Kromschroder FCU 500 Technical Information Download Page 10 | Manualshive

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FCU 500, FCU 505 · Edition 02.17

10

Application

1 .1 .2 Modulating burner control

For processes that do not require
heavy circulation in the furnace, e.g.
aluminium smelting furnaces.

This system is suitable for process-

es in which infiltrated air may flow
into the furnace through switched
off burners. The capacity can be
adjusted continuously by activating
the air control valve (analogue or

3-point step signal). The pneumatic

ratio control system controls the
gas pressure proportionally 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.
One burner control unit per burner
is required for ignition and monitor-
ing.

The centrally checked safety func-

tions such as pre-purge, setting the
valve to ignition position via a but-
terfly valve control system, tight-
ness test, flow detector and pres-
sure switch check (gas

min.

, gas

max.

,

air

min.

) are provided by the FCU 500.

FCU 500..F1

µC

P

DG

DG

DG

VAS

VAS

VCG

VCG

DG

min

DG

max

49

15

13

14

50

53

45

47 48

58

p

u

/2

M

PZL

PZH

PZ

PZL

PDZ

TE

BCU 460..L

BCU 460..L

M

M

TC

90°

➔

0°

0°

➔

90°

54

55

VAS

DG

DG

>750°

ϑ

1

2

3

DL

min

DL

Purge

46

STM

«
...
8
9
10
11
12
...
»

Summary of Contents for FCU 500

Page 1: ...valve system leak tightness check optional Safety temperature monitor STM or safety temperature limiter STL optional Long service life due to replaceable power module for fail safe outputs Visualization and adaptation to the specific application via the PC programming and diagnostic software BCSoft to simplify logistics management Protective system controls FCU 500 FCU 505 ...

Page 2: ... control 27 5 1 Controlled air flow 28 5 2 Capacity control 29 6 Furnace zone control 31 7 Valve proving system 33 7 1 Tightness control 34 7 1 1 Test instant 35 7 1 2 One test volume between 2 gas solenoid valves 36 7 1 3 One test volume for system tightness 39 7 1 4 Two test volumes for system tightness 42 7 1 5 Large test volumes with reduced testing time 46 7 2 Test period tP 48 7 2 1 For one ...

Page 3: ... 5 6 Measurement time Vp1 110 12 5 7 Measurement time Vp1 and Vp2 110 12 5 8 Valve opening time 1 tL1 112 12 5 9 Valve opening time 2 tL2 112 12 6 Behaviour during start up 113 12 6 1 Minimum pause time tMP 113 12 6 2 Switch on delay time tE 113 12 6 3 Filling time before start up 113 12 7 Manual mode 114 12 7 1 Operating time in Manual mode 114 12 8 Functions of terminals 51 65 66 67 and 68 115 1...

Page 4: ...n 137 17 3 Electrical connection 137 17 4 Installation 138 17 5 Selection 138 17 6 Technical data 138 18 Technical data 139 18 1 Electrical data 139 18 2 Mechanical data 140 18 3 Environment 140 18 4 FCU H1 140 18 5 Dimensions 140 18 6 Safety specific characteristic values 141 18 7 Converting units 142 19 Maintenance 143 20 Legend 144 21 Glossary 145 21 1 Safety shut down 145 21 2 Fault lock out 1...

Page 5: ...ntegrated safety temperature monitor or safety temperature limiter integrated tightness control and with an interface for controlling the capacity of actuators or a frequency converter interface The program status and device parameters can be read directly from the unit The FCU can be activated manu ally using the integrated Manual mode for setting and diagnostic purposes Thanks to the optionally ...

Page 6: ...ead of standard control units The program status statistics parameter values 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 Thanks to the operator control unit OCU display functions and operation of the FCU can be relocated to the control cabinet door The optional bus module BCM 500 m...

Page 7: ...FCU 500 FCU 505 Edition 02 17 7 Application Roller hearth kiln in the ceramics industry Shaft melting furnace Smelting and holding furnace ...

Page 8: ...means of a variable ratio of the operating time to the pause time In this type of control the burner output pulse frequency always maintains full momentum and results in maximum convection in the furnace chamber even with regulated heating The pneumatic ratio control sys tem controls the gas pressure on the burner proportionally to the air pressure and thus maintains a con stant air gas ratio At t...

Page 9: ...he centrally checked safety func tions such as pre purge tightness test flow detector and pressure switch check gasmin gasmax airmin are provided by the FCU 500 M PZL PZH PZ PZL PDZ TE M BCU 460 L BCU 460 L FCU 500 F0 µC P DG DG DG VAS VAS VAS VCG VCG 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 STM ...

Page 10: ...sure proportionally 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 One burner control unit per burner is required for ignition and monitor ing The centrally checked safety func tions such as pre purge setting the valve to ignition position via a but terfly valve control system tight ness test flow detector and pres s...

Page 11: ...al To ensure that the correct air vol ume is available for ignition start fuel flow rate when starting the burners the FCU sends the burner start enable signal to the BCUs via the LDS limits during start up output The circuit design of the safety interlock and LDS outputs on the FCU and the corresponding in puts on the BCUs ensures that the burners can only start if the safety interlocks and the L...

Page 12: ...T output that the furnace sys tem is in High temperature mode HT When the HT in put is activated the burner control units switch to High temperature mode They operate without evaluation of the flame signal and their internal flame control system is non functional If the furnace temperature falls below the spontaneous ignition temperature 750 C the FCU disconnects the HT output from the electrical ...

Page 13: ...e FCU 500 furnace FCU performs central tasks such as checking the safety interlocks fan control sys tem leak tightness check and pre purge It signals to the FCU 505 in the zones that the butterfly valves can be moved to the purge position Signals are sent to the butterfly valves by the FCU 505 The but terfly valves move into position A signal is sent to the FCU 505 via their safety interlock input...

Page 14: ...rements of the Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC FM approved Factory Mutual Research Class 7610 Combustion Safe guards and Flame Sensing Systems Suitable for applica tions pursuant to NFPA 86 www approvalguide com ANSI CSA approved American National Standards Institute Canadian Standards Association ANSI Z21 20 CSA C22 2 No 199 www csagroup org Class number 3335 01 natural...

Page 15: ...on see page 120 Project planning information Explanation of symbols see page 144 Legend 1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68 41 42 16 17 18 57 13 14 15 53 54 55 56 62 61 5 6 7 8 11 12 N P HT ϑ 0 V L1 V1 V2 V3 LDS FCU 505 K2 K1 k11 k21 3 15AT µC 24V DC 88 M 24 V PZL PDZ PZL PZH P70 P71 P73 P72 P69 PZL PDZ PZL PZH P70 P71 P73 P72 pu 2 GZL PZL 58 5AT 44 FCU 500 Airmin Air STM STL Gasmax Gasmin...

