Parameter 79 the following connection dia grams apply see also page 69 Pilot burner Alternating pilot burner Parameter 79 0 BCU 580 F1 µC 88 c c 24 V 24V DC 9 11 12 10 62 61 230V 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70...

Page 21: ...l Wait until the running time has elapsed P42 02 Safety time 1 tSA1 running ignition in process valves V1 and V4 open If no flame detected max 3 start up attempts or fault lock out 03 Flame proving period 1 tFS1 running P95 In the event of flame failure fault lock out 04 Pilot burner operation signalling contact closes In the event of flame failure restart or fault lock out 05 Main burner start up...

Page 22: ... flame failure restart or fault lock out A8 External actuation of the air valve for capacity control 08 Controlled shut down via ϑ signals for pilot and main burners 00 If min operating time tB has elapsed operation signalling contact opens gas valves close and running time P42 starts to elapse Function BCU 580 program sequence ...

Page 23: ... for this purpose by the capacity control system of the BCU After being enabled by the protective system the BCU can start the burners The capacity is controlled during operation by an external temperature control system VAS M PZL PZH PZ PZL PDZ TE BCU 580 F3 FCU 500 F0 µC P DG DG DG VAS VAS VAG VAS VAS VR L VR L DG DG DGmin DGmax 49 15 13 14 50 45 47 48 58 750 pu 2 ϑ 1 46 2 3 DLmin DLPurge BCU 58...

Page 24: ... at terminals 1 and 4 The control element can be activated to control the burner s capacity dependent on parameters 48 and 49 Modulating control Parameter 48 3 After the operating signal has been received from the burner and after expiry of the delay time for the controller enable signal parameter 44 the BCU issues the controller enable signal via the output at terminal 56 Access to the control el...

Page 25: ...me if there is adequate air flow After the elapse of the pre purge time the air valve closes for ignition Once the protective system terminal 46 safety interlocks has issued the enable signal the burner can be started by the start up signal at terminal 1 The gas valves for the 1st stage are opened and the burner is ignited on the BCU C1 after a successful valve check After the operating signal has...

Page 26: ... For details see following chapter Tightness test and page 33 Proof of closure function 5 1 Tightness test The aim of the tightness control is to identify an inadmissible leak on one of the gas solenoid valves and to prevent burner start Gas solenoid valves V1 and V2 are tested as is the pipe work between the valves V2 pu Vp1 V1 PZ pu 2 European standards EN 746 2 and EN 676 stipulate tightness co...

Page 27: ...t burner is ignited when pre purge is ended and the tightness has been checked successfully After burner shut down After the burner has been shut down the BCU checks the tight ness of the gas solenoid valves and the pipework between them Once the test has been carried out successfully the next burner start is enabled The BCU always conducts a tightness test if mains voltage is available or if it i...

Page 28: ...ght Valve V2 is opened for the set opening time tL V2 closes again During the measurement time tM the tightness control checks the pressure pZ between the valves If pressure pZ is greater than half the inlet pressure pu 2 valve V1 is leaking If pressure pZ is less than half the inlet pressure pu 2 valve V1 is tight The tightness test can only be performed if pressure pd down stream of V2 is around...

Page 29: ... tightness control checks the pressure pZ between the valves If pressure pZ pu 2 valve V2 is leaking If pressure pZ pu 2 valve V2 is tight The tightness test can only be performed if pressure pd down stream of V2 is around atmospheric pressure and the volume downstream of V2 is at least 5 higher than the volume between the valves tL P59 tM P56 pZ pu 2 OK V1 V1 V1 OK V2 V1 V2 pZ pu 2 tL P59 tM P56 ...

Page 30: ...e tightness control in the BCU can be ad justed for each individual system by adapting the measure ment time tM The longer the measurement time tM the greater the sensitivity of the tightness control The measurement time is set using parameter 56 to a value between 3 and 3600 s see page 90 Measurement time Vp1 The required measurement time tM is calculated from Inlet pressure pu mbar Leakage rate ...

Page 31: ... 1 1 25 0 5 VAS 7 1 4 40 1 3 VAS 8 2 3 50 2 VAS 9 4 3 65 3 3 VG 10 0 01 80 5 VG 15 0 07 100 7 9 VG 20 0 12 125 12 3 VG 25 0 2 150 17 7 VG 40 VK 40 0 7 200 31 4 VG 50 VK 50 1 2 250 49 VG 65 VK 65 2 VG 80 VK 80 4 VK 100 8 3 VK 125 13 6 VK 150 20 VK 200 42 VK 250 66 The measurement time required for the test volume Vp1 must be set on the basis of the calculation using parameter 56 For the calculation...

Page 32: ...65 pu 50 mbar Q N max 200 m3 h DN65 9 5 m Leakage rate QL 200 m3 h x 1000 l h 200 l h 1000 x 1 m3 h Test volume Vp1 1 1 l 9 5 m x 3 3 l m 32 45 l see page 30 Test volume Vp1 Measurement time for one test volume Vp1 Parameter 70 0 tM s 2 x 50 mbar x 32 45 l 16 23 s 200 l h Set the next highest value 20 s using parameter 56 see page 90 Measurement time Vp1 Valve proving system Tightness test Measure...

