Kromschroder BCU 465 Technical Information Download Page 2

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T-Product · BCU 465 · 2006 April

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Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 2

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BCU 465 for Modulating Control Systems . . . . . . . . . . .4

BCU 465 for Frequency Firing Systems . . . . . . . . . . . . .5

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ignition Transformer Ratings and Minimum Cycle

Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Design Information. . . . . . . . . . . . . . . . . .7

Cable Selection and Wiring . . . . . . . . . . . . . . . . . . . 7

A = Ionization line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

B = Ignition lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

C = UV cell leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . 8

Safety period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Safety Interlock (Limits). . . . . . . . . . . . . . . . . . . . . . . . . .8

Low ﬁre delay time (parameter 36) . . . . . . . . . . . . . . . . .8

Use of UVS 6, UVS 8 detectors in continous operation .8

Reset limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Operation of ﬁring systems at temperatures above

1400 °F (760 °C) . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation Information . . . . . . . . . . . . . . . . . . . 10

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Terminal Wiring BCU 465 . . . . . . . . . . . . . . . . . . .12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Program Status and Fault Indication . . . . . . . . . . .14

Normal Start-up Sequence for BCU 465 . . . . . . . .15

Safety Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Switch Power “On” . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Self-Check Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Trial for Ignition / Safety Period on start-up . . . . . . . . . .15

Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Air Valve Control of BCU 465 . . . . . . . . . . . . . . . . 16

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Air Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Pre-purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

BCU program-controlled air valve function . . . . . . . . . .16

Post-purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

External control of air valve function . . . . . . . . . . . . . . . 17

Additional Features . . . . . . . . . . . . . . . . . . . . . . . 18

Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

1400 °F (750 °C) Auto Ignition Flame Management

Bypass Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Order information. . . . . . . . . . . . . . . . . . . . . . . . 20

Factory Options and Field Programmable

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Factory options . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Control Input for Proof of Closure Switch (POC);

Parameter 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Flame Failure Response Time; Parameter 14 . . . . . . . . 21

Safety Period on Start-up; Parameter 22 . . . . . . . . . . . 21

Digital Input as 1400°F Auto Ignition Flame

Management Bypass, Parameter 33 . . . . . . . . . . . . . . 21

Field programmable options . . . . . . . . . . . . . . . . .22

Switch-off Threshold of Flame Ampliﬁer, Parameter 04 22

Restart Attempt, Parameter 12 . . . . . . . . . . . . . . . . . . 22

Flame-simulation Test in Standby Position,

Parameter 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Minimum burner on time tB, Parameter 20 . . . . . . . . . 22

Minimum burner off time tBP, Parameter 21. . . . . . . . . 22

Flame Proving Period, Parameter 23 . . . . . . . . . . . . . .23

Manual Mode Limit, Parameter 34 . . . . . . . . . . . . . . . .23

Automatic shutdown and restart after 24 h operation,

Parameter 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Reading the Parameters . . . . . . . . . . . . . . . . . . . 23

Parameter setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Optical adapter including CD-ROM „BC-Soft“ . . 26

External fastening set . . . . . . . . . . . . . . . . . . . . . 26

Angular fastening set . . . . . . . . . . . . . . . . . . . . . . 26

UVS 6T Ultraviolet ﬂame detector . . . . . . . . . . . . 26

Summary of Contents for BCU 465

Page 1: ...witch POC control input Optional digital input for 1 400 F auto ignition lockout Displays program status unit parameters fault code or ﬂame signals Optional optical interface for diagnostic information and parameter settings Manual mode for burner adjustments and trouble shooting Select restart or immediate fault lockout in the event of a ﬂame failure Removable bottom mounting plate with ﬁve 5 con...

Page 2: ...ing 16 Air Valve Control 16 Pre purge 16 BCU program controlled air valve function 16 Post purge 16 External control of air valve function 17 Additional Features 18 Manual Mode 18 1400 F 750 C Auto Ignition Flame Management Bypass Input 19 Order information 20 Factory Options and Field Programmable Options 21 Factory options 21 Control Input for Proof of Closure Switch POC Parameter 09 21 Flame Fa...

Page 3: ...start up no ignition spark occurs the display ﬂashes and indicates 02 28 At start up no gas supply the display ﬂashes and indicates 02 28 At start up ﬂame veriﬁed visually display ﬂashes and indicates 02 or 03 29 The display ﬂashes and indicates 30 29 The display ﬂashes and indicates 31 29 The display ﬂashes and indicates 32 29 The display ﬂashes and indicates 51 29 The display ﬂashes and indicate...

Page 4: ...ly monitors the burner operation The BCU is designed to mount close to the burner to reduce installation costs and simplify commissioning and troubleshooting efforts Application example BCU 465 for Modulating Con trol Systems The ﬁgure shows a typical modulat ing control system The burner is ignited when the air butterﬂy valve is in the ignition position low ﬁre Once the burner is ignited the air ...

Page 5: ...he burner is ignited the air valve is either opened or closed with a signal from a PLC or frequency controller The gas is controlled with an air fuel ratio regulator cross connected to the burner air supply piping The On and Off time is determined by the frequency control algorithm However BCU 465 provides a minimum off time and a minimum on time to slow down the process and avoid process errors i...