Page 16: ...age 120 Project planning information Explanation of symbols see page 144 Legend 1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68 41 42 16 17 18 57 13 14 15 53 54 55 56 62 61 5 6 7 8 11 12 N P HT ϑ 0 V L1 V1 V2 V3 LDS FCU 505 K2 K1 k11 k21 3 15AT µC 24V DC 88 M 24 V PZL PDZ PZL PZH P70 P71 P73 P72 P69 PZL PDZ PZL PZH P70 P71 P73 P72 pu 2 GZL PZL Airmin Air STM STL Gasmax Gasmin 0 6 IN IN 0 6 ...

Page 17: ... the integrated temperature module of the FCU H1 11 12 V AC input Supply voltage Voltage to operate the FCU 11 phase L1 12 neutral conductor N 13 Safety circuit output Gas valve V1 Connection of phase for gas valve V1 14 Gas valve V2 Connection of phase for gas valve V2 15 Gas valve V3 Connection of phase for gas valve V3 57 Safety interlocks limits Safety enable signal to the burner control units...

Page 18: ...ost purge see Parameters 35 38 49 Minimum gas pressure Connection for pressure switch to monitor the minimum gas pressure see Parameter 13 50 Maximum gas pressure Connection for pressure switch to monitor the maximum gas pressure see Parameter 12 51 65 66 67 68 Programmable inputs The terminals can be assigned a function using parameters To do so logical AND gatings with terminals 46 47 48 49 or 5...

Page 19: ... position standby H0 Start up with ϑ signal Switch on delay time tE running parameter 63 Safety interlocks check 01 Fan run up time tGV running parameter 30 Pre purge starts 1 Air flow monitoring P1 Pre purge time tPV running parameter 34 Tightness test if equipped with TC 08 Gas enable via valves V1 and V2 Enable signal to burner control units for the burner start via the safety interlock output ...

Page 20: ...nterlocks check 01 Fan run up time tGV running parameter 30 Pre purge starts A Actuator moves to the position for maximum capacity 1 Air flow monitoring P1 Pre purge time tPV running parameter 34 Tightness test if equipped with TC A Actuator moves to the position for ignition capacity H7 Gas enable via valves V1 and V2 Enable signal to burner control units for the burner start via the safety inter...

Page 21: ...Start up with ϑ signal Switch on delay time tE running parameter 63 Safety interlocks check 01 Fan run up time tGV running parameter 30 Pre purge starts A Actuator moves to the position for maximum capacity P1 FCU 500 pre purge time tPV running Tightness test if equipped with TC A Actuator moves to the position for ignition capacity H8 Controller enabler signal delay time tRF running 08 Operation ...

Page 22: ... bottom of the window as on a DVD player To play the animation you will need Adobe Reader 9 or a newer version If you do not have Adobe Reader on your system you can download it from the Internet Go to www adobe com click on Adobe Reader at the bottom of the page and follow the instructions If the animation does not start to play you can down load it from the document library www docuthek com as a...

Page 23: ...perature Double thermocouples are connected to the temperature module to measure the temperature The functions STM and STL can also be combined In this case the connected double thermocouple must re liably detect whether the spontaneous ignition temper ature 750 C has been exceeded and also whether the maximum permitted furnace temperature has been exceeded The safety temperature monitor and safet...

Page 24: ... power supply As soon as the signal to the HT inputs of the burner control units is no longer present the flame signals are once again monitored by a UV sensor or flame rod In the event of a fault in a temperature monitoring com ponent e g sensor discontinuity sensor short circuit or in the event of a mains failure the flame control task is transferred to the burner control units Either the temper...

Page 25: ...e during high temperature operation FCU 50x H0 FCU 50x H1 M BCU 4xx D µC 9 BCU 4xx D µC 9 HT 18 6 6 HT HT 66 STM 4 1 3 With integrated and external STM The integrated temperature module can also be used in conjunction with an external safety temperature moni tor STM The spontaneous ignition temperature can then be monitored at two different points in the furnace FCU 50x H1 M BCU 4xx D µC 9 BCU 4xx...

Page 26: ...ithin the permit ted temperature range e g sensor discontinuity sensor short circuit the FCU will perform a fault lock out The safety interlock output will no longer be set The temperature module integrated in the FCU H1 or an external safety temperature limiter STL can be used for this function 4 2 1 With integrated STL FSTL FCU 50x H1 M BCU 4xx D 9 BCU 4xx D 9 BCU 4xx D 9 57 5 5 5 8 STL 4 2 2 Wi...

Page 27: ... 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 580 F3 VAG VAS VAS M PZL PDZ BCU 580 F3 FCU 500 F0 µC P VR L VR L DG DG 49 15 13 14 50 45 47 48 58 750 ϑ 1 46 2 3 DLmin DLPurge BCU 580 F3 M STM The capacity control function provided by the FCU 500 F1 F2 and FCU 505 F1 F2 allows an additional cen tral actuator or a frequency con...

Page 28: ... 81 Low air pressure protection page 88 Air monitoring during controlled air flow and page 89 Air flow monitoring during pre purge The controlled air flow function is no longer performed once the start up signal has been received at terminal 1 1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68 41 42 16 17 18 57 13 14 15 53 54 55 56 62 61 5 6 7 8 11 12 N P HT ϑ 0 V L1 V1 V2 V3 LDS FCU 505 K2 K1 k11 k21 3 ...

Page 29: ...ended limits during start up pre purge and also tightness test for FCU C1 the gas enable signal is issued via the valve outputs V1 terminal 13 and V2 terminal 14 and the burner start enable signal is issued to the burner control units via the safety interlock output termi nal 57 The correct air volume for ignition start fuel flow rate must be available for each burner start restart or start up att...

Page 30: ...tion For pertinent parameter set tings see page 101 Burner operating signal BCU V1 BCU V1 FCU 500 F1 µC 54 55 53 1 67 BCU F0 24V L1 M 4 24V 4 54 55 53 M Depending on parameter 40 actuators IC 20 and IC 40 an actuator with an RBW interface or a fan controlled by a frequency converter can be actuated via the out puts for central capacity control see page 91 Ca pacity control ...

Page 31: ...one control 6 Furnace zone control For furnace zone control one FCU 500 is used to control the furnace and several FCU 505 are used to control the individual modulating zones FCU 505 F1 or FCU 505 F2 When connecting several FCUs in a circuit a hierarchical operating structure is applied The furnace FCU FCU 500 performs central tasks such as checking the central safety functions fan con trol system...

Page 32: ...he zone FCUs via the input at terminal 66 that they should move the actuators to purge position After the purge and the tightness test if applicable has been ended the furnace FCU signals to the zone FCUs via the input at terminal 46 that burner start is enabled When they receive this signal the zone FCUs move the valves to ignition position for starting the burners and then issue the enable signa...

Page 33: ...can be checked using a POC switch see page 57 Proof of closure function Once the test has been carried out successfully the furnace is enabled for start up The tightness control function satisfies the require ments of EN 1643 Valve proving systems for automat ic shut off valves for gas burners and gas appliances By checking the closed position using the proof of clo sure function the FCU complies ...

