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Honeywell Krom Schroeder BCU 480 Manual Download Page 77

BCU 480 · Edition 03.16l

77

88

200 mm (7.87")

A

55

mm

B

C

D
E

200 m

m (7.87")

50

mm

(1.97")

(2.17")

4,5 mm

0.177"

163 mm 6.42"

185 m

m

7.28"

Technical data

9 .4 Housing dimensions

Die-cast aluminium housing with plug-in terminal 
blocks and plug-in M20 cable glands or (16-pin) indus-
trial plug connector for input signals and optionally pre-
assembled cables for output signals.

9 .5 Operating controls

A: Optical interface.
B:  Labelling field for individual labelling of the system 

components.

C: 2-digit 7-segment display.
D:  Mains switch to isolate the BCU on two poles from 

the mains.

E:  Reset/Information button to reset the system after a 

fault or to scan parameters on the display.

9 .6 Installation

Recommended installation position: vertical (cable 

glands pointing downwards).

Open the BCU and attach with four screws Ø 4 mm or 
screw on the closed unit using the external securing bar, 
see page 71 (Accessories).
Electrical connection via plug-in connection terminals 
(2.5 mm²) and plug-in cable glands. The latter can be 
removed in order to facilitate installation. When install-
ing, ensure that there is sufficient space to open the 
BCU.

Summary of Contents for Krom Schroeder BCU 480

Page 1: ...rmittent or continuous operation Replace the local control cabinet Flame control by UV ionization or a further option of using the furnace chamber temperature Display of the program status unit parameters and flame signal Manual mode for burner adjustment and for diagnostic purposes Burner control units BCU 480 ...

Page 2: ...arameters 30 4 2 Flame control 31 4 2 1 Flame signal pilot burner 31 4 2 2 Flame signal main burner 31 4 2 3 Program status when the most recent fault occurred 31 4 2 4 Switch off threshold of the flame amplifier 31 4 2 5 High temperature operation in the case of BCU D2 or BCU D3 32 4 2 6 UVS check 35 4 3 Pilot and main burner monitoring 36 4 3 1 Permanent pilot burner 37 4 3 2 Interrupted pilot b...

Page 3: ...otecting the pilot burner from overload 61 6 13 Installation 61 6 14 Wiring 62 6 15 BCU and BCU E1 with and without adapted power management 62 6 16 Signal distributor board 62 6 17 PROFIBUS DP 63 6 17 1 Safety related control signals 63 6 17 2 Wiring the PROFIBUS plug connector 63 6 17 3 EMC 63 6 17 4 Unit replacement 63 6 17 5 Status and fault messages for PROFIBUS DP 64 6 18 Third gas valve can...

Page 4: ...mulation delay time tLV 79 11 5 Safety time during operation tSB 80 11 6 Flame signal 80 11 7 Fault lock out 80 11 8 Safety interlocks Limits 80 11 9 Pilot gas valve V1 80 11 10 Main gas valve V2 81 11 11 Continuous operation 81 11 12 Air valve 81 11 13 Diagnostic coverage DC 81 11 14 Mode of operation 81 11 15 Safe failure fraction SFF 81 11 16 Probability of dangerous failure PFHD 82 11 17 Mean ...

Page 5: ...s the BCU reduces the load on the central furnace control by taking over tasks that only relate to the burner for example it ensures that the burner always ignites in a safe condition when it is restarted The air valve control assists the furnace control for cool ing purging and capacity control tasks The program status the unit parameters and the level of the flame signal can be read directly fro...

Page 6: ... purpose As a standardized fieldbus system the PROFIBUS DP considerably reduces development installation and commissioning costs compared to conventional wiring The use of a standard bus system offers massive ben efits compared to manufacturer specific bespoke solu tions Time tested hardware components standardized connection methods and a series of tools of bus diag nostics and optimization are a...

Page 7: ...r can be started with reduced capacity after the operat ing signal from the pilot burner has been detected The pilot burner is switched off automatically 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 A UV sensor monitors the flame sig nal from pilot and main burners UV sensor UVD...