Page 6: ...onstructed from die cast aluminum with 5 x conduit openings for wiring devices Op tional quick disconnect plug con nectors available upon request The BCU 465 has been designed with a cycle time between two start ups This is to avoid overheating the ignition transformer as the result of excessively frequent switching Cy cling the BCU on off too quickly will lead to a fault signal The minimum cycle ...

Page 7: ... F 80 C Order No 04250409 When using one electrode for igni tion and ﬂame monitoring a direct connection from burner ground to BCU must be provided A Ionization line I 9 A Length of ionization line maximum 16 ft 5 m Note If transformer is externally mounted the sensor lead can be up to 160 ft 50 m Do not lie in parallel with ignition cable B Ignition lead Z B Length of ignition lead Recommend ed 3...

Page 8: ...etectors are used in applications for continous operation Parameter 35 should be set to 1 This forces the BCU to shut down once every 24 hrs to self check the UV detectors Reset limit In order to prevent an automatic re set from PLCs or excessive resetting by customers without monitoring the burner a reset limit of 5 resets in 15 minutes is given After 5 resets a ﬂashing 10 is shown as a warning T...

Page 9: ...A safety temperature monitor with a double thermocouple shall be used to measure the temperature A sen sor break or short circuit the failure of a component or a supply failure must result in the system being set to a safe condition Only when the temperature in the working chamber and or the wall temperature exceeds 1400 F volt age 115 Vac may the digital input be activated see Terminal wiring If ...

Page 10: ...Installation The BCU can be easily mounted at or near the burner by attaching the housing with 4 screws The holes are located on the back of housing a Screw on BCU with 4 screws from inside minimum length 5 8 b Screw on BCU from the back with 4 screws 6 mm and minimum length 5 8 88 88 88 Mount the BCU in a vertical posi tion with conduit openings pointing downwards The BCU should be a minimum of 6...

Page 11: ...mm 9 05 230 mm 1 77 45 mm BCU 74960414 8 34 212 mm 7 28 185 mm ø 0 15 4 mm Installation Information Installation Fastening sets External fastening may be used to save installation costs because the BCU does not need to be opened to install it to the system ...

Page 12: ...80 50 51 F1 T 3 15A H IEC 60127 2 5 Fuse 5 F3 T 3 15A H IEC 60127 2 5 BCU 465T C 30 31 32 33 34 35 36 37 38 N V2 6 Digital Input BCU 465T D2 BCU 465T D3 1400 F auto ignition digital input BCU 465T O OCS 7 8 9 11 10 N 230V 1 2 3 UVS Installation Information Terminal Wiring BCU 465 Electrical connections are via hard wiring to screw terminals Flexible conduit connections can be made easily through t...

Page 13: ...utton for re setting after a fault or for calling parameters onto the display During operation the 7 segment display shows the program status Should a fault occur the BCU stops the program sequence and the dis play ﬂashes displaying the sequence or fault code The ﬂame signal and all the following parameters of the BCU can be viewed on the display consecutively by repeatedly pressing the Reset Info...

Page 14: ...eriod 3 Flame failure during proving period Normal operation 4 Flame loss during operation 10 Too many romote resets Air valve operation main burner A Cooling A0 1 Proof of closure switch POC Fault Startup X POC operation fault in postion X High temperature mode 51 Fuse F1 Fault or no input from limits circuit 52 Permanent remote reset 53 Pulse ﬁring cycle too short In manual mode two dots blink s...

Page 15: ...the self check is complete and a start signal is present at terminal 4 the BCU will begin the trial for ignition sequence The gas valve output terminal 12 and terminal 14 for BCU O POC versions and the ignition transformer terminal 7 are energized The ignition time t z is constant and lasts for 3 or 6 sec onds depending on the safety period After the ignition transformer is de energized the ﬂame a...

Page 16: ... control Low ﬁre delay time parameter 36 If the gas is controlled with an air fuel ratio regulator cross connected to the burner air supply piping this time may be factory set up to 25 seconds on demand This ensures the burner is at low ﬁre before switching off when operating in an off low high low off control system Caution Use only with cross con nected ratio regulator Gas valve remains opened w...

Page 17: ... program status If parameter 31 is set to 0 the air valve cannot be activated externally on start up between start up and operation signal of the main burner Burners that are unable to start at maximum airﬂow rate use this set ting If parameter 32 is set to 1 the air valve may be activated even during a fault With setting 0 it remains closed It cannot be activated how ever when the automatic burne...

Page 18: ... to 0 2 or 0 3 Press button for 2 seconds The BCU opens valve V2 if not POC version The display changes to 0 4 Within three seconds the display shows the ﬂame signal instead of the program status to make burner adjustment easier Press button for 2 seconds The BCU returns back to stand by position Press button again for two sec onds to repeat the procedure If a fault occurs the current pro gram sta...