Page 34: ...000 Btu h The FCU offers several ways of testing tightness 1 Between 2 gas solenoid valves with one test volume parameter 53 1 V2 pu Vp1 V1 PZ pu 2 2 The system tightness of a complete gas inlet section with one test volume and pressure reduction using a relief valve parameter 53 2 V1 PZ Vp1 pu pu 2 V3 3 The system tightness of a complete gas inlet section with two test volumes and pressure reduct...

Page 35: ...llel to the pre purge time The gas line is always safeguarded by a gas solenoid valve during this check When pre purge is finished and the tightness has been checked suc cessfully the safety valves for operating the system are opened after the safety interlocks have been enabled After furnace shut down 08 00 ϑ TC Test 1 2 1 13 14 57 42 t tPN After the furnace has been shut down the FCU starts test...

Page 36: ... One test volume between 2 gas solenoid valves PZL PZH FCU 500 C1 µC P 49 13 14 50 45 45 47 58 48 pu 2 TC PZ PZL PDZ M 750 ϑ 1 2 3 pu 2 PZ Vp1 V1 V2 pu pz pd The tightness control checks the tightness of the test volume Vp1 between gas solenoid valves V1 and V2 ...

Page 37: ... If pressure pZ is greater than half the inlet pressure pu 2 valve V2 is tight 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 tigh...

Page 38: ...or the set opening time tL V1 closes again During the measurement time tM the 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 downstream of V2 is around atmospheric pressure tL P59 tM P56 pZ pu 2 OK V1 V1 V1 OK V2 V1 V2 pZ pu 2 tL P59 tM P56 V2 V2 tL P59...

Page 39: ...µC P 49 15 13 14 50 45 47 58 48 pu 2 TC PZ PZL PDZ M 750 ϑ 1 2 3 pu 2 PZ Vp1 V1 V3 pu pz The tightness control checks the system tightness of the test volume Vp1 between the central shut off valve V1 relief valve V3 and the burner valves The opening times of the relief valve V3 and the shut off valve V1 are identical ...

Page 40: ...essure pZ is greater than half the inlet pressure pu 2 test volume Vp1 is tight Valve V3 is opened for the set opening time tL V3 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 tig...

Page 41: ...ening time tL V1 closes again During the measurement time tM the tightness control checks the pressure pZ between the valves If pressure pZ pu 2 test volume Vp1 is tight If pressure pZ pu 2 test volume Vp1 is leaking The tightness test can only be performed if pressure pd downstream of V3 is around atmospheric pressure tL P59 tM P56 tL P59 tM P56 pZ pu 2 Vp1 OK pZ pu 2 V1 OK V1 Vp1 OK V1 V1 V1 OK ...

Page 42: ...alve V3 is opened to reduce the pressure of the test volume Vp2 to around atmospheric pressure The opening time for V3 can be defined using parameter 55 see page 110 Opening time relief valve V3 The tightness con trol queries the pressure pZ using the external pres sure switch to check the first test volume If pressure pZ pu 2 program A starts see page 43 Program A If pressure pZ pu 2 program B st...

Page 43: ...ses again During the measure ment time tM set in parameter 56 the tightness control checks the pressure pZ between the valves V1 and V2 If pressure pZ pu 2 valve V2 is leaking If pressure pZ pu 2 valve V2 is tight Valve V2 opens for the opening time tL set in param eter 59 V2 closes again During the measurement time tM the tightness control checks the pressure pZ between the valves If pressure pZ ...

Page 44: ...again During the measure ment time tM set in parameter 56 the tightness control checks the pressure pZ between the valves V1 and V2 If the pressure pZ pu 2 valve V1 is leaking If the pressure pZ pu 2 valve V1 is tight Valve V1 opens for the opening time tL set in param eter 59 V1 closes again During the measurement time tM the tightness control checks the pressure pZ between the valves If pressure...

Page 45: ...2 are connected to each other After a waiting time of 1 s valve V1 opens for the opening time tL set in parameter 59 Valve V1 then closes and the measure ment time set in parameter 57 starts to elapse see page 110 Measurement time Vp1 and Vp2 After the measurement time has elapsed the tightness control checks pressure pZ If pZ pu 2 the test volume Vp2 is leaking relief valve V3 the burner valves o...

Page 46: ...pres sure pu the second one to of the inlet pressure Parameter 70 must be set to 1 for this purpose see page 116 Function of terminal 65 Program sequence The tightness control queries the pressure pZ using the first pressure switch pu 4 If pressure pZ pu 4 program A starts see page 47 Program A reduced testing time If pressure pZ pu 4 program B starts see page 47 Program B reduced testing time PZL...

Page 47: ...t 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 pu 4 valve V1 is tight If pressure pZ pu 4 valve V1 is leaking Program B reduced testing time Valve V2 opens for the opening time tL set in param eter 59 V2 closes again During the measurement time tM the tightness control ch...

Page 48: ...7 58 48 pu 2 TC PZ PZL PDZ M 750 ϑ 1 2 3 pu 2 PZ Vp1 V1 V2 pu pz pd The test period tP is calculated from Opening times tL for V1 and V2 Measurement times tM for V1 and V2 tP s 2 x tL 2 x tM 7 2 2 For one test volume Vp1 for system tightness PZL PZH FCU 500 C1 µC P 49 15 13 14 50 45 47 58 48 pu 2 TC PZ PZL PDZ M 750 ϑ 1 2 3 pu 2 PZ Vp1 V1 V3 pu pz The test period tP is calculated from Opening time...

Page 49: ...p2 see page 42 Two test volumes for system tightness and page 110 Opening time relief valve V3 Opening times tL for V1 and V2 to check the test vol ume Vp1 and test volumes Vp1 Vp2 see page 42 Two test volumes for system tightness Measurement times tM for V1 and V2 to check the test volume Vp1 parameter 56 see page 110 Measurement time Vp1 Waiting time 1 s Measurement time tM to check the test vol...

Page 50: ...the test volume pressure bypass valves with an extended opening time may be used e g VAS 1 or bypass valves with an additional orifice 1 Tightness test between 2 gas solenoid valves with one test volume parameter 53 1 VK VK VAS 1 VAS 1 14 13 57 V1 V2 2 System leak tightness check with one test volume and pressure reduction using relief valve parameter 53 2 57 VK V3 V1 13 VAS 1 15 3 System leak tig...

Page 51: ... h 100 000 l h 0 05 50 l h Required opening time tL tL s 400 VO ρ π d2 0 7 2 pu VO l h max gas volume in combustion chamber 50 l h d mm orifice diameter of bypass valve 9 45 mm flow factor 0 7 pu mbar inlet pressure 20 mbar ρ kg m3 density of gas 0 8 kg m3 tL s 400 50 l h 0 8 kg m3 14 26 s 3 14 9 452 0 7 2 20 mbar Enter the next lowest value for parameter 59 P59 14 to set the opening time see page...