Page 8: ...tion 1 1 2 Stage controlled main burner with permanent pilot burner Control Main burner ON OFF The main burner can be started with reduced capacity after the operat ing signal from the pilot burner has been detected Pilot and main burn ers can be operated simultaneously This reduces the time required by the main burner for starting up The BCU provides the cooling and purging processes ...

Page 9: ...anent pilot burner Control Main burner ON OFF with ignition via bypass The main burner can be started at low fire rate after the operating sig nal from the pilot burner has been detected When the operating state is reached the BCU issues the En able signal for the maximum burner capacity Pilot and main burners can be operated simultaneously This reduces the time required by the main burner for sta...

Page 10: ... for air is moved to ignition position in order to start the main burner The main burner can be started at low fire rate after the operating signal from the pilot burner has been detected The con trol system controls the burner ca pacity via the butterfly valve for air after the operating state has been signalled Pilot and main burners can be operated simultaneously This reduces the time required ...

Page 11: ...ogram status Control signals that are relevant for safety such as the safety interlocks purge optional and digital input are transferred independently of the bus communication by separate cables 1 1 6 BCU 480 D High temperature equipment Indirect flame control using the temperature During the start up process as long as the wall temper ature is below auto ignition temper ature the flame must be co...

Page 12: ...2004 108 EC ANSI CSA approved American National Standards Institute Canadian Standards Association ANSI Z21 20 CSA C22 2 No 199 UL 372 www csagroup org Class numbers 3335 01 and 3335 81 FM approved Factory Mutual Research Class 7610 Combustion Safeguards and Flame Sensing Systems Suitable for applications pursuant to NFPA 86 www approvalguide com AGA approved AGA Australian Gas Association Approva...

Page 13: ...3 BCU 480 C 40 41 42 43 44 45 46 47 UVS 1 2 3 P 5 6 7 8 11 9 10 12 13 14 15 25 26 27 18 19 20 22 24 PE 7 8 9 10 24 25 PE 7 8 9 24 Test N1 O I BCU 480 E1 ϑ1 ϑ2 A 23 2 1 16 17 28 29 21 3 4 Function 3 Function 3 1 Connection diagrams 3 1 1 BCU 480 E1 For cable selection and wiring see page 57 Project planning information For the explanation of symbols see page 78 Leg end ...

Page 14: ... 36 37 DI 50 51 l 38 F3 BCU 480 C 40 41 42 43 44 45 46 47 UVS 1 2 3 P 5 6 7 8 11 9 10 12 13 14 15 25 26 27 18 19 20 22 24 PE 7 8 9 10 24 25 PE 7 8 9 24 Test O I BCU 480 ϑ1 ϑ2 A 23 2 1 16 17 28 29 21 3 4 Function 3 1 2 BCU 480 For cable selection and wiring see page 57 Project planning information For the explanation of symbols see page 78 Leg end ...

Page 15: ...1 l 38 F3 BCU 480 C 40 41 42 43 44 45 46 47 UVS 1 2 3 P 5 6 7 8 11 9 10 12 13 14 15 25 26 27 18 19 20 22 24 PE 7 8 9 10 24 25 PE 7 8 9 24 Test BCU 480 B1 E1 O I N1 BCU B1 1 PROFIBUS DP 1B 1A 2B 2A OFF ON OFF ON Function 3 1 3 BCU 480 B1 E1 For cable selection and wiring see page 57 Project planning information For the explanation of symbols see page 78 Leg end ...

Page 16: ...0 51 l 38 F3 BCU 480 C 40 41 42 43 44 45 46 47 UVS 1 2 3 P 5 6 7 8 11 9 10 12 13 14 15 25 26 27 18 19 20 22 24 PE 7 8 9 10 24 25 PE 7 8 9 24 Test O I N1 BCU 480 B1 BCU B1 1 PROFIBUS DP 1B 1A 2B 2A OFF ON OFF ON Function 3 1 4 BCU 480 B1 For cable selection and wiring see page 57 Project planning information For the explanation of symbols see page 78 Leg end ...

