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Krom Schroder PFU 780, Technical Information, Page: 1 / 70

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6 

Edition 02.12

AGA

Technical Information · GB

Burner control unit PFU 780

• 

For pilot and main burners of unlimited capacity in thermoprocessing 

equipment pursuant to EN 746-2

• 

Plug-in function unit for mounting in 19" module subracks

• 

Separate flame control for pilot burner and main burner by UV,  

ionisation 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

• 

Visualisation and adaptation to the specific application via the PC 

programming and diagnostic software BCSoft to simplify logistics 

management

• 

Air valve control relieves the furnace control

• 

Certified for systems up to SIL 3 and compliant with PL e

Summary of Contents for PFU 780

Page 1: ...and main burner by UV ionisation 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...

Page 2: ...ur during start up 30 4 5 1 Safety time on start up tSA 30 4 5 2 Flame proving period tFS 31 4 5 3 Minimum combustion time tB 31 4 5 4 Burner start up attempts 32 4 6 Behaviour during operation 34 4 6...

Page 3: ...ed parameters stickers 55 8 5 Radio interference suppressed electrode adapters 56 8 6 Socket connectors 56 8 7 Module subrack 56 8 8 Power supply PFP 700 57 8 9 Relay module PFR 704 58 8 10 Field bus...

Page 4: ...rial furnaces the PFU 780 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...

Page 5: ...PFU 780 Edition 02 12 5 Application Bogie hearth forging furnace in the metallurgical industry Intermittent shuttle kiln in the ceramics industry Walking beam furnace with overhead firing...

Page 6: ...er Control Main burner ON OFF The main burner can be started with reduced capacity after the operating signal from the pilot burner has been detected The pilot burner is switched off automatically aft...

Page 7: ...06 08 04 2 1 1 2 C 1 2 26a Application Examples of application 1 1 2 Stage controlled main burner with permanent pilot burner Control Main burner ON OFF The main burner can be started with reduced cap...

Page 8: ...Control Main burner continuous The butterfly valve for air BV is moved to ignition position in order to start the main burner The main burner can be started at low fire rate after the operat ing sign...

Page 9: ...ature equipment The flame is controlled indirectly on the basis of the temperature During the start up process as long as the wall temperature is below auto ignition tem perature the flame must be con...

Page 10: ...certified pursuant to Gas Appliances Directive 2009 142 EC in conjunction with EN 298 2004 01 Meets the requirements of the Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC PFU T is FM appr...

Page 11: ...V c2 10c 12c 10a 12a 30e 22a P DI A 2 1 1 N 2 28c 26a 1 2 14a 14e 10e 12e 24c 20c 18a l 20c 18a N 26a 26a N 28c 28c 18a Z I UVS 1 2 3 24c L N M V2 V1 C C SK A S PFU 780 3 Function 3 1 Connection diag...

Page 12: ...c1 24 V 0 V c2 10c 12c 10a 12a 30e 22a P DI A 2 1 1 N 2 28c 26a 1 2 14a 14e 10e 12e 24c 20c 18a l 20c 18a N 26a 26a N 28c 28c 18a Z I UVS 1 2 3 24c L N M V2 V1 C C SK A S PFU 780 K2 Function Connecti...

Page 13: ...pilot burner has been started suc cessfully and its flame has stabilised the burner control unit issues the Enable signal for main burner operation The operation signalling contact for the pilot burne...

Page 14: ...inals 14a and 14e the PFU 780 opens valve V2 The main burner is ignited by the pilot burner If a flame is detected during the safety time tSA2 the flame proving period tFS2 starts after the safety tim...

Page 15: ...ils during operation either an immediate fault lock out occurs or a restart occurs This procedure can be set via the optical interface parameter 13 Main burner restart Function PFU 780 program sequenc...

Page 16: ...e 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 dur...

Page 17: ...6 Short circuit on ignition or valve output 51 Safety interlock failure 52 Permanent reset 53 Time between two start ups is too short In Manual mode two dots will blink on the display in program statu...

Page 18: ...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 combustion time tB 20 2...

Page 19: ...ive 1 Function active On parameterisation ensure that the program sequence started matches the application Select the parameters so that the burner can restart as intended in all operating phases 4 1...

Page 20: ...gram position the unit was in when the fault was detected waiting 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 flam...

Page 21: ...fety function of the device internal flame control system is placed out of operation In High temperature mode the gas valves are opened without flame control The precondition for high temperature oper...

Page 22: ...re FA When High temperature mode is ended the PFU switches off the burner and restarts with flame simulation check recom mended in the case of UV control with UVS Parameter 33 2 06 07 08 08 t tSA2 tFS...