Page 33: ...h the requirements of NFPA 85 Boiler and Combustion Systems Hazards Code and NFPA 86 Standard for Ovens and Furnaces 5 2 1 Program sequence When the start up signal ϑ1 is received at terminal 1 the BCU checks that valve V1 is in its closed position using the POC switch After a timeout time of 10 s a signal from the POC switch valve V1 is closed must be received at terminal 45 Otherwise the BCU per...

Page 34: ...arameters on Windows based PCs in order to adjust the BCU to the specific application In addition BCSoft provides extended access to the individual statistics and protocol functions In addition to the engineering tool BCSoft an opto adapter or Bluetooth adapter is required to read the device parameters in and out see also page 106 BCSoft ...

Page 35: ...et also provides acyclic data exchange for events which are not constantly repeated such as sending parameter settings and configu ration data when the IO devices start up or sending a diag nostic message from the IO device to the IO controller during operation The data read or written acyclically by read write services are specified by an index see page 44 Indexes for acyclic communication The te...

Page 36: ... an internal 2 port switch This allows the BCM 500 together with the BCU to be integrated in various network topologies star tree or line topology Requirements such as Auto Negotiation and Auto Crossover are satisfied Safety related signals and interlocks e g safety interlock must be wired independently of the fieldbus communication direct to the BCU and the protective system e g FCU BUS FCU P HT ...

Page 37: ...he device image and communications properties of the BCU Modules defined in the GSD file may be selected for configuration to integrate the BCU see page 38 Modules for cyclic data exchange The GSD file for the bus module can be ordered at www docuthek com The steps required to integrate the file are described in the instructions for the engineering tool for your automation system For parameter set...

Page 38: ...ng table The modules are assigned to the slots Module Slot Input ad dress Output address Inputs outputs 1 n n 2 n Burner 1 flame signal 2 n Burner 2 flame signal 3 n Status signal 4 n Fault and warning signals 5 n n 1 Remaining times 6 n n 1 TC remaining times1 7 n n 1 PLC output information 8 n BCU input terminal information 9 n n 2 BCU output terminal information 10 n n 1 1 Only for BCU C1 Slot ...

Page 39: ...which are output by the PLC IO controller to the BCU IO device The digital sig nals to control the burner control unit BCU occupy 1 byte 8 bits Parallel to the bus communication terminals 1 to 4 44 and 50 of the BCU can be wired This allows the BCU to be con trolled using the digital signals of the bus communication or the inputs at the terminals In the event that the bus communication is faulty o...

Page 40: ...C as an analogue value using this module The flame signal occupies one byte with values from 0 to 255 flame signal from 0 to 25 5 µA Bit Byte n Data type Format Value 0 Burner 2 flame signal Byte DEC 0 255 0 25 5 μA 1 2 3 4 5 6 7 Status signal module device controller slot 4 This module transfers the status signals from the BCU to the PLC The status signals occupy one byte 0 to 255 Every status si...

Page 41: ...als Bit Byte n Data type Format Value 0 Fault signals Byte DEC 0 255 see Code table GSD_Codes_ BCU580 xlsx at www docuthek com 1 2 3 4 5 6 7 Bit Byte n 1 Data type Format Value 0 Warning signals Byte DEC 0 255 see Code table GSD_Codes_ BCU580 xlsx at www docuthek com 1 2 3 4 5 6 7 Remaining times module device controller slot 6 This module transfers the remaining times of various processes from th...

Page 42: ...e n 1 Data type Format Value 0 Remaining times of the valve prov ing system Word DEC 0 6554 0 6554 s 1 2 3 4 5 6 7 PLC output information module device controller slot 8 This module transfers information on signals which the PLC uses to control the BCU back to the PLC This allows the signal transfer from the PLC to the BCU to be checked Bit Byte n Format 0 Reset BOOL 1 Burner 1 start BOOL 2 Extern...

Page 43: ...l 46 Terminal 66 Free BOOL 7 Terminal 47 Terminal 67 Free BOOL BCU output terminal information module device controller slot 10 This module transfers the signal states of the digital outputs on the BCU output terminals to the PLC Bit Byte n Byte n 1 Format 0 Terminal 9 Terminal 42 BOOL 1 Terminal 10 Terminal 43 BOOL 2 Terminal 13 Terminal 531 BOOL 3 Terminal 14 Terminal 54 BOOL 4 Terminal 15 Termi...

Page 44: ...n block Siemens FSB 52 RDREC The available data records differ in terms of their indexes Index Description 1001 Parameter 1002 Device statistics counter 1003 Device statistics faults warnings 1004 Operator statistics counter 1005 Operator statistics faults warnings 1006 Fault history 1007 Power module statistics The contents and description of the indexes are described in the code table GSD Codes ...