Page 17: ... 7 8 11 9 10 12 13 14 15 25 26 27 18 19 20 22 24 PE 7 8 9 10 24 25 PE 7 8 9 24 23 3 4 2 DI 16 15 14 12 11 10 9 8 7 6 5 4 3 2 1 P A L1 L1 N L2 PE 16 15 14 8 7 12 5 11 10 4 3 9 2 1 6 2 1 21 17 16 28 29 ϑ1 ϑ2 N1 O I BCU 480 P E1 Function 3 1 5 BCU 460 P E1 with industrial plug connector For cable selection and wiring see page 57 Project planning information For the explanation of symbols see page 78 ...

Page 18: ... 5 6 7 8 11 9 10 12 13 14 15 25 26 27 18 19 20 22 24 PE 7 8 9 10 24 25 PE 7 8 9 24 23 3 4 2 DI 16 15 14 12 11 10 9 8 7 6 5 4 3 2 1 P A L1 L1 N L2 PE 16 15 14 8 7 12 5 11 10 4 3 9 2 1 6 2 1 21 17 16 28 29 ϑ1 ϑ2 O I BCU 480 P Function 3 1 6 BCU 460 P with industrial plug connector For cable selection and wiring see page 57 Project planning information For the explanation of symbols see page 78 Leg e...

Page 19: ...lug connector pursuant to VDE 0627 This 16 pin plug connector ensures fast con necting or disconnecting of units without any addition al wiring required This simplifies replacing the unit and reduces standstill times All signals to the higher level control system the mains supply and the safety interlocks are routed via this plug see page 71 Accessories ...

Page 20: ...a 2 core shielded cable as standard The bus system transfers the control signals for start ing resetting and for controlling the air valve to purge the furnace or kiln or for cooling in start up position and heating during operation from the control system PLC to the BCU B1 In the opposite direction it sends operating status the level of the flame signal and the current program status 3 3 1 Safety...

Page 21: ...the distributed stations slaves on the ba sis of a defined cycle This includes for instance the PLC PC CNC or VME systems with which the PROFI BUS DP is operated DP Masters Class 2 DPM2 DPM2 devices are programming project planning or operator control devices They are used for configu ration and commissioning of the system or for system operation and visualization in ongoing operation DP Slaves Th...

Page 22: ...fic parameters of each station are to be taken into account To allow for simple and standardized planning the pa rameters of the BCU B1 have been summarized in a so called device master data file GSD The file struc ture is standardized so that it can be read by the plan ning devices of different manufacturers The GSD file is supplied on the BCSoft CD which is in cluded in the delivery of BCU B1 Th...

Page 23: ... kbit s The max range per segment depends on the baud rate Baud rate kbit s Range m 93 75 1200 187 5 1000 500 400 1500 200 The specified ranges may be increased by using repeat ers No more than three repeaters should be connected in series The specified ranges relate to bus cable type A two core shielded and twisted e g Siemens Order No 6XV1830 0EH10 or Lapp cable unitronic Order No 2170 220T ...

Page 24: ... a malfunction of the internal electronic circuitry or of the flame sensors the burner can be started The pilot burner start up is activated via the signal input Start up signal ϑ1 terminal 4 Once the start up signal ϑ1 has been applied the BCU 480 opens valve V1 and ignites the burner The ignition time tZ is constant If a flame is detected during the safety time tSA1 the flame proving period tFS1...

Page 25: ... V2 The main burner is ignited by the pilot burner If a flame is detected during the safe ty time tSA2 the flame proving period tFS2 starts after the safety time tSA2 has elapsed If the main burner has been started successfully and its flame has stabi lized the operation signalling contact terminals 28 29 closes Start up of the pilot burner without flame signal If no flame is detected during the s...

Page 26: ...ia the optical interface pa rameter 12 Pilot burner restart Start up of the main burner without flame signal If no flame is detected during the safety time tSA2 either a fault lock out occurs or up to two further start up attempts occur The re quired functions and if applicable the number of start up attempts must be specified when ordering parameter 11 Main burner start up attempts Behaviour of t...

Page 27: ...od pilot burner Operation pilot burner 4 Flame failure during operation pilot burner Waiting time main burner 5 Flame simulation main burner Safety time on start up main burner 6 Start up without flame signal main burner Flame proving period main burner 7 Flame failure during flame proving period main burner Operation main burner 8 Flame failure during operation main burner 10 Too many remote rese...