Page 52: ...orifice diameter Set the next lowest value for parameter 59 to set the opening time see page 112 Valve opening time 1 tL1 Calculating the extended valve opening time Gas type Lower calorific value Density ρ Capacity P Inlet pressure pu VAS 1 on main valve or orifice diameter d Opening time tL Metric Imperial Nominal flow rate Q N Max gas volume in combustion chamber VO Erdgas H 914 BTU scf 0 049 l...

Page 53: ...est volume see page 54 Test volume Vp For one test volume Vp1 between 2 gas solenoid valves or for system tightness Adjustable using parameter 56 tM s 2 pu x Vp1 QL For a large test volume Vp1 with reduced testing time Adjustable using parameter 56 tM s 0 9 pu x Vp1 QL For two test volumes for system tightness Vp1 Vp2 Adjustable using parameter 57 tM s 2 pu x Vp1 Vp2 QL For two large test volumes ...

Page 54: ...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 test volumes Vp1 and Vp2 must be set on the basis of the calculation using parameters 56 and 57 For the calcul...

Page 55: ...Vp Test volume Vp2 300 l assumed as an example Measurement time for one test volume Vp1 between 2 gas solenoid valves or for system tightness Parameter 53 1 between 2 gas solenoid valves parameter 53 2 for system tightness venting via V3 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 110 Measurement time Vp1 Measurement time fo...

Page 56: ... x 50 mbar x 32 45 l 7 3 s 200 l h Set the next highest value 10 s using parameter 56 see page 110 Measurement time Vp1 Measurement time for two large test volumes Vp1 Vp2 with reduced testing time Parameter 53 3 parameter 70 1 tM s 0 9 x 50 mbar x 32 45 l 300 l 74 8 s 200 l h Set the next highest value 80 s using parameter 57 see page 110 Measurement time Vp1 and Vp2 ...

Page 57: ... function the FCU complies with the requirements of NFPA 85 Boiler and Combustion Systems Hazards Code and NFPA 86 Standard for Ovens and Furnaces Program sequence Parallel to the fan run up time see page 19 Pro gram sequence the FCU checks that valve V1 is in its closed position using the POC switch If a signal is not received at terminal 45 from the POC switch after a timeout time of 10 s valve ...

Page 58: ...vice pa rameters on Windows based PCs in order to adjust the FCU to the specific application In addition BCSoft pro vides 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 131 BC Soft ...

Page 59: ...hout functional safety Profinet and Modbus TCP are bus variants for fieldbus communication optimized for speed and low connec tion costs 1 2 3 BCU 5xx BCM BCU 5xx BCM BCU 5xx BCM L1 BUS FCU P HT BCM B2 PROFINET BCM B4 Modbus TCP SPS The basic function of Profinet and Modbus TCP is the exchange of process and required data between a controller e g PLC and several distributed devices e g BCU FCU The...

Page 60: ... port switch This allows the BCM 500 together with the FCU to be integrated in various network topologies star tree or line topology Requirements such as Auto Negotia tion and Auto Crossover are satisfied Safety related signals and interlocks e g safety in terlock must be routed independently of the fieldbus communication direct from the FCU to the burner con trol units e g BCU and vice versa FCU ...

Page 61: ...of the PLC The GSD file contains the device image the communications properties and all fault messages from the device in text form which are important for the configuration of the Profinet network and the data exchange Modules defined in the GSD file may be selected for configura tion to integrate the device The GSD file for the bus module can be ordered at www docuthek com The steps required to ...

Page 62: ...1 r Status signal 2 9 n r Fault and warning signals 3 12 n n 1 r Remaining times 4 15 n n 1 r TC remaining times2 5 18 n n 1 r PLC output information 6 21 n r FCU input terminal information 7 24 n n 1 r 25 n 2 r FCU output terminal information 8 27 n n 1 r STM temperature 9 30 n n 1 r STL temperature 31 n 2 n 3 r STM STL status 32 n 4 r 1 Modbus TCP see table Modbus TCP register structure 2 Only f...

Page 63: ... shut down Free BOOL 5 Warning Free BOOL 6 ON Free BOOL 7 Manual mode Free BOOL 1 Only with three point step control via bus Output byte PLC FCU The output byte describes the digital signals which are output by the PLC to the FCU The digital signals to control the protective system control FCU occupy 1 byte 8 bits Parallel to the bus communication terminals 1 to 4 and 44 of the FCU can be wired Th...

Page 64: ...00 or Modbus Profile FCU 50x at www docuthek com Fault and warning signals FCU PLC The fault and warning signals are transferred from the FCU to the PLC using this module register The fault and warning signals occupy one byte each 0 to 255 The same allocation table applies to the fault signals and the warning signals Bit Byte n Data type Format Value 0 1 2 3 4 5 6 7 Fault signals Byte DEC 0 255 1 ...

Page 65: ...the valve proving system FCU PLC Only for FCU C1 The module register in FCU C0 contains no information This module register transfers the remaining time of the valve proving system from the FCU C1 to the PLC The remaining time occupies 2 bytes The valve check runs parallel to other time related pro cesses e g pre purge To display the remaining time of the valve proving system separately it is tran...

Page 66: ...uts on the FCU input terminals to the PLC Bit Byte n Byte n 1 Byte n 2 Format 0 Terminal 1 Terminal 48 Terminal 68 BOOL 1 Terminal 2 Terminal 49 Free BOOL 2 Terminal 3 Terminal 50 Free BOOL 3 Terminal 4 Terminal 51 Free BOOL 4 Terminal 44 Terminal 52 Free BOOL 5 Terminal 45 Terminal 65 Free BOOL 6 Terminal 46 Terminal 66 Free BOOL 7 Terminal 47 Terminal 67 Free BOOL FCU output terminal information...

Page 67: ...e Format Value 0 STM temperature Word DEC 0 65535 0 to 65 535K 1 2 3 4 5 6 7 Bytes 3 and 4 are used to transfer the higher of the two temperature values measured by the double thermo couple to the PLC The measured temperature must be higher than the set limit value see page 84 STL FSTL limit value system protection Bit Byte n 2 Byte n 3 Data type Format Value 0 STL temperature Word DEC 0 65535 0 t...

Page 68: ...nings 1006 Fault history 1007 Power module statistics The available data records differ in terms of their in dexes The contents and description of the indexes are described in the code table GSD Codes FCU 500 download from www docuthek com Modbus TCP Address Description 256 511 Parameter 512 767 Device statistics counter 768 1023 Device statistics faults warnings 1024 1279 Operator statistics coun...