Page 45: ... H1 Delay A Approaching minimum capacity2 A Approaching maximum capacity2 A Approaching ignition capacity2 Valve check 02 Safety time 1 A2 Safety time 1 H2 Delay 03 Flame proving period 1 tFS1 A3 Flame proving period 1 tFS1 04 Burner 1 operation A4 Burner 1 operation H4 Delay H5 Delay 06 Safety time 2 A6 Safety time 2 07 Flame proving period 2 A7 Flame proving period 2 ...

Page 46: ...tep status 08 Burner 2 operation A8 Burner 2 operation H8 Delay U I Remote control with OCU Data transfer programming mode Device Off 1 In Manual mode two dots blink on the display 2 Air actuator control element valve is open Program step status ...

Page 47: ...Too many restarts for burner 2 12 5 restarts in 15 minutes Controller enable output terminal 56 20 Controller enable output incorrectly connected supplied with power from an external source Simultaneous activation terminals 51 and 52 21 Maximum capacity and Ignition capacity position feedback from butterfly valve set simultaneously Actuator wiring terminals 52 55 22 Faulty wiring of terminals 52 t...

Page 48: ...e control Internal error 80 Flame amplifier error device error Internal error 89 Error in processing internal data Internal error 94 Error at digital inputs Internal error 95 Error at digital outputs Internal error 96 Error when checking the SFR Internal error 97 Error when reading the EEProm Internal error 98 Error when writing to the EEProm emBoss 99 Shut down without application error Minimum c...

Page 49: ...llocated in the network name Controller in STOP position 4 Controller in STOP position Burner 1 flame simulation A1 Burner 1 flame simulation while air valve open No flame after safety time 1 A2 No flame during safety time 1 while air valve open Flame failure during flame proving period 1 A3 Flame failure during flame proving period 1 while air valve open Flame failure during burner 1 operation A4...

Page 50: ...rner 2 FS2 flame signal switch off thresh old in µA 2 5 when P04 1 Flame control 04 0 1 2 3 4 5 6 7 8 Ionization UVS UVD Ionization1 and UVS 2 Ionization1 and UVD 2 UVS 1 and ionization 2 UVD 1 and UVD 2 UVD 1 and ionization 2 UVD 1 and UVS 2 0 High temperature operation 06 0 2 3 Off Intermittent operation with UVS Continuous operation with ionization UVD 0 Burner 1 start up attempts 07 1 2 3 1 st...

Page 51: ...19 0 1 2 Time in seconds 1 Capacity control 40 0 1 2 3 5 Off With IC 20 With IC 40 With RBW With air valve BCU F0 0 BCU F1 1 BCU F2 3 BCU F3 5 Running time selection 41 0 1 2 3 Off checking the positions for minimum maximum capacity On for approaching the positions for mini mum maximum capacity On for approaching the position for maxi mum capacity On for approaching the position for mini mum capac...

Page 52: ...ge 1 Opens with operating signal Controller enable following operating sig nal or in standby Opens with V4 pilot burner 0 Air actuator can be activated ex ternally on start up 49 0 1 Cannot be activated Can be activated externally 0 Air actuator in the event of fault 50 0 1 Cannot be activated Can be activated externally 1 Valve proving system 51 0 1 2 3 4 Off Tightness test before start up Tightn...

Page 53: ...n of terminal 50 68 23 24 Purge with Low signal Purge with High signal 24 Function of terminal 51 69 0 8 13 Off AND with emergency stop trm 46 Max capacity position feedback IC 40 RBW 0 Function of terminal 65 70 0 8 Off AND with emergency stop trm 46 0 Function of terminal 66 71 0 8 20 Off AND with emergency stop trm 46 LDS ignition position check 0 Function of terminal 67 72 0 8 21 Off AND with ...

Page 54: ...sition burner quick start 0 Password 77 0000 9999 Four digit number code 1234 Burner application 78 0 1 2 3 4 5 Burner 1 Burner 1 with pilot gas Burner 1 and burner 2 Burner 1 and burner 2 with pilot gas Two stage burner 1 Burner 1 and two stage burner 2 2 Pilot burner 79 0 1 With shut down In continuous operation 0 Fieldbus communication 80 0 1 2 Off With address check No address check 1 Safety t...

Page 55: ...meter 01 In the case of UV control this value can be increased should the burner to be monitored be influenced by other burners for example Burner 2 flame signal switch off threshold FS2 Parameter 02 The sensitivity at which the burner control unit detects a flame at burner 2 can be set using parameter 02 In the case of UV control this value can be increased should the burner to be monitored be in...

Page 56: ...eration UVD Burner 2 flame control is performed with an ionization electrode Parameter 04 8 burner 1 flame control is performed with a UV sensor for continuous operation UVD Burner 2 flame control is performed with a UV sensor for intermittent opera tion UVS UV sensor for intermittent operation For intermittent operation the operating state of the complete system is limited to 24 h pursuant to EN ...