Page 28: ... EEPROM data change FS 32 Undervoltage in power pack 33 Faulty parameterization Bus module fault 51 Safety interlock failure 52 Permanent remote reset 53 Timing cycle too short In Manual mode two dots will blink on the display in program status 01 08 standard option FS input output safety circuit NFS input output control system ...

Page 29: ...rner 12 0 1 0 Restart main burner 13 0 1 0 Safety time during operation for V1 and V2 tSB 14 1 2 s 1 s Flame simulation check in start up position standby 15 0 1 1 Permanent pilot burner 16 0 1 1 Minimum burner on time tB 20 25 s tSA Minimum burner pause time tBP 21 0 250 s 0 s Pilot burner safety time on start up tSA1 22 3 5 10 s Pilot burner flame proving period tFS1 23 0 25 s 0 s Main burner sa...

Page 30: ...ion ensure that the program se quence started matches the application This param eter may be set in this way only if the burner can restart as intended in all operating phases 4 1 Scanning the parameters During operation the 7 segment display shows the pro gram status see page 27 Program status and fault messages The flame signal and all following parameters of the BCU can be scanned one after the...

Page 31: ... the unit was in when the fault was detected wait ing time 01 or standby 00 Result a flame simulation was detected during the waiting time or standby 4 2 4 Switch off threshold of the flame amplifier Parameter 04 pilot burner switch off threshold Parameter 05 main burner switch off threshold The sensitivity at which the burner control unit still de tects a flame can be set between 1 and 20 μA Exam...

Page 32: ...ns the BCU operates without evaluation of the flame signal The safety function of the device internal flame con trol system is placed out of operation In High temperature mode the gas valves are opened without flame control The precondition for high temperature operation is that an external flame safeguard ensures the presence of the flame in fail safe manner indirectly via the tempera ture For th...

Page 33: ...hes off the burner once the DI input has been disconnected from the electrical power supply and restarts with flame simulation check recommend ed in the case of UV control with UVS Parameter 33 3 BCU D3 08 08 t 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e 22a V1 1 V2 2 ϑ1 ϑ2 2 1 DI The burner remains in operation and the BCU performs flame control again recommended in the case of ioni ...

Page 34: ...op eration is deactivated the burner control unit performs a fault lock out regardless of parameter 33 Fault pilot burner t 9 12 V1 1 14 V2 2 ϑ1 ϑ2 2 16 17 1 24 21 88 4 5 1 7 18 19 28 29 6 DI 04 04 Fault main burner 08 t 9 12 V1 1 14 V2 2 ϑ1 ϑ2 2 16 17 1 24 21 88 4 5 1 7 18 19 28 29 6 DI 08 ...

Page 35: ...UV sensor for intermittent operation For intermittent operation the operating state of the complete system is limited to 24 h pursuant to EN 298 To meet the requirement for intermittent operation the burner is shut down and restarted automatically after an operating time of 24 hours The restart does not meet the requirements of EN 298 for UV sensor con tinuous operation because the required self t...

Page 36: ...ble Permanent pilot burner t 1 2 ϑ1 ϑ2 88 02 04 06 08 04 06 08 04 For applications which require a high system availabil ity or where a continuously burning flame is necessary The pilot burner is ignited once and remains constantly in operation The main burner is controlled separately Intermittent pilot burner t 1 2 ϑ 88 02 04 06 08 00 02 04 06 08 00 Pilot and main burners are controlled with one ...

Page 37: ...nt pilot burner Start up as in the illustration Permanent pilot burner with the difference being that the start up signal for pi lot and main burners is applied synchronously and that immediately after the flame proving period tFS1 the main burner is started 4 3 2 Interrupted pilot burner Parameter 16 0 tSA1 tZ 04 06 07 08 02 03 00 t tFS1 tSA2 tFS2 88 9 12 V1 1 14 V2 2 2 1 24 21 4 5 2 7 18 19 16 1...

Page 38: ...urner Parameter 15 0 The flame simulation check is conduct ed after applying the start up signal ϑ during the waiting time tW Parameter 15 1 The flame simulation check is con ducted provided no start up signal ϑ is applied during the so called start up position standby This allows fast start up of the burner since there is no waiting time tW The burner must have been switched off for at least 4 s ...