Page 69: ... flow state check 01 Fan run up time tGV A Approaching maximum capacity 1 Low air pressure protection check P1 Pre purge A Approaching ignition capacity Valve check H7 Delay H8 Delay 08 Operation controller enable P9 Post purge C1 Controlled air flow U I Remote control with OCU Data transfer programming mode X X High temperature operation Device Off In Manual mode two dots blink on the display ...

Page 70: ...tent FS fail safe parameters 31 Abnormal data change in the parameters set for the FCU Mains voltage 32 Supply voltage too low or too high Faulty parameterization 33 Parameter set contains illegal settings or internal device error Incompatible bus module 35 Bus module and control unit are incompatible Power module defective 36 Relay contact error Contactor function check trm 68 37 Faulty feedback ...

Page 71: ...outside range 67 Operation outside temperature range Burner control unit operating signal 70 No operating signal within the period defined in parameter 47 Burner control units not ready 72 Burner control units do not signal Standby mode Internal error 89 Error in processing internal data Temperature monitoring 90 Internal fault in module Internal error 94 Error at digital inputs Internal error 95 ...

Page 72: ...ck signal from the pressure switches at terminals 47 48 Low air pressure display d1 1 Fault Air monitor make contact check no signal from pressure switch at terminal 48 Low air pressure display d2 d3 d4 d5 d6 d7 d8 or d9 2 3 4 5 6 7 8 9 No input signal from pressure switch or failure in air supply during program step 2 3 4 5 6 7 8 or 9 Air flow during pre purge display dP P No input signal from pr...

Page 73: ...7 73 Fault signalling Fault message blinking DISPLAY Description Low gas pressure display u1 u2 u3 u4 u5 u6 u7 u8 or u9 1 2 3 4 5 6 7 8 9 No input signal from pressure switch at terminal 49 during program step 1 2 3 4 5 6 7 8 or 9 ...

Page 74: ...ing operation tSB 19 0 1 2 Time in seconds 1 Temperature monitoring mode 20 0 1 2 3 Off STM function STL function STM and STL function FCU H0 0 FCU H1 2 Thermocouple 22 1 2 3 Type K Type N Type S 1 Temperature difference limit value 23 10 100 Temperature in C 50 STM limit value high temperature operation 24 650 1200 STM limit value high temperature operation in C 750 STL FSTL limit value system pr...

Page 75: ...ment to ignition capacity Off control element controller enable 1 Capacity control 40 0 1 2 3 4 Off With IC 20 With IC 40 With RBW With frequency converter FCU F0 0 FCU F1 1 FCU F2 3 Running time selection 41 0 1 2 3 Off checking the positions for minimum maximum capacity On for approaching the positions for minimum maximum capacity On for approaching the position for maximum capacity On for appro...

Page 76: ...Vp1 Vp1 pressure reduction via V3 Vp1 Vp2 pressure reduction via V3 1 Pressure reduction Vp2 54 0 1 In standby Upon start up 0 Opening time relief valve V3 55 0 6000 Time in seconds 0 Measurement time Vp1 56 3 5 25 30 3600 Time in seconds in 5 s steps in 10 s steps 10 Measurement time Vp1 and Vp2 57 3 5 25 30 3600 Time in seconds in 5 s steps in 10 s steps 10 Valve opening time 1 tL1 59 2 25 Time ...

Page 77: ... trm 49 AND with gas max trm 50 0 Function of terminal 66 71 0 1 2 3 4 5 6 7 Off FCU as zone control unit External HT signal AND with emergency stop trm 46 AND with air min trm 47 AND with air flow monitoring trm 48 AND with gas min trm 49 AND with gas max trm 50 0 Function of terminal 67 72 0 1 2 3 4 5 6 7 Off BCU ready if not safety shut down BCU ready if not fault lock out AND with emergency st...

Page 78: ... for MIN capacity MIN to MAX capacity standby in CLOSED position IGNITION to MAX capacity standby in CLOSED position MIN to MAX capacity standby in position for MIN capacity burner quick start IGNITION to MAX capacity standby in CLOSED position burner quick start 0 Password 77 0000 9999 Four digit number code 1234 Fieldbus communication 80 0 1 2 Off With address check No address check 1 ...

Page 79: ...monitoring and safety time during operation to the system re quirements 12 2 1 Emergency stop Parameter 10 Function of the controller enable emergency stop input terminal 46 This input is the safety interlock input of the FCU The properties of this function can be activated deacti vated using parameter 10 If there is no input signal the FCU will perform a shut down depending on the func tion selec...

Page 80: ... there is no sig nal at the gasmax input terminal 50 Parameter 12 2 with fault lock out A fault lock out will be performed if there is no signal at the gasmax input terminal 50 12 2 3 Low gas pressure protection Parameter 13 Function of the gasmin input terminal 49 The low pressure cut off provides verification of the gas pressure when the fan run up time tGV starts to elapse If the gas pressure f...

Page 81: ...w must be detected within a timeout 250 s After the elapse of this timeout the FCU will perform a shut down depending on the function selected in param eter 15 Parameter 15 0 OFF the function is not required Parameter 15 1 with safety shut down A safety shut down will be performed if there is no input signal Parameter 15 2 with fault lock out A fault lock out will be performed if there is no input...

Page 82: ... the spontaneous ignition temperature 750 C has been exceeded Parameter 20 2 Maximum temperature monitoring using STL Maximum temperature monitoring with fault lock out reset after the fault has been eliminated by pressing the button on the front panel or using an externally connected remote reset device The required double thermocouple must be positioned at the warmest point in the combustion cha...

Page 83: ...Rh Pt 0 to 1600 C Thermocouples connected to the integrated tempera ture module for the safety temperature limiter STL and safety temperature monitor STM are monitored for cable discontinuity or short circuit This is only pos sible with double thermocouples It is not permitted to use single thermocouples and connect the inputs in parallel using wire straps If sepa rate sensor fittings are used the...

Page 84: ...erature in the furnace chamber falls below the value defined in parameter 24 the FCU disconnects the HT output from the electrical power supply High temperature mode is deactivated on the burner control units The furnace is operated with flame control see also page 123 High temperature operation 12 3 5 STL FSTL limit value system protection Parameter 25 This parameter is used to define the upper l...

Page 85: ...nitor ing using STL on and off High temperature operation with STM FCU 50x H1 M BCU 4xx D µC 9 BCU 4xx D µC 9 HT 18 6 6 HT HT 5 8 STM High temperature mode is reactivated as soon as the temperature exceeds the STM limit value and the de fined temperature hysteresis If the temperature falls below the STM limit value lower limit for high temperature operation High temperature mode is ended Maximum t...

Page 86: ...defined in parameter 24 With the external STM the FCU detects high tempera ture operation by means of a high signal at terminal 66 On FCUs with capacity control FCU F1 FCU F2 the actuator must be moved to ignition position or if a fre quency converter is used the fan must be accelerated to ignition speed to start the burner If the FCU F1 is used in conjunction with actuator IC 20 the ignition posi...