Page 57: ...n the HT input is activated terminal 49 the burner control unit reverts to High temperature mode i e the BCU operates without evaluation of the flame signal The safety function of the device internal flame control system is deactivated In High temperature mode the gas valves are opened and the burners are started as usual without monitoring the pres ence of a flame The precondition for this operat...

Page 58: ... 06 07 08 08 t tSA2 tFS2 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 41 42 49 tSA1 tZ 04 02 03 01 tFS1 tW L1 HT The BCU switches off the burner once the HT input has been disconnected from the electrical power supply and restarts with flame simulation check recommended in the case of UV control with UVS Parameter 06 3 BCU D1 08 08 t 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 41 42 49 L1 HT Despite the ...

Page 59: ...ed the burner control unit performs a fault lock out regardless of parameter 06 Fault pilot burner t 04 04 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 41 42 49 L1 HT Fault main burner t 08 08 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 41 42 49 L1 HT Parameters Flame control High temperature operation ...

Page 60: ...41 42 L1 If no flame is formed during the start up so that at the end of the safety time tSA1 no flame signal is detected this will result in a BCU safety shut down with subsequent fault lock out The fault message 04 will flash in the BCU display depending on the burner operating mode Parameter 07 2 3 two or three start up attempts tSA1 tZ tSA1 tZ t 00 02 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 4...

Page 61: ...e start up so that at the end of the safety time tSA1 no flame signal is detected this will result in a BCU safety shut down with subsequent fault lock out The fault message 06 will flash in the BCU display depending on the burner operating mode Parameter 08 2 3 two or three start up attempts tSA2 tSA2 tSA2 tSA1 tZ 04 06 02 03 00 t tFS1 06 tW 06 06 05 05 tW 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9...

Page 62: ...4 2 1 3 9 14 15 13 5 17 18 t tFS1 tSA1 tBP Parameter 78 1 burner 1 with pilot gas Three valves V1 V2 and V3 are included for a burner with a pilot gas valve These are connected to the valve outputs terminals 13 14 and 15 Valves V1 and V3 open to start the burner The burner is started with a limited ignition capacity using gas valve V3 After the elapse of the safety time tSA1 program step 02 valve ...

Page 63: ...ner has an additional pilot gas valve V3 The valves are connected to the valve outputs terminals 13 14 15 and 57 Valves V1 and V4 open to start the pilot burner The burner is started with a limited ignition capacity using gas valve V3 After the elapse of the safety time tSA2 program step 06 valve V2 opens terminal 14 Pilot gas valve V3 is closed again after the elapse of the flame proving period t...

Page 64: ... 5 17 18 t tFS1 tSA1 tBP 1 Parameter 78 5 burner 1 and two stage burner 2 In this application the burner has an additional pilot gas valve V3 The valves are connected to the valve outputs terminals 13 14 15 and 57 Valves V1 and V4 open to start the pilot burner The burner is started with a limited ignition capacity using gas valve V3 Valve V2 terminal 14 can be opened with the operating signal pro...

Page 65: ...or two ad ditional start up attempts P07 2 or 3 The BCU will complete a maximum of three start up attempts Safety time 1 must be determined on the basis of current na tional standards and regulations The burner application and the burner capacity are the main criteria for this If the ϑ1 signal terminal 1 drops out during safety time 1 the valves will not be switched off until the end of safety tim...

Page 66: ... one or two ad ditional start up attempts P08 2 or 3 The BCU will complete a maximum of three start up attempts Safety time 2 must be determined on the basis of current national standards and regulations The burner application and the burner capacity are the main criteria for this If the ϑ1 signal terminal 1 drops out during safety time 2 the valves will not be switched off until the end of safety...

Page 67: ...g phases In this case it must be ensured that the program sequence started by the BCU matches the application Parameter 09 0 Off 04 t tSB 04 88 ϑ 1 46 11 9 5 13 V1 57 V4 L1 42 41 A safety shut down with subsequent fault lock out takes place in the event of flame failure during operation Parameter 09 1 burner 1 The restart function is active tSA tZ 04 04 02 03 01 t tFS tW tSB 1x 2 s 88 ϑ 1 46 9 5 1...

Page 68: ... shows the fault message Parameter 09 3 burner 1 and burner 2 Parameter 09 4 max 5 in 15 min for burner 1 The restart function is active and is also monitored In certain conditions it is possible that the restart function is repeated continu ously without a safety shut down with subsequent fault lock out being performed The BCU has a safety shut down with subsequent fault lock out option if more t...

Page 69: ...tart of operation controller enable e g during pre purge the burner control unit reverts directly to the start up position standby and the burner is not ignited The minimum operating time can be cancelled by switching off the BCU or if a safety shut down occurs 10 4 3 Pilot burner Parameter 79 tSA1 04 06 07 08 02 03 00 t tFS1 tSA2 tFS2 13 V1 14 V2 15 V3 57 V4 ϑ1 ϑ2 4 88 1 9 P79 1 If a burner with ...