Page 39: ... until the end of the pause time After the pause time the burner is started if the start up signal ϑ is applied The minimum burner pause time tBP serves to adapt the program sequence to the requirements of the applica tion The time should be set such that the system can be moved to ignition position i e butterfly valves can be closed and possibly gas can be flared off before a re start occurs Exam...

Page 40: ...1 tZ 88 04 02 03 00 t tFS1 4 5 1 7 9 18 19 12 V1 16 17 1 1 ϑ1 This indicates the safety time on start up tSA1 for the pilot burner Main burner Parameter 24 tSA1 tZ 04 06 07 08 02 03 00 t tFS1 tSA2 tFS2 9 12 V1 1 14 V2 2 ϑ1 ϑ2 2 1 24 21 88 4 5 2 7 18 19 16 17 28 29 This indicates the safety time on start up tSA2 for the main burner ...

Page 41: ...elapses before the BCU starts the next pro gram step so as to give the flame time to stabilize 4 5 3 Minimum burner on time tB Parameter 20 Programmable time in the range from minimum safety time on start up tSA2 to maximum 25 s during which the main burner remains in operation In the case of brief activation of the start up signal input ϑ2 e g with a pulse the burner on time tB is started and the...

Page 42: ... at tempts must be specified when ordering 1 start up attempt Parameter 10 1 tSA tZ 88 02 00 t 4 5 1 7 9 18 19 12 V1 14 V2 16 17 02 ϑ1 If no flame forms during start up a fault lock out is performed after expiry of time tSA The display blinks and shows the cause of the fault 2 or 3 start up attempts Parameter 10 2 3 ϑ1 tSA tZ 88 02 00 t 4 5 1 7 9 18 19 12 V1 14 V2 16 17 01 02 tSA tZ tW If several ...

Page 43: ...0 t tFS1 tSA2 9 12 V1 1 14 V2 2 2 16 17 1 24 21 06 88 4 5 1 7 18 19 28 29 ϑ1 ϑ2 If no flame forms during the start up of the main burner a fault lock out is performed after expiry of time tSA2 The display blinks and shows the cause of the fault 2 or 3 start up attempts Parameter 11 2 3 tSA2 tSA2 tSA2 tSA1 tZ 04 06 02 03 00 t tFS1 9 12 V1 1 14 V2 2 2 16 17 1 24 21 06 88 4 5 1 7 18 19 28 29 tW 06 06...

Page 44: ...f the Standards 4 6 2 Fault lock out or restart pilot burner Parameter 12 This parameter determines whether the BCU initiates a one off restart or performs an immediate fault lock out for the burner after a flame failure see also page 57 Project planning information Immediate fault lock out in the event of flame failure Parameter 12 0 Pilot burner fault lock out 04 t tSB 04 88 4 5 1 7 9 18 19 12 V...

Page 45: ...t now attempts to restart the burner once If the burner does not function a fault lock out occurs The display blinks and shows the cause of the fault In accordance with EN 746 2 a restart may be con ducted only if the safety of the installation is not im paired Restart is recommended for burners which oc casionally display unstable behaviour during operation The precondition for a restart is that ...

Page 46: ...ult lock out within the safety time during operation tSB This involves disconnecting the power from the gas valves and the ignition transformer The fault signalling contact closes the display blinks and shows the current program status see table on page 27 Program sta tus and fault messages After a fault lock out the burner control unit can be reset either with the button on the front panel or usi...

Page 47: ...ault In accordance with EN 746 2 a restart may be con ducted only if the safety of the installation is not im paired Restart is recommended for burners which oc casionally display unstable behaviour during operation The precondition for a restart is that activation of the restart allows the burner to restart as intended in all operating phases In this case it must be ensured that the program seque...

Page 48: ...sition Low fire over run time tKN after a controlled shut down 4 7 1 Purge In the case of multiple burner applications burners with mechanical combustion air supply are used The air for combustion and pre purge is supplied by a central fan controlled by a separate logic This logic determines the purging time The BCU L E1 with adapted power management sup ports centrally controlled pre purge or pos...

Page 49: ... opens if it is activated externally via input 23 Parameter 31 0 The air valve remains closed during start up even if it is activated externally These settings are required on burners on which the gas air ratio is controlled via a pneumatic ratio control system and which also need to be started at low fire e g on two stage controlled burners In this case ac tivation of the air valve during burner ...