Page 19: ...l regu latory agencies and your insurance underwriter for additional safety re quirements and approved controllers See also Safety Considerations If the D1 input is used parameter 33 must be conﬁgured for desired opera tion of the BCU If parameter 33 2 the BCU will shut down the burner and restart when the high temperature operation has ended This is recommended if UV ﬂame detection devices are us...

Page 20: ...5 seconds low ﬁre delay time 15 seconds low ﬁre delay time 25 seconds R 115 V AC 50 60 Hz for grounded and ungrounded mains 1 2 3 8 ignition transformer TZI 5 15 100 ignition transformer TZI 7 25 20 ignition transformer TZI 7 5 12 100 ignition transformer TZI 7 5 20 33 D2 D3 1400 F Auto ignition bypass digital input shut down restart 1400 F Auto ignition bypass digital input operation resumes O C ...

Page 21: ... ﬂame loss before a safety shutdown ap plies Safety Period on Start up Pa rameter 22 The trial for ignition safety period on start up can be 5 seconds or 10 seconds This is the maximum time the gas valves may remain open without a ﬂame signal during start up until a safety shutdown applies Digital Input as 1400 F Auto Ignition Flame Management Bypass Parameter 33 If the D1 input is used parameter ...

Page 22: ...witched off in standby position 1 This allows a fast start of the burner since the waiting time tW does not need to run Prereq uisite Minimum switch off time is 4 seconds Otherwise 0 ﬂame simulation monitoring is performed after the start up signal is applied The waiting time tW expires before the burner is ignited Minimum Burner On Time tB Parameter 20 Field programmable time in the range of mini...

Page 23: ...UVS 8 UV detectors are used this function is recommended to self check the UV detector every day parameter 35 1 restart pa rameter 35 0 continue Note Description of parameters 30 31 32 and 36 through 41 see Air Valve Control of BCU 465 Reading the Parameters 0 Reading the ﬂame signals factory options and ﬁeld programmable op tions are explained as follows Press the Reset Information but ton for 2 ...

Page 24: ... in Start up 1 in Stand by 1 Minimum On Time 20 up to 25 s minimum Safety period at start up 0 Minimum Off Time 21 2 25 seconds 2 Safety period on start up tSA 22 3 5 10 s Flame proving period tFS 23 0 25 s 0 s Air valve control 30 0 only externally 1 simultaneously to V1 2 simultaneously to V2 0 Air valve on start up can be activated externally 31 0 No 1 Yes 0 External air valve control possible ...

Page 25: ...Shut down 39 0 255 seconds Activation of Pre Purge before Recycle Attempt 40 0 No 1 Yes Activation of Pre Purge after Reset 41 0 No 1 Yes Field programmable option Adjustable with software BCSoft and PC optical adapter Factory option Please state when ordering Time ignition transformer is evergized Saftey period 10 sec 6 sec safety period 5 sec 3 sec Factory Options and Field Programmable Options ...

Page 26: ...al information proc ess values and ﬂame signals External fastening set Part No 74960414 Angular fastening set Part No 74960422 UVS 6T Ultraviolet ﬂame de tector Part No 84315100 UVS 8T Ultraviolet ﬂame de tector Part No 84333120 Angular plug ø 4 mm inter ference suppressed Part No 04115308 Straight plug ø 4 mm inter ference suppressed Part No 04115307 ...

Page 27: ...ﬂame signal or a param eter is being displayed In this case press the Reset Info button until the display starts to ﬂash Note If the BCU does not respond even though all faults have been cor rected remove unit and return it to the manufacturer for inspection Assistance in the Event of Malfunction Caution Electric shocks can be fatal Disconnect electrical cables from the power supply be fore workin...

Page 28: ...o volt age signal when valve is opened during start up If the wiring is correct check the switch and the valve for proper operation Remove the valve im mediately if you have any doubt of correct operation At start up the display ﬂash es and indicates 2 The BCU has got no informa tion that the OCS contact has opened Make sure that the wiring is cor rect The BCU needs line voltage when valve is clos...

Page 29: ...ments in chapter System De sign Information The display ﬂashes and indi cates 31 The unit has suffered an internal unit fault Make sure that you meet require ments in chapter System De sign Information Remove the unit and return it to the manufacturer for inspection The display ﬂashes and indi cates 32 The supply voltage of the unit is below the rated voltage Ensure correct voltage supply maximum ...

Page 30: ...s than the minimum time Comply with Table Minimum Cy cle Times The display ﬂashes and indi cates 10 The BCU is repeatedly reset more than 5 times in 15 min utes Avoid automatic reset by PLC or without monitoring the burner Reset BCU manually BCU does not start even though all faults have been cor rected and the BCU has been reset Remove unit and return it to the manufacturer for inspection Trouble...

Page 31: ... Underwriters recommendation and care of operation We reserve the right to make technical changes designed to improve our products without prior notice For current product information visit our website at www kromschroder com Contact G Kromschröder AG Strotheweg 1 D 49504 Lotte Büren Tel 49 0 5 41 12 14 0 Fax 49 0 5 41 12 14 370 KROMSCHRODER INC 1595 H Georgetown Rd Hudson OH 44236 Ph 330 342 0595...

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