Page 70: ...an interruption at the safety current inputs terminals 45 to 51 and 65 to 68 The safety time can be set to 1 or 2 s Prolong ing the safety time during operation increases the installation availability in the case of brief duration signal fades e g fades of the flame signal In accordance with EN 298 the maximum reaction time to a flame failure must not exceed 1 s In accordance with EN 746 2 the saf...

Page 71: ...20 IC 40 RBW or air valve Parameter 40 0 Off no capacity control no air actuator Parameter 40 1 with IC 20 The interface is configured to the requirements of actuators IC 20 IC 20 E IC 50 or IC 50 E Alternatively comparable three point step actuators may be used IC 20 53 54 55 56 52 65 66 67 68 49 50 51 17 13 14 15 BCU 580 F1 3 15AT µC 88 24V DC PE L1 N 3PS 3 2 1 16 6 7 4 8 12 11 15 13 S3 S4 S11 S...

Page 72: ...rent function The wiring between the BCU and the 3 point step controller can be adjusted so that the control range of the actuator is between the positions for maximum and ignition capacity 53 54 55 56 52 1 2 3 46 45 65 66 67 68 49 50 51 17 18 37 38 13 14 15 BCU 580 F1 3 15AT µC 88 c c 41 42 24V DC 5 6 9 11 12 10 7 62 61 PE L1 N 3 2 1 16 6 7 4 8 12 11 15 13 S11 S10 0 90 IC 20 PE 90 0 0 90 3PS The ...

Page 73: ... During the controller enable procedure the actuator can be adjusted infinitely between the positions for maximum and minimum capacity by a controller 0 4 20 mA 0 10 V using the setpoint device on terminals 17 and 18 or the bus signal There is no timeout active in this case If bus control is active parameter 75 the controller enable out put terminal 56 has a different function The wiring between t...

Page 74: ...capacity If the position is not reached within the timeout time of 255 s a safety shut down of the BCU will be performed A fault message A A or A will be displayed see page 47 Fault signalling If a controller enable is active the control system is enabled for operation via the outputs at terminals 53 and 55 Operating mode 11 Operating mode 11 allows cyclic operation ON OFF and OFF Low High OFF The...

Page 75: ...In the event of a fault there will be no signal at terminals 53 and 55 so that the actuator moves to the closed position When approaching the closed position no timeout of 255 s is active since no feedback input is checked This may result in a situation where the program is continued in the case of a request for the closed position without the butterfly valve being closed The outputs at terminals ...

Page 76: ...0 the system monitors the movement to the positions for maximum and minimum capacity with a timeout time of 255 s Reaching the relevant position imme diately triggers the program continue switch conditions If reaching the position is not signalled within the timeout time of 255 s a safety shut down of the BCU will be performed A fault message A or A will be displayed see page 47 Fault signalling I...

Page 77: ...y is reached BCU 580 F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 9 13 14 57 8 5 Parameter 42 Running time can be used to adjust the be haviour of slow opening and closing air valves so that the system can be set to ignition position before a start up is initiated Parameter 41 Running time selection must be set to 1 to adjust this behaviour See page 78 Running time and 78 Running time se lection P...

Page 78: ... the position for minimum capacity is signalled and monitored Parameter 41 3 On for approaching the position for mini mum capacity No signal is returned that the position for mini mum capacity has been reached The Running time set using parameter 42 is activated for approaching the position for minimum capacity After this time has elapsed the BCU will initiate the next program step Approaching the...

Page 79: ...ion for minimum capacity is reached If the flame is extinguished this does not result in a fault Parameter 43 2 3 4 5 10 20 30 or 40 only for BCU F3 time in seconds During this time the gas valve remains open The air valve is closed with deactivated start up signal ϑ BCU 580 F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 9 13 14 57 8 5 This means that the burner is initially adjusted down to low fir...

Page 80: ...ir gas ratio is controlled by a pneumatic air gas ratio control system and which need to be started at low fire rate e g on two stage controlled burners see page 10 Two stage controlled main burner with permanent pilot burner In this case activation of the air actuator during burner start via the input at terminal 2 must be prevented External control allows switchover between low fire and high fir...

Page 81: ...er start up and during operation Parameter 48 3 controller enable following operating signal or in standby This parameter is used to activate modulating capacity control on BCU F1 and F2 The controller enable signal is issued via the output at terminal 56 in the start up position standby and during operation tSA1 tZ 04 02 03 00 t tFS1 tSA2 tFS2 08 06 07 88 ϑ1 46 1 ϑ2 4 11 9 5 37 38 13 V1 1 2 14 V2...

Page 82: ... A0 00 A8 A6 A7 2 10 53 A 88 ϑ1 46 1 ϑ2 4 11 9 5 37 38 13 V1 1 2 14 V2 14 V3 57 V4 17 18 8 M The air valve opens with the start up fuel rate The air valve can be activated externally via the input at terminal 2 for cooling the burner in the start up position standby Parameters Air control Air actuator control ...