Page 50: ...8 A 18 19 23 26 28 29 12 9 V1 1 14 V2 4 5 2 7 24 2 21 16 17 1 2 tSA1 tZ tFS1 A3 ϑ1 ϑ2 VAS VAS L UV BCU 480 L A P L1 1 2 VAS 1 ϑ Parameter 30 0 The air valve opens if it is activated externally via input 23 Parameter 31 1 The air valve can be activated even during start up These settings may be selected only if the burner can start with full air capacity ...

Page 51: ... 7 24 2 21 16 17 1 2 tSA1 tZ tFS1 03 ϑ1 ϑ2 VR R VAS BCU 480 L A P L1 1 2 SPS PLC CPE VAS 1 ϑ 1 2 Parameter 30 2 The air valve opens simultaneously with valve V2 Application single stage controlled main burner is switched ON OFF via the ϑ input The air valve can be activated externally via input 23 for cooling the burner in the start up position standby ...

Page 52: ...2 7 24 2 21 16 17 1 2 ϑ1 ϑ2 VR R VAG BCU 480 L A P L1 1 2 VAS 1 ϑ 1 2 SPS PLC CPE Parameter 30 3 The air valve opens simultaneously with the operating signal Application two stage controlled main burner is switched ON OFF via the ϑ input The air valve can be activated externally via input 23 for cooling the burner in the start up position standby ...

Page 53: ...low ly The air flowing in during the closing time increases the O2 content in the combustion chamber Parameter 36 5 15 or 25 low fire over run time tKN 5 15 or 25 s The air valve closes slowly after the activation signal has been switched off The gas valve remains open for tKN This means that the burner after deactivation of the start up signal ϑ is initially adjusted down to low fire and then swi...

Page 54: ...r 32 This determines whether the air valve can be activated in the event of a fault lock out Parameter 32 0 The air valve is closed in the event of a fault It cannot be activated externally via terminal 23 Parameter 32 1 The air valve can be activated exter nally via input 23 even during a fault e g for cooling ...

Page 55: ...stops there Briefly pressing the Reset Information button 1 s displays the relevant Manual mode step When the operating position is reached program sta tus 4 Operation pilot burner or 8 Operation main burner the flame signal is indicated instead of the program parameter after approx 3 s If there is flame simulation during start up the flame signal is displayed immediately On units with air valve c...

Page 56: ...tage 230 V AC 15 10 50 60 Hz 115 V AC 15 10 50 60 Hz 1 2 3 8 Ignition transformer TZI 5 15 100 TZI 7 25 20 TZI 7 5 12 100 TZI 7 5 20 33 GB Front film in English with additional stickers in D F I NL E P Industrial plug connector D2 D3 High temperature operation in conjunction with UVS ionization sensor or UVD S2 S3 Number of start up attempts pilot burner 2 3 Number of start up attempts main burner...

Page 57: ...t lay together with ignition cable 6 1 2 Ignition cable Use unscreened high voltage cable see page 71 Accessories Cable length for integrated ignition max 5 m 16 4 ft Avoid external electrical interference The longer the ig nition cable the lower the ignition capacity Lay cable individually and if possible not in a metal conduit Do not lay UV ionization cable and ignition cable to gether and lay t...

Page 58: ...BCU 480 Edition 03 16l 58 Project planning information 6 3 Calculating the safety time tSA ...

Page 59: ... rele vant safety control and switching equipment for the use of the application e g safety temperature limiter mini mum and maximum gas pressure tightness control must isolate terminal 5 from the voltage supply If the safety interlock is interrupted or if fuse F1 has tripped the display shows a blinking 51 to indicate a fault If the safety interlocks fail an immediate program abort with switch of...

Page 60: ...r 10 Too many remote resets is displayed The error can only be acknowledged with the Reset Information button on the unit The burner malfunction must be remedied The mal function cannot be remedied by changing the method of activation 6 9 Burner start A furnace start may only be initiated if it has been ensured using an appropriate procedure that there is no combus tible mixture in the combustion ...