Page 87: ...lay 01 The fan run up time can be parameterized in a range between 0 and 250 s 12 4 3 Fan ready for operation Parameter 31 Using this parameter it is possible to select whether a feedback from the ready fan is to be taken into consid eration by the FCU The fan sends a binary feedback signal to terminal 44 of the FCU if it is available for operation If there is no signal the FCU will perform a shut...

Page 88: ...tor can be changed using an exter nal temperature controller controlled cooling The air flow is not monitored Controlled air flow is only possible in standby with no start up signal 12 4 5 Pre purge time tPV Parameter 34 A burner start may only occur if it has been ensured that the concentration of inflammable components in all sections of the burner tile and the connected areas and the flue gas d...

Page 89: ...A safety shut down will be performed if there is no input signal Parameter 35 2 with fault lock out A fault lock out will be performed if there is no input signal Air flow monitoring is to be set on the basis of the rel evant application standard e g EN 676 EN 746 2 NFPA 85 or NFPA 86 12 4 7 Post purge time tPN Parameter 37 The post purge time defines the period during which air for purging fuel g...

Page 90: ...ameter 38 1 OFF control element to maximum capacity The actuator is moved to the position for maximum capacity during the post purge time The air flow is not monitored Parameter 38 2 OFF control element to ignition ca pacity The actuator is moved to the position for ignition ca pacity during the post purge time If the position of the actuator at this time is less than the position for ignition cap...

Page 91: ... air ac tuator Parameter 40 1 with IC 20 The interface is configured to the requirements of ac tuators IC 20 IC 20 E IC 50 or IC 50 E Alternatively comparable three point step actuators may be used IC 20 3 46 47 48 49 50 4 67 44 52 45 51 65 66 68 16 17 18 57 13 14 15 53 54 55 56 58 FCU 500 F1 5AT 3 15AT µC 24V DC 88 PE L1 N 3PS 3 2 1 16 6 7 4 8 12 11 15 13 S3 S4 S11 S10 0 90 M IC 20 PE S1 S2 90 0 ...

Page 92: ...se Control range between the positions for maximum capacity and ignition capacity The wiring between the FCU and the 3 point step con troller can be adjusted so that the control range of the actuator is between the positions for maximum and ignition capacity 4 67 44 52 45 51 65 66 68 13 14 15 53 54 55 56 58 FCU 500 F1 5AT µC 88 PE L1 N 3PS 3 2 1 16 6 7 4 8 12 11 15 13 S3 S4 S11 S10 0 90 M IC 20 PE...

Page 93: ...e A A or A will be displayed see page 70 Fault sig nalling Control range between the positions for minimum and maximum capacity 0 90 S4 S1 S3 Burner control range Butterfly valve setting range Control range Move to ignition position Ignition pos Min pos Closed pos Max pos MIN MIN MIN MAX MAX MAX The control system is enabled during operation via the controller enable output terminal 56 During the ...

Page 94: ...he positions for maximum capacity and ignition capacity can be set using the actuator Terminal 51 checks whether the position for maximum capacity has been reached Terminal 52 checks the position for igni tion capacity If the position is not reached within the timeout time of 255 s a fault lock out of the FCU will be performed A fault message A A or A will be dis played see page 70 Fault signallin...

Page 95: ...closed position When approaching the closed posi tion 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 56 controller enable and 54 closed position on the FCU are non functional and are not activated Manual m...

Page 96: ...y via a signal to terminal 51 The actuator reports that it has reached the position for minimum capacity via a signal to terminal 52 The simultaneous activation of terminals 51 and 52 results in a fault lock out of the FCU If parameter 41 0 the system monitors the movement to the positions for maximum and minimum capac ity with a timeout time of 255 s Reaching the relevant position immediately tri...

Page 97: ... 56 0 20 mA Any position between minimum and maximum capacity 53 54 Purge Maximum capacity Manual mode In Manual mode no external controller is enabled dur ing the controller enable procedure The actuator can be moved to the positions for maximum capacity or ig nition capacity by the user 3 point step operation is not possible No timeout is active when approaching these positions ...

Page 98: ...l to the FCU via terminal 52 After the elapse of the pre purge time the FCU bridges the connections at terminals 53 and 55 COM LO bridge The frequency converter accelerates the fan to the speed for minimum capacity ignition capacity with a timeout of 255 s The frequency converter reports that the speed for minimum capacity ignition capacity has been reached by a signal target actual via termi nal ...

Page 99: ...ition capacity 53 56 DI 3 0 20 mA Any speed between minimum and maximum capacity 53 54 DI 1 DI 3 Purge Maximum capacity Manual mode In Manual mode the frequency converter can be set to the speed for maximum air volume or minimum air volume pilot air volume Adjustment by the control system is not possible No timeout is active when accel erating to these speeds ...

Page 100: ...proaching the position for minimum capacity is signalled and monitored Parameter 41 3 On for approaching the position for minimum capacity No signal is returned that the posi tion for minimum capacity has been reached The Run ning time set using parameter 42 is activated for ap proaching the position for minimum capacity After this time has elapsed the FCU will initiate the next program step Appro...

Page 101: ...city control FCU F1 F2 param eter 45 can be used to set a minimum enable time 0 to 250 s for the burner start during which the actuator or frequency converter stays in the position for minimum capacity The minimum enable time must be selected so that the downstream burners can be started safely The burner operating signal terminal 4 is not evaluated until the minimum enable time has elapsed if par...

Page 102: ...ners have started up BCU V1 BCU V1 FCU 500 F1 µC 54 55 53 1 67 BCU F0 24V L1 M 4 24V 4 54 55 53 M To ensure that the furnace control unit does not end lessly wait for the enable signal a time 0 to 60 min can be defined using parameter 47 by which the burn ers must reach their operating position If no feedback signal is received during this time the FCU performs a fault lock out The time does not s...

Page 103: ...C 20 RBW or 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 stand by S1 for igniti...

Page 104: ...tterfly 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 stand by 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 position of the...

Page 105: ...ult 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 stand by 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 of the but...

Page 106: ...lowest possible position of 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 rota tion to approach the position for ignition capacity S1 for ignition capacity of the burner S2 for reversing the directi...

Page 107: ... purge 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 forminimumcapacityandignitioncapacityoftheburner S2 for reversing the direction of rotation to approach the position for ignition capacity The actuator will m...

Page 108: ...art up and after shut down An additional bypass relief valve must be fitted in gas sections with an air gas ratio control see also page 108 Relief valve VPS The valve allows the closed air gas ratio control to be bypassed during the tightness test Parameter 51 4 proof of closure function POC PZL PZH BCU 570 C1 µC P 49 13 14 50 47 58 48 TC PZL PDZ M 750 ϑ 1 2 3 V1 V2 45 GZL A signal is sent to the ...