Page 83: ...3 ϑ1 ϑ2 53 M The air actuator can be activated externally via the input at terminal 2 during start up Parameter 48 must be set to 0 for this purpose see also page 80 Air actuator control 10 6 8 Air actuator in the event of fault Parameter 50 This parameter decides whether the air actuator can be ac tivated externally via the input at terminal 2 in the event of a fault lock out Parameter 50 0 canno...

Page 84: ...ly with a comparable three point step ac tuator If the air supply is stopped on a heated furnace with the burner switched off the controls may be damaged by the hot furnace atmosphere as a result of the lowest possible position of the butterfly valve limited by S4 IC 20 Switching cam setting for ignition capacity minimum and maximum capacity as well as pre purge and standby S1 for ignition capacit...

Page 85: ...of the butterfly valve being in the closed position limited by S4 Check whether the burner can cope without cooling in this situation IC 20 Switching cam setting for ignition capacity minimum and maximum capacity as well as pre purge and standby S1 for ignition capacity of the burner S2 for minimum capacity of the burner S3 for maximum capacity of the burner and pre purge S4 for the closed positio...

Page 86: ...e as a result of the butterfly valve being in the closed position limited by S4 Check whether the burner can cope without cooling in this situation IC 20 Switching cam setting for ignition capacity minimum and maximum capacity as well as pre purge and standby S1 for minimum capacity and ignition capacity of the burner S3 for maximum capacity of the burner and pre purge S4 for the closed position o...

Page 87: ...the butterfly valve limited by S4 If pre purge is active considerably lower air capacity than the maximum air capacity will be used for purging IC 20 Switching cam setting for ignition capacity minimum and maximum capacity and reverse direction of rotation to ap proach the position for ignition capacity S1 for ignition capacity of the burner S2 for reversing the direction of rotation to approach t...

Page 88: ...is active considerably lower air capacity than the maximum air capacity will be used for purging IC 20 The position for maximum capacity is achieved by the controller enable output terminal 56 Switching cam settings S1 S2 S3 and S4 S1 for minimum capacity and ignition capacity of the burner S2 for reversing the direction of rotation to approach the po sition for ignition capacity The actuator will...

Page 89: ...1 tightness test before start up Parameter 51 2 tightness test after shut down With this setting a tightness test is also performed after a fault is reset and after mains on Parameter 51 3 tightness test before start up and after shut down An additional bypass valve must be installed in gas sections with an air gas ratio control The valve allows the closed air gas ratio control to be bypassed duri...

Page 90: ...rged via the valve connected to terminal 15 Parameter 52 4 V4 The test volume is discharged via the valve connected to terminal 57 10 7 3 Measurement time Vp1 Parameter 56 The required measurement time must be determined ac cording to the requirements of the appropriate application standards e g EN 1643 BCU 56x C1 µC P 13 14 45 pu 2 TC PZ 750 ϑ 1 2 3 pu 2 PZ Vp1 V1 V2 The required measurement time...

Page 91: ...opening time tL 2 s is inadequate e g if slow opening valves are used to fill the test volume or reduce the pressure between the valves bypass valves can be used instead of the main valves The opening time may be longer than the 3 s permitted by the standard EN 1643 2000 if the gas volume which flows into the combustion chamber is equal to or less than 0 083 of the maximum flow rate and if bypass ...

Page 92: ...ause time tBP Parameter 62 A minimum pause time tBP 0 to 3600 s can be defined to achieve stable operation of the burners If a signal is applied to terminal 1 burner start up or terminal 2 cooling during the minimum pause time status display Delay H0 will appear Parameters ...

Page 93: ...d and closed as required By holding the button the actuator is first opened further The BCU indicates A with blinking dots Once the button has been released the actuator stops in the relevant position Pressing it again will result in closing the actuator to the position for minimum capacity The BCU indicates A with blinking dots A change of direction takes place each time the button is released an...

Page 94: ...ge In the case of multiple burner applications burners with mechanical combustion air supply are used The air for combustion and pre ventilation is supplied by a central fan controlled by a separate automation system The automation system sends a signal to terminal 50 during purg ing At this point the BCU opens the air actuator actuator air valve regardless of the status of the other inputs The di...

Page 95: ... with the start up fuel rate the FCU issues an enable signal to start the burner via terminal 66 to the BCU with setting P71 20 In addition the safety interlocks must have been enabled by the FCU BCU BCU FCU µC 54 55 53 24V M L1 L1 54 55 53 M 66 66 10 10 5 Function of terminal 67 Parameter 72 Parameter 72 0 Off Parameter 72 8 AND with input at terminal 46 emergency stop 10 10 6 Function of termina...

Page 96: ...ameter 80 when bus module BCM 500 is connected A device name must be entered in the automation system for the unique identification of the control unit BCU FCU in the Profinet IO system Parameter 80 0 Off Parameterization access using BCSoft via Ethernet is still possible Parameter 80 1 with address check The device name on delivery for the BCU 580 is not assigned bcu 580 xxx The expression not as...