Page 61: ...1 and the ignition transformer used tSA s Ignition transformer TZI Max start ups min 3 5 15 100 6 5 5 15 100 6 10 5 15 100 3 3 7 25 20 3 5 7 25 20 2 10 7 25 20 1 3 7 5 12 100 6 5 7 5 12 100 4 10 7 5 12 100 2 3 7 5 20 33 4 5 7 5 20 33 3 10 7 5 20 33 2 6 13 Installation Recommended installation position vertical cable glands pointing downwards When installing ensure that there is sufficient space to...

Page 62: ... systems It features a new power management scheme for simplified installa tion and control The power for the ignition transformer and valves is supplied via the phase terminal 1 and must no longer be supplied by the safety interlocks No effort and expenditure is thus required for coupling contactors and their safety devices Unit replacement A BCU without power management may not be re placed with...

Page 63: ...e bus terminator is provided by the BCU The bus terminator can be connected in the PROFIBUS plug connector Ensure an equipotential bond between the different slaves and masters 6 17 3 EMC To achieve a high immunity of the system against elec tromagnetic interference radiation a shielded data cable must be used The shield must be connected to protective earth on both sides using wide area shield cl...

Page 64: ...thout flame signal 3 03 A3 Flame proving period Flame failure during flame proving period 4 04 A4 Operation Flame failure during operation 5 05 A5 Waiting time main burner Flame simulation main burner 6 06 A6 Safety time on start up main burner Start up without flame signal main burner 7 07 A7 Flame proving period main burner Flame failure during flame proving period main burner 8 08 A8 Operation ...

Page 65: ...Fault signal Byte 0 Bit 2 1 51 51 Fuse F1 defective or safety interlocks discontinuity 52 52 Permanent remote reset 53 53 Timing cycle too short 99 88 Internal error negative flame current Display on BCU L upon activation of the air valve during program step x FS input output safety circuit NFS input output control system ...

Page 66: ...e an additional contact terminal which closes at the same time as the air valve This can be used to activate a third gas valve V3 To do this the output of valve V1 or V2 must be used as auxiliary energy as a result of the required flame control 13 N 14 15 50 51 V3 V2 The opposite application describes a two stage controlled burner without a pneumatic air gas ratio control system The third gas valv...

Page 67: ...t does not meet the require ments of EN 50156 1 2004 5 2 2 Switch disconnec tors set out in chapter 5 for a device to disconnect the power supply Although the mains switch cannot be used for discon necting from the electrical power supply in accordance with EN 50156 it does allow the burner to be isolated functionally from the central control system This func tion is required for manual operation ...

Page 68: ... flame failure or whether the pilot burner is to burn permanently in the case of pilot and main burner moni toring The software package with PC opto adapter as well as Changed parameters stickers are available as acces sories see page 71 Accessories The unit parameters set at the factory are specified in the enclosed delivery note Document changed parameters in BCSoft using the protocol function a...

Page 69: ...ot workpieces or red hot furnace walls In the event of incident UV radiation the UV sensor rec tifies the supplied alternating voltage As with ioniza tion control the burner control unit only detects this DC signal When using UV sensors of Type UVS the burner control unit may be used for intermittent operation only This means that operation must be interrupted at least once every 24 hours This can...

Page 70: ... case of BCU D2 or BCU D3 During heating up standard monitoring methods ioni zation or UV must be used for flame control When the working temperature has exceeded 750 C indirect flame control can be taken over by a central monitoring device When the DI input terminal 6 is activated the burner control unit reverts to this operating mode Important in High temperature operation HT opera tion i e with...

Page 71: ...us terminator Order No 74960431 GSD files for BCU Profibus DP on BCSoft CD ROM Or der No 74960436 or at www docuthek com Bibliography PROFIBUS Specification EN 50170 Vol 2 version 1 0 Installation Guideline for PROFIBUS DP FMS avail able from the Profibus User Organization PUO PROFIBUS Technology and Application Order No 4 001 available from the PUO M Popp The New Rapid Way to PROFIBUS DP a text b...

Page 72: ...Osnabrück Germany Achtung geänderte Parameter Die Angaben auf dem Typenschild gelten nicht 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 ...