Page 109: ...is opened to re duce the pressure in the test volume by venting to a safe area V1 PZ Vp1 pu pu 2 V3 Parameter 53 3 Vp1 Vp2 pressure reduction via V3 The system tightness is checked with two test volumes Vp1 and Vp2 During the tightness test of Vp1 almost at mospheric pressure must prevail in the test volume Vp2 Relief valve V3 is opened to reduce the pressure in test volume Vp2 Pressure switch DGV...

Page 110: ... be determined according to the requirements of the appropriate appli cation standards e g EN 1643 The required measurement time for the tightness test of Vp1 can be set using parameter 56 The possible set tings are 3 s 5 to 25 s in 5 s steps or 30 to 3600 s in 10 s steps See also page 53 Measurement time tM 12 5 7 Measurement time Vp1 and Vp2 Parameter 57 For a system leak tightness check the pre...

Page 111: ...that it monitors of the inlet pres sure pu the second pressure switch at terminal 65 monitors of the inlet pressure pu The Reduced DG test duration function is activated by setting parameter 70 to 1 Terminal 65 is thus assigned the function Input for 3pu 4 pressure switch for tight ness test Terminal 45 is thus assigned the function Input for pu 4 pressure switch for tightness test PZL PZH FCU 500...

Page 112: ...open for longer than the 3 s permitted by the standard EN 1643 2000 The required volume limit can be achieved by fitting a restrictor or orifice for example The opening time to be set is then calculated on the ba sis of this restrictor or orifice Current rating of safety interlock output terminal 57 max 0 5 A see also page 127 Safety interlock output in the case of higher power requirement Calcula...

Page 113: ...he load on the power supply The switch on delay also applies to the TC function 12 6 3 Filling time before start up Parameter 65 The filling time for the pressure build up in the gas line before start up is defined using this parameter This allows the tripping of the safety shut off valve to be prevented after the main gas valves have been released Bypass valves V3 and V4 are required for the slow...

Page 114: ... 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 FCU indicates A with blinking dots A change of direc tion takes place each time the button is released and pressed again When the actuator has reached its final position the dots disappear Frequency converter Following co...

Page 115: ...igned a given func tion 12 8 1 Function of terminal 51 Parameter 69 The terminal can be set to the function IC 40 RBW max air volume feedback to query the position for maximum capacity of an IC 40 RBW actuator see page 96 Parameter 40 3 with RBW Parameter 69 0 Off Parameter 69 1 max capacity position feedback IC 40 RBW Parameter 69 2 AND with emergency stop termi nal 46 Parameter 69 3 AND with air...

Page 116: ...5 1 2 Parameter 70 0 Off Parameter 70 1 reduced DG test duration Parameter 70 2 AND with emergency stop terminal 46 Parameter 70 3 AND with airmin terminal 47 Parameter70 4 ANDwithairflowmonitoring terminal48 Parameter 70 5 AND with gasmin terminal 49 Parameter 70 6 AND with gasmax terminal 50 12 8 3 Function of terminal 66 Parameter 71 An external safety temperature monitor module STM module can ...

Page 117: ...arameter 72 2 BCU ready if not fault lock out If there is no feedback signal a fault lock out will be performed see page 145 Fault lock out Parameter 72 2 AND with emergency stop termi nal 46 Parameter 72 3 AND with airmin terminal 47 Parameter 72 4 AND with air flow monitoring termi nal 48 Parameter 72 5 AND with gasmin terminal 49 Parameter 72 6 AND with gasmax terminal 50 12 8 5 Function of ter...

Page 118: ...eter 80 when bus module BCM 500 is connected A device name network name must be entered in the automation system for the unique identification of the control unit BCU FCU in the fieldbus system Parameter 80 0 OFF Parameterization access using BCSoft via Ethernet is still possible Parameter 80 1 with address check The device name network name on delivery is not assigned fcu 500 xxx The expression n...

Page 119: ...ystem control Furnace zone control Q W Mains voltage 120 V AC 50 60 Hz 230 V AC 50 60 Hz C0 C1 Integrated tightness control or POC none with integrated tightness control or POC F0 F1 F2 Capacity control none modulating with interface for actuator IC modulating with interface for RBW H0 H1 Temperature monitoring none with temperature monitoring K0 K1 K2 Connection terminals none screw terminals spr...

Page 120: ... rail is aligned vertically end clamps are re quired e g Clipfix 35 by Phoenix Contact to prevent the FCU from slipping Environment Install in a clean environment e g a control cabinet with an enclosure IP 54 whereby no condensation is permitted 14 2 Commissioning Do not start the FCU until the parameter settings and wiring are correct and the faultless processing of all input and output signals c...

Page 121: ... via relay contacts only 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 FCU cables in the same cable duct as frequency converter cables or cables emitting strong fields Control lines must satisfy the requirements of EN 60204 1 Chapter 12 External electrical interference must be avoided 14 3 1 OCU Cables for signalling and t...

Page 122: ...be designed so that the sensor with the lowest switching capacity is protected The 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 1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68 62 61 ϑ L1 24 V PZL PDZ PZL PZH P70 P71 P73 P72 P69 PZL PDZ PZL PZH P70 P71 P73 P...

Page 123: ... the safety temperature monitor fitted in the temperature module in conjunc tion with an external double thermocouple DIN 3440 Sensor discontinuity sensor short circuit failure of a component or mains failure must set the installation to a safe state Voltage may be applied to the HT input of a burner control unit so as to activate High temperature mode only if the temperature at the furnace wall h...

Page 124: ...temperature range C Type K 270 to 1372 0 to 1200 Type N 270 to 1300 0 to 1200 Type S 50 to 1768 0 to 1600 Can be used as a substitute for Type K 14 4 4 Thermocouples Materials which are used for thermocouples are defined in EN 60584 The temperature ranges for the various materials and the expected voltages are also listed there Type K nickel chromium nickel aluminium NiCr Ni This thermocouple is f...

Page 125: ...ficients To avoid errors at the transition points the thermocouples are connected to the temperature module using thermo cables or compensating cables Thermo cables KX have the same chemical composi tion as Type K thermocouples This means they act like an attached thermocouple Compensating cables KCA KCB NC SCA or SCB are made of a substitute material which is not identical to the thermocouple mat...

Page 126: ...6 66 DCdrift 0 6 66 ThetotalfailurerateforthethermocoupleandSTM STL temperaturemoduleoftheFCU H1iscalculatedasfollows PFHDtotal λDU thermocouple PFHDSTM STLtemperaturemodule PFHD STM STL temperature module 5 84 10 9 1 h See also page 141 Mean probability of danger ous failure PFHD of individual safety functions and page 147 Probability of dangerous failure PFHD Calculation Enterthemanufacturer sin...

Page 127: ... higher power requirement In the event that a higher output current is required the output current can be increased by the additional con nection of 2 contactors K1 K2 k1 k1 k2 k2 L1 1 2 3 46 47 48 49 50 4 67 44 52 45 51 65 66 68 41 42 16 17 18 57 13 14 15 53 54 55 56 58 62 61 5 6 7 8 11 12 STW STB N 24 V L1 FCU 5AT 3 15AT µC 24V DC 88 Input automatic burner control unit F IN 0 6 Use contactors wi...