Page 97: ...s voltage 120 V AC 50 60 Hz 230 V AC 50 60 Hz C0 C1 No valve proving system With valve proving system F1 F2 F3 Capacity control interface for actuator IC interface for RBW actuators air valve control U0 Ionization or UV control in case of operation with gas D0 D1 Digital input none for high temperature operation K0 K1 K2 No plug in terminals Plug in terminals with screw connection Plug in terminal...

Page 98: ...ertically end clamps are required e g Clipfix 35 by Phoenix Contact to prevent the BCU from slipping Environment Install in a clean environment e g a control cabinet with an enclosure IP 54 whereby no condensation is permitted 12 2 Commissioning Do not start the BCU until the parameter settings and wiring are correct and the faultless processing of all input and output signals complies with the lo...

Page 99: ...pressure switches gas valves outside enclosed instal lation spaces must be protected from mechanical damage and stress e g vibration or bending as well as short circuits short circuits to ground and cross circuits Signal and control line for screw terminals max 2 5 mm2 AWG 12 for spring force terminals max 1 5 mm2 AWG 16 Do not route BCU cables in the same cable duct as frequency converter cables ...

Page 100: ... cabling outside enclosed installation spaces must be protected from mechanical damage and stress e g vibration or bending as well as short circuits short circuits to ground and cross circuits 17 18 37 38 N max 1A 24VDC 250VAC BCU 580 3 15AT µC 88 c c 0 V 24 V 41 42 24V DC 9 11 12 10 62 61 230V 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70 P69 P73 P72 P72 HT pu 2 GZL PZL P71 0 6 IN 46 45 65 66 67 68 49 50 51 5 6 7...

Page 101: ... it is used for the display in a control room for example then the cable to the control room must be screened Alternating pilot burner Parameter 79 0 N BCU 580 F1 µC 88 c c 0 V 24V DC 9 11 12 10 62 61 230V 1 2 3 4 ϑ1 P73 72 72 46 45 65 66 67 68 49 50 51 52 5 6 7 8 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 A 53 54 55 56 mA 2 1 N L1 0 V 24 V 0 20 mA UVD1 1 2 4 3 5 6 Per...

Page 102: ...BCU F1 checks the position to which the actuator IC 20 has moved using terminal 52 feedback by lifting the signal to terminal 53 54 or 55 see page 121 Lifting To ensure this check is possible BCU F1 and actuator IC 20 or equivalent three point step actuators must be wired as shown in the connection diagram 17 18 37 38 N max 1A 24VDC 250VAC BCU 580 3 15AT µC 88 c c 0 V 24 V 41 42 24V DC 9 11 12 10 ...

Page 103: ...purpose The valid parameters are then adopted by the new BCU The old device and the new BCU must have an identical type code 12 6 Protecting the pilot burner from overload To protect the unit against overload by frequent cycling only a specific number of pilot burner start up attempts can be carried out by the BCU The maximum number of start up attempts per minute depends on the safety time tSA an...

Page 104: ...BCU 580 Edition 11 15 104 12 7 Calculating the safety time tSA Project planning information ...

Page 105: ... the output of a gas valve must be used as auxiliary energy e g V2 as a result of the required flame control BCU F3 13 14 15 N V2 V3 V1 53 54 V5 57 V4 The following application describes a two stage controlled burner without a pneumatic air gas ratio control system V2 and the air valve are activated simultaneously V2 must not be activated during purging BCU 580 F3 V1 15 13 V2 V3 V4 14 57 10 53 54 ...

Page 106: ...617 13 2 OCU For installation in the control cabinet door in standard grid dimensions The program step status or fault messages can be read on the OCU In Manual mode the OCU can be used to proceed through the sequence of operating steps For details see from page 108 OCU OCU 500 1 Order No 84327030 OCU 500 2 Order No 84327031 13 3 Connection plug set For wiring the BCU Connection plugs with screw t...

Page 107: ...icht mehr in vollem Umfang Aktuelle Parameter direkt auslesen Important changed parameters The details on the type label are no longer completely accurate Read the current parameters direct from the unit Attention paramètres modifiés Les informations figurant sur la plaque signalétique ne sont plus valables dans leur intégralité Veuillez vous référer directement aux paramètres actualisés Affix on ...

Page 108: ...00 BCU 500 series The external operator control unit OCU may be installed in the door of a control cabinet for example Thus the control cabinet does not need to be opened to read out process val ues statistics flame signal intensities or parameter values to change settings on the OCU or to control or adjust connected butterfly valves in Manual mode ...

Page 109: ...can use the OK key to change to Service mode OK Back In Service mode you can use the Back key to switch from one setting level to the next higher one By holding down the key for a certain time you can change directly to the status display OK Navigation UP DOWN In Service mode the navigation keys can be used to select individual functions on one level In Manual mode those keys can be used to open a...

Page 110: ...e threaded adapters of the OCU are suitable for 23 mm boreholes which are drilled at intervals of 30 mm 60 mm 90 mm 23 mm 15 mm 90 mm OK 14 5 Selection The OCU can be supplied with various language kits Type Languages Order No OCU 500 1 German English French Dutch Spanish Italian 84327030 OCU 500 2 English Danish Swedish Nor wegian Turkish Portuguese 84327031 OCU 500 3 English US English Spanish B...