Page 73: ...stening set 174 mm 222 mm 230 mm 45 mm 263 mm 20 mm 16 5 mm 12 mm 22 mm 7 mm Order No 74960422 8 8 Radio interference suppressed electrode plugs Angle plug 4 mm interference suppressed Order No 04115308 Straight plug 4 mm interference suppressed Order No 04115307 Straight plug 6 mm interference suppressed Order No 04115306 ...

Page 74: ...is supplied for two cable glands with one seal insert each for cable diameters between 7 and 12 mm Input voltage of signal inputs Rated value 115 V AC 230 V AC Signal 1 80 126 5 160 253 Signal 0 0 20 0 40 Frequency 50 60 Hz 50 60 Hz Input current of signal inputs Signal 1 typ 2 mA Output current max 1 A cos ϕ 1 for the valve outputs or SRC out puts but total current for valves and ignition transfo...

Page 75: ...0 C 4 to 140 F climate no condensation permitted Enclosure IP 54 pursuant to IEC 529 Weight approx 5 kg 11 lb depending on version Ignition transformer Input Output V AC Hz A V mA TZI 5 15 100W 230 50 60 0 45 0 35 5000 15 11 TZI 7 25 20W 230 50 60 1 1 0 8 7000 25 18 TZI 7 5 12 100W 230 50 60 0 6 0 45 7500 12 9 TZI 7 5 20 33W 230 50 60 0 9 0 7 7500 20 15 TZI 5 15 100R 115 50 60 0 9 0 7 5000 15 11 T...

Page 76: ...nation with ionization electrode sensor and a unit of the BCU 400 series No characteristic values are available for flame control with UVS sensor For flame control with UVD sensor safety specific characteristic values are available for the Safety Integ rity Level SIL Further information can be found in TI UVD 1 at www docuthek com Relationship between the Performance Level PL and the Safety Integr...

Page 77: ...system components C 2 digit 7 segment display D Mains switch to isolate the BCU on two poles from the mains E Reset Information button to reset the system after a fault or to scan parameters on the display 9 6 Installation Recommended installation position vertical cable glands pointing downwards Open the BCU and attach with four screws Ø 4 mm or screw on the closed unit using the external securin...

Page 78: ...ignal pilot burner 2 Operating signal main burner Fault signal Reset Input signal Output signal Flame simulation check tW Waiting time 2 s tSA Safety time on start up 3 s 5 s or 10 s tSB Safety time during operation 1 s or 2 s tZ Ignition time 2 s 3 s or 6 s tLV Flame simulation delay time 25 s tFS Flame proving period 0 25 s tB Minimum burner on time tSA up to max 25 s tBP Minimum burner pause ti...

Page 79: ...ntrol unit 11 3 Ignition time tZ If no malfunction is detected during the waiting time tW the ignition time tZ then starts to elapse Voltage is supplied to the pilot gas valve V1 and the ignition trans former and the burner is ignited The duration of the ignition time is either 2 3 or 7 seconds depending on safety time tSA selected 11 4 Flame simulation Flame simulation delay time tLV t 1 14 4 5 9...

Page 80: ... flame signal 11 7 Fault lock out In the event of a fault lock out all valves and the igni tion transformer are disconnected from the electrical power supply and a fault is signalled Resetting must take place manually following a fault lock out 11 8 Safety interlocks Limits The limiters in the safety interlock linking of all the rel evant safety control and switching equipment for the use of the a...

Page 81: ...ing for purging to control the burner capacity in ON OFF mode and in High Low mode when using a pneumatic air gas ratio control system 11 13 Diagnostic coverage DC Measure of the effectiveness of diagnostics which may be determined as the ratio between the failure rate of detected dangerous failures and the failure rate of total dangerous failures NOTE Diagnostic coverage can exist for the whole o...

Page 82: ...e PFHD Value describing the likelihood of dangerous failure per hour of a component for high demand mode or con tinuous mode Unit 1 h from EN 13611 A2 2011 11 17 Mean time to dangerous failure MTTFd Expectation of the mean time to dangerous failure from EN ISO 13849 1 2008 ...

Page 83: ...swer 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 Tel 49 541 1214 0 Fax 49 541 1214 370 info kromschroeder com www kromschroeder com Contact The current addresses of our international agents are available on the I...

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