Page 128: ...c1 F1 230V v1 c2 v2 max 2A 253 V V1 V2 C N S µC L l 30 31 32 33 34 35 36 37 38 50 51 l F3 40 41 42 43 44 45 46 47 1 2 5 6 11 9 10 12 13 14 15 18 19 20 26 27 22 8 7 PE Z I V1 V2 P L1 L1 N L2 DI Test L1 BCU 460 N1 N1 N1 N1 O I ϑ 3 4 16 17 n max 2A 253V A 23 In the event that a higher output current is required the output current can be increased by means of a contact multiplier using 3 contactors K3...

Page 129: ...eedback can be activated by setting parameter 73 to 1 14 6 Actuators If actuators are used the start gas rate of the burners must be limited for SIL 3 applications in compliance with the standard 14 6 1 IC 20 The FCU 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 146 Lift ing To ensure this check is pos...

Page 130: ... removed from the old unit and inserted into the new FCU The FCU must be disconnected from the electrical power supply for this purpose The valid parameters are then adopted by the new FCU The old device and the new FCU must have an identical type code 14 9 System leak tightness check V3 DGV3 pu Vp1 PZ pu 2 V1 V2 PZ Vp2 V3 DGV3 15 N A pressure switch DGV3 can be connected between V3 and terminal 1...

Page 131: ...cluding BCSoft CD ROM Order No 74960625 15 1 2 Bluetooth adapter PCO 300 Including BCSoft CD ROM Order No 74960617 15 2 OCU For installation in the control cabinet door in standard grid dimensions The program step status or fault mes sages 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 133 OCU OCU 500 1 Order N...

Page 132: ...ckers D 49018 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 ...

Page 133: ...l unit of the FCU 500 BCU 500 series The external operator control unit OCU is installed in the door of a control cabinet Thus the control cabinet does not need to be opened to read out process values statistics flame signal intensities or parameter values to change settings on the OCU or to control or adjust connected valves in Manual mode ...

Page 134: ...ddition you can operate connected control units in Manual mode There are five control keys for the OCU and the control unit connected to it OK ON OFF Use the ON OFF key to switch the control unit on or off OK Reset Use the Reset key to reset the control unit to its starting position in the event of a fault OK OK Press the OK key to confirm a selection or query Starting from the status display you ...

Page 135: ...y and ignition capacity of an actuator can be adjusted us ing the OCU The OCU supports the process by means of a cyclic automatic repeat approach to the selected position The actuator can be moved within the menu to make changes to the cam settings After start up has been completed the navigation keys can be used for example to open or close a valve in program step 08 16 3 Electrical connection Th...

Page 136: ...se 84327031 OCU 500 3 English US English Spanish Brazilian Portuguese French 84327032 OCU 500 4 English Russian Polish Croatian Romanian Czech 84327033 16 6 Technical data for OCU Ambient temperature 20 to 60 C Relative humidity 30 to 95 no condensation permitted Enclosure IP 65 NEMA 3 when fitted control cabinet door Dimensions of the operator control unit 90 x 90 x 18 mm W x H x D Electrical con...

Page 137: ...nals 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 automation system PLC to the BCM In the opposite direction it sends operating status the level of the flame signal and the current program step 17 3 Electrical connection Use only cable and plug components which comply with the approp...

Page 138: ...abinet with an enclosure IP 54 whereby no condensation is permitted 17 5 Selection Code Description BCM Bus module 500 Series 500 S0 Standard communication B2 B4 Profinet1 Modbus TCP2 3 Two RJ45 sockets 3 Three point step control via bus 1 Order No 74960663 2 Order No 74960688 17 6 Technical data Electrical data Power consumption 1 2 VA Power loss 0 7 W Mechanical data Dimensions W H D 32 5 115 10...

Page 139: ...ous activation of con trol outputs HT purge LDS and safety interlocks valve outputs V1 V2 and V3 and the actuator max 2 5 A 24 V DC signalling contact for fault operation termi nal 41 42 max 0 1 A Fan max 3 A start up current 6 A 1 s Number of operating cycles FCU 24 V DC signalling contact for fault operation max 10 000 000 On Off button Reset Information button 1000 power module control outputs ...

Page 140: ...uant to IEC 529 Installation location min IP 54 for installation in a control cabinet 18 4 FCU H1 Terminals 5 6 7 and 8 Maximum voltage 5 V input voltage range for double thermocouples Type K 0 to 54 9 mV Type N 0 to 47 5 mV Type S 0 to 18 7 mV Function of Type 2 to EN 14597 type of action 2B 2K and 2P with STL also 2A and 2N ESD protection of terminals 5 to 8 Level 4 to IEC 61000 4 2 ESD Maximum ...

Page 141: ...tion 4 9 x 10 9 1 h Ready feedback 5 9 x 10 9 1 h IC 20 ignition position feedback 6 7 x 10 9 1 h RBW Low position feedback 6 7 x 10 9 1 h Low gas pressure protection 4 9 x 10 9 1 h High gas pressure protection 4 9 x 10 9 1 h Contactor feedback 4 8 x 10 9 1 h STM STL temperature module 5 8 x 10 9 1 h see page 126 PFHD value for STM STL temperature module and thermocouple SIL 3 is not achieved in c...

Page 142: ...FCU 500 FCU 505 Edition 02 17 142 Technical data 18 7 Converting units See www adlatus org ...

Page 143: ...down path 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 BC Soft for further diagnostics and troubleshooting The user stat...

Page 144: ...al pressure switch Pxx Input signal depending on parameter xx M Control element with butterfly valve TC Tightness control pu 2 Half of the inlet pressure pu 4 A quarter of the inlet pressure 3pu 4 Three quarters of the inlet pressure pu Inlet pressure pd Outlet pressure Vp Test volume GZL Valve with proof of closure switch Fan Three point step switch Input Output safety circuit IN Current consumpt...

Page 145: ...ock out is a safety shut down with subsequent fault lock out The system can only be restarted fol lowing manual reset The protective system cannot be reset by mains failure In the event of a fault lock out of the FCU the fault sig nalling contact closes the display blinks and shows the current program step see page 70 Fault signalling The gas valves are disconnected from the electrical power suppl...

Page 146: ... 6 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 or parts of a safety related system For example diagnos tic coverage could exist for sensors and or logic system and or final elements Unit...

Page 147: ... to appear from EN 13611 A2 2011 21 9 Probability of dangerous failure 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 21 10 Mean time to dangerous failure MTTFd Expectation of the mean time to dangerous failure from EN ISO 13849 1 2008 ...

Page 148: ...se 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 hts lotte honeywell com www kromschroeder com The current addresses of our international agents are available on the Internet www k...

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