Page 23: ...t 04 04 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e 22a V1 1 V2 2 1 2 2 1 DI Fault main burner 08 t 08 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e 22a V1 1 V2 2 1 2 2 1 DI P...

Page 24: ...ach time the start up signal is applied Parameter 35 0 Unlimited burner operation Parameter 35 1 An automatic restart is activated once every 24 hours It must be ensured in this case that the program...

Page 25: ...pilot burner t 1 2 1 2 88 02 04 06 08 04 06 08 04 For applications which require a high system availability or where a continuously burning flame is necessary The pilot burner is ignited once and rema...

Page 26: ...d main burner monitoring Operating mode Intermittent pilot burner Start up as in the illustration Permanent pilot burner with the difference being that the start up signal for pilot and main burners i...

Page 27: ...as elapsed In this setting the flame signal can be connected to terminals 18a or 26a The pilot burner is switched off after the main burner safety time tSA2 has elapsed Parameters Pilot and main burne...

Page 28: ...ected by the main burner Parameter 15 0 The flame simulation check is conducted after applying the start up signal during the waiting time tW Parameter 15 1 The flame simulation check is conducted pro...

Page 29: ...he pause time After the pause time the burner is started if the start up signal is applied The minimum burner pause time tBP serves to adapt the pro gram sequence to the requirements of the applicatio...

Page 30: ...02 03 00 t tFS 26a 16c 18e 2c 4c 88 10e 26e 30a 28c 2e 4e V1 1 V2 1 1 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 26a 16c 1...

Page 31: ...25 s This time elapses before the PFU starts the next program step so as to give the flame time to stabilise 4 5 3 Minimum combustion time tB Parameter 20 Programmable time to maximum 25 s during whic...

Page 32: ...by FM Approval see type label it is only possible to select one start up attempt 1 start up attempt Parameter 10 1 tSA tZ 02 00 t 02 26a 16c 18e 2c 4c 88 10e 26e 30a 28c 2e 4e V1 V2 1 If no flame for...

Page 33: ...empt Parameter 11 1 tSA1 tZ 04 06 02 03 00 t tFS1 tSA2 06 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e V1 1 V2 2 1 2 2 1 If no flame forms during the start up of the main burner a fault lo...

Page 34: ...ock out or restart pilot burner Parameter 12 This parameter determines whether the PFU starts a one off restart or performs an immediate fault lock out for the burner after an installation fault such...

Page 35: ...he 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 conducted only if the safety of the installation is...

Page 36: ...within the safety time during operation tSB This in volves disconnecting the power from the gas valves and the ignition transformer The fault signalling contact closes the display blinks and shows the...

Page 37: ...urner 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 conducted only if the safety of the...

Page 38: ...r a normal shut down 4 7 1 Purge Parameter 42 0 The air valve is closed when voltage is applied to terminal 30e Parameter 42 1 The air valve is opened when voltage is applied to terminal 30e In the ca...

Page 39: ...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 link and which also nee...

Page 40: ...2 1 2 2 1 VAG PFU 780 L A P L1 1 2 VAS TZI 2 1 UV VAS 1 Parameter 30 0 The air valve opens if it is activated externally via input 10a Parameter 31 1 The air valve can be activated even during start u...

Page 41: ...6a 6e V1 1 V2 2 1 2 2 1 PFU 780 L A P L1 1 2 VR R VAG VBY TZI 2 1 SPS PLC CPE Parameter 30 2 The air valve opens simultaneously with valve V2 Application Single stage controlled main burner is switch...

Page 42: ...2 1 2 2 1 PFU 780 L A P L1 1 2 VR R VAG VBY TZI 2 1 SPS PLC CPE Parameter 30 3 The air valve opens simultaneously with the operating signal Application Two stage controlled main burner is switched ON...

Page 43: ...during the closing time increases the O2 content in the com bustion chamber Parameter 36 3 5 10 15 25 or 60 low fire over run time tKN 3 5 10 15 25 or 60 s The air valve closes slowly after the activa...

Page 44: ...ther the air valve can be activated in the case 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 10a Parameter 32 1 The...

Page 45: ...xt section of the program sequence and stops there After approx 3 s the flame signal will be displayed instead of the program parameter Briefly pressing the Reset Informa tion button 1 s displays the...

Page 46: ...parameter settings a password is stored in parameter 50 Changes to parameter settings can only be made once this number has been entered The password can be changed using BCSoft Note the effect of pa...

Page 47: ...PFU 780 Edition 02 12 47 5 Selection 5 1 Calculating the safety time tSA...