Page 111: ...control cabinet door Dimensions of the operator control unit 90 x 90 x 18 mm W x H x D Electrical connection Connection data wire cross section flexible min 0 25 mm wire cross section flexible max 0 34 mm wire cross section AWG kcmil min 24 wire cross section AWG kcmil max 22 AWG to UL CUL min 24 AWG to UL CUL max 22 Cable length inside control cabinet max 10 m OCU ...

Page 112: ...perating status the level of the flame signal and the current program step 15 3 Electrical connection Use only cable and plug components which comply with the appropriate Profinet specifications Use shielded RJ45 plugs Cable length between 2 Profinet stations max 100 m Profinet installation guidelines see www profibus com 15 4 Installation Installation position vertically upright horizontal or til...

Page 113: ...4960663 15 6 Technical data Electrical data Power consumption 1 2 VA Power loss 0 7 W Mechanical data Dimensions W H D 32 5 115 100 mm Weight 0 3 kg Environment Ambient temperature 20 to 60 C 4 to 140 F Storage temperature 20 to 60 C 4 to 140 F Climate no condensation permitted Enclosure IP 20 pursuant to IEC 529 Installation location min IP 54 for installation in a control cabinet BCM 500 ...

Page 114: ...nals 53 54 and 55 max 1 A each cos ϕ 1 Ignition transformer terminal 9 max 2 A Total current for the simultaneous activation of the valve outputs terminals 13 14 15 and 57 the actuator termi nals 53 56 and the ignition transformer max 2 5 A Signalling contact for operating and fault signals max 1 A external fuse required Number of operating cycles The fail safe valve outputs V1 V2 V3 and V4 are mo...

Page 115: ...rce terminal nominal cross section 2 x 1 5 mm wire cross section min 0 2 mm wire cross section AWG min 24 wire cross section AWG max 16 wire cross section max 1 5 mm rated current 10 A 8 A UL to be observed in case of daisy chain 16 3 Environment Ambient temperature 20 to 60 C 4 to 140 F no condensation permitted Enclosure IP 20 pursuant to IEC 529 Installation location min IP 54 for installation ...

Page 116: ... flow monitoring 7 2 x 10 9 1 h Air flow monitoring with optional input 7 1 x 10 9 1 h Flame control 6 5 x 10 9 1 h Approaching position for ignition capacity with F1 IC 20 5 6 x 10 9 1 h Approaching position for ignition capacity with F2 RBW 5 9 x 10 9 1 h Approaching position for ignition capacity with F3 5 3 x 10 9 1 h SIL 3 is only achieved in conjunction with actuators IC 20 or RBW if a separ...

Page 117: ...BCU 580 Edition 11 15 117 16 6 Converting units See www adlatus org Technical data ...

Page 118: ...od isolation of the valve outputs from the mains In the event of a defect e g fault 36 the power module must be replaced See www partdetective de optimized for smartphones for a replacement order option for the power module The device and user statistics can be displayed using the operator control unit OCU or engineering tool BCSoft for further diagnostics and troubleshooting The user statistics c...

Page 119: ...um pressure PZL Pressure switch for minimum pressure PDZ Differential pressure switch Pxx Input signal depending on parameter xx M Actuator with butterfly valve TC Tightness test pu 2 Half of the inlet pressure pu Inlet pressure pd Outlet pressure Vp1 Test volume GZL Valve with proof of closure switch Fan Three point step switch Emergency stop Input Output safety circuit IN Current consumption of ...

Page 120: ...ty control and switching equipment for the use of the ap plication e g safety temperature limiter minimum maximum gas pressure must isolate input from the voltage supply 19 4 Safety time on start up tSA1 This refers to the period of time between switching on and switching off of the gas valve when no flame signal is detected The safety time on start up tSA1 2 3 5 or 10 s is the minimum operating t...

Page 121: ...ens if the mains voltage fails In order to restart the BCU can only be reset manually using the button on the front panel the OCU or the remote reset input terminal 3 19 8 Warning signal The BCU reacts to operating faults e g in the case of perma nent remote resets with a warning signal The display blinks and shows the corresponding warning message The warning signal ends once the cause has been e...

Page 122: ... mode the frequency of demands for operation made on a safety related system is not greater than one per year and is not greater than twice the proof test frequency In high demand mode or continuous mode the frequency of demands for operation made on a safety related system is greater than one per year or greater than twice the proof test frequency See also IEC 61508 4 19 14 Safe failure fraction ...

Page 123: ...answer Use To get to know the product To choose a product Planning To look for information My scope of functions Technical department Sales No answer Remarks Elster GmbH Postfach 2809 49018 Osnabrück Strotheweg 1 49504 Lotte Büren Germany T 49 541 1214 0 F 49 541 1214 370 info kromschroeder com www kromschroeder com The current addresses of our international agents are available on the Internet ww...

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Elster BCU 580, Technical Information

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