Page 48: ...rd available Order example PFU 780LT 5 2 1 Type code Code Description L Air valve control Mains voltage T 220 240 V 15 10 50 60 Hz N 110 120 V 15 10 50 60 Hz D Digital input to interrupt flame control...

Page 49: ...o not lay UV ionisation cable and ignition cables together and lay them as far apart as possible 6 1 2 Ionisation cable Use unscreened high voltage cable see page 55 Acces sories Cable length max 100...

Page 50: ...on time only has an effect on the behaviour of the main burner The minimum combustion time for the pilot burner is limited to the safety time on start up tSA1 Background The pilot burner is only used...

Page 51: ...The malfunction can not be remedied by changing the method of activation 6 6 4 Burner start A furnace start may only be initiated if it has been ensured using an appropriate procedure that there is n...

Page 52: ...tion is permitted Cable length between PFU and burner max 100 m 6 10 Wiring The PFU is suitable for hard wiring only Do not reverse phase and neutral conductor Different phases of a three phase curren...

Page 53: ...with EN 50156 it does allow the burner to be isolated functionally from the central control system This function is required for manual operation and in the case of PROFIBUS units to switch off the un...

Page 54: ...ust be interrupted at least once every 24 hours This can be programmed using parameter 35 For further information see brochure UVS The burner control unit PFU U is prepared for UV sensor UVD 1 This en...

Page 55: ...17 5 mm Colour silver 8 4 Changed parameters stickers D 49018 Osnabr ck Germany Achtung ge nderte Parameter Die Angaben auf dem Typenschild gelten nicht mehr in vollem Umfang Aktuelle Parameter direkt...

Page 56: ...printed circuit board with rear terminal strip function tested standard documentation guide rails without partial front plates screw terminals at the rear single zone operation for MPT 700 operating m...

Page 57: ...wer supply PFP 700 For supplying the control inputs of burner control unit PFU or for supplying the auxiliary voltage to relay module PFR 704 Operating status display on the front plate PFP switches o...

Page 58: ...230 V 24 V 115 V 230 V 24 V 115 V 230 V 24 V 8 9 Relay module PFR 704 For contact multiplication e g if several air valves are activated via a single control signal for pre purge or for heating cool...

Page 59: ...FU 19c 17b 30e 26e PFU 24 V L1 PROFIBUS DP Accessories 8 10 Field bus interface PFA 700 For connection of up to nine automatic burner control units PFU 760 to industrial communication networks using P...

Page 60: ...lated thanks to intermittent operation and thereby constant temperature distribution and shorter heating up periods for all gas fired heat treatment furnaces are ensured Mains voltage 95 240 V AC 10 5...

Page 61: ...20 V 0 40 V Frequency 50 60 Hz 50 60 Hz Rated value 24 V DC Signal 1 24 V 10 Signal 0 1 V Inherent current Signal 1 typ 5 mA Output voltage for voltage related outputs mains voltage Contact rating Gas...

Page 62: ...ursuant to IEC 127 2 5 Ambient temperature 20 to 60 C 4 to 60 00 C Climate no condensation permitted Enclosure IP 00 pursuant to IEC 529 after installing in a 19 module subrack according to the in str...

Page 63: ...e PFHD 1 34 x 10 8 l h Mean time to dangerous failure MTTFd Safe failure fraction SFF 99 2 The specified values apply for the combination with ionization electrode sensor and PFU 780 logic Relationshi...

Page 64: ...3 HE 133 4 5 3 8 TE 40 6 1 6 9 2 Operating controls A 2 digit 7 segment display B Reset Information button to reset the system after a fault or to scan parameters on the display C Mains switch D Optic...

Page 65: ...PFU 780 Edition 02 12 65 10 Maintenance cycles Burner control unit PFU requires little servicing...

Page 66: ...ilot 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 o...

Page 67: ...starts to elapse Voltage is supplied to the pilot gas valve V1 and the ignition transformer and the burner is ignited The duration of the ignition time is either 2 3 or 7 seconds depending on safety...

Page 68: ...e voltage supply 12 9 Pilot gas valve V1 The start fuel flow rate for the pilot burner is released by pilot gas valve V1 It opens when the safety time on start up tSA1 starts to elapse It remains open...

Page 69: ...High demand mode or continuous mode Operating mode where the frequency of demands for opera tion made on a safety related system is greater than one per year or greater than twice the proof test frequ...

Page 70: ...the product To choose a product Planning To look for information My scope of functions Technical department Sales No answer Remarks Adobe Reader 7 or higher required www adobe com Elster GmbH Postfac...

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