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 Burner Control CBR 

 

 

 

Testing the Safety Features 

Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, 
remain principally the same. 

 
 

Tools: 

 

 

• 

Screw driver 

 

 

 

Accessories: 

 

 

• 

Digital thermometer 

 

 

 

Salient notes: 

 

 

Safety features of the thermal processing line must not circumvented or disabled.  
Functionality of the safety features of every burner must be validated prior to each application 
start-up, such as may occur after commissioning, maintenance work or extended down times.  
 

 

 

 

 

 

How to: 

 

 

 

 

 
 

 

1. Test ground connection 
Attention! Every burner must be connected with ground. This can be achieved via the burner 
control unit or directly through the system ground. It is not permissible to daisy chain ground 
connections from burner to burner! 

 

 

 

 

 

2. Safety shut-down in flame mode 
The following manipulations must lead to a fault shut-down of the firing burner: 

• 

interruption of the gas supply (via manual shut-off valve) 

• 

interruption of the combustion air supply (via manual shut-off valve) 

• 

removing the UV sensor head from the burner 

 

 

 

 

 

3. Safety shut-down in FLOX

- mode 

The following manipulations must lead to a fault shut-down of the firing burner: 

• 

interruption of the combustion air supply (via manual shut-off valve) 

• 

removing the connector from the pressure switch (Delta-p air min.) 

 

 

 

 

 
 
 
 
 
 
 
 
 

4. Safety relevant FLOX

- release temperature  

Regular validation of the temperature measurements and the associated fault shut-off and alarms is 
required: 
 
Comparative measurement of the dual thermocouple for FLOX

- release.  

(reference measuring point, for example inline testing port) with CBR information display: 

• 

select information display vie + and 

↵

↵↵

↵

  

• 

0 = temperature in hundreds – 1 = temperature in single digits (e.g. 0 08 + 1 70 = 870°C) 

•  ↵

↵↵

↵

 = continue to next information display;  

←

←

←

←

 = exit or, timeout after 20 seconds 

Interrupt the temperature measurement circuit. 

• 

dual thermocouple for FLOX

- release 

→

 fault shut-off 

F 5C

  

b)   burner head thermocouple 

→

 fault shut-off 

P

  

1 

 

  

Summary of Contents for D-71272

Page 1: ...the power supply voltage 4 variations which are project customized pre configured and tested Technical Specifications Power Supply 230V AC 15 10 50 60Hz or 115V AC 15 10 50 60Hz Electrical connection Phase correct connection and ground connection according to electrical diagram Touch protection Must be present for thermocouples and the UV sensor flame rod powerless installation and connection Fuse...

Page 2: ...s red Fault flashing The functions of the buttons button combinations information operating and fault codes are described on two labels Labels are available in different languages and are changeable Code label 1 Code label 2 Each CBR is configured for its specific application and tested prior to delivery The most important parameters can be visualized on the display Comfort Configuration by applyi...

Page 3: ...d parameters are documented in the burner control certificate This certificate is archived according the serial number Please notify our electrical engineering department of any changes All configured parameters are documented in the burner control certificate This certificate is archived according the serial number Please notify our electrical engineering department of any changes ...

Page 4: ...afety chain interlocked with the application safety chain to the control box Make the connections according to the electrical schematics supplied by WS All connections must be fused properly depending on wire lengths wire gauge ambient temperature and power draw The safety chain signal carries the load from the ignition transformer and the gas valves connected to the burner Signal exchange for bur...

Page 5: ... mode the FLOX Flame switching logic especially the electrical connections must be validated by trained personnel Validation to be performed with the gas supply turned off Incorrect implementation can result in EXPLOSION Electrical connects are made directly inside the CBR terminal section remove power and lock out As an option the CBR can be supplied with an industrial connector for power supply ...

Page 6: ...laves A bus terminator must be placed at the beginning and end of each segment Termination can be achieved via the switch within each Profibus connector To maintain fault free bus operation each terminated device must have power connected Repeaters boosters must be used for more than 32 devices or to extend the range of the bus network It is recommended to utilize shielded 2 wire cable for example...

Page 7: ...e bus terminals within the connector are labeled 1A 1B 2A 2B Make sure the same conductor colour is maintained throughout devices and that they are connected to the same label throughout There is no applicable code pertaining to wiring colours for Profibus It has become semi standard to use green for A and red for B Incoming connections are terminated on 1A 1B and the outgoing connections are term...

Page 8: ...diag slave has external diagnostic data Bit 4 Diag not supported requested function not supported by slave Bit 5 Diag invalid_slave_response perm sets slave to 0 Bit 6 Diag prm_fault incorrect set up ID number etc Bit 7 Diag master_lock set by master slave configured by other master Octet 2 Bit 0 Diag prm_req slave must be reconfigured Bit 1 Diag stat_diag statistical diagnosis Byte Diag Bits Bit ...

Page 9: ...operate the burner control unit in manual mode without a valid Profibus address Data transfer Bytes Bits from master host to the CBR burner control unit Please follow all applicable safety regulations Depicted configurations may differ from the actual scope of delivery procedures however remain principally the same Please contact our sales or engineering department Following tables illustrate the ...

Page 10: ...mum time start mode 14 0E A2 14 Flame Start mode max 24 h 15 0F H2 15 Manual mode pause 2 16 10 A3 16 Flame minimum time flame mode 17 11 A3 H3 17 Flame Flame operation manual mode pause 18 12 H4 18 Manual mode pause 3 19 13 A4 19 Flame Post purge 20 14 A4 20 Flame Post combustion duration 21 15 A4 21 Flame Minimum pause flame mode 22 16 b0 22 FLOX waiting for heat demand 23 17 b1 23 FLOX idle che...

Page 11: ...mber 93 5D F 5d 0x5D Temperature logging ambient 94 5E F 5E 0x5E Temperature ambient too high 95 5F F 5F 0x5F Temperature combustion chamber too high 98 62 F 62 0x62 Fault external FLOX Flame selection too many cycles 162 A2 F A2 0xA2 Safety chain input without signal 166 A6 F A6 0xA6 False flame signal at start up or ground fault at ionisation electrode 167 A7 F A7 0xA7 no flame formation at star...

Page 12: ...ontrol CBR Enter Profibus Address initial commissioning WS Delivery 127 invalid Test Profibus communication Test Profibus address Enter Profibus Address correction Example change from 4 to 3 Test Profibus communication ...

Page 13: ...uisites The power supply must be connected phase correct and all contacts of the process line permissives safety limits are closed so that power same potential is present at the safety chain terminal of the CBR The following adjustments can be made via Comfort Configuration Step 0 or Parameter 10 0 Automatic operation 1 Manual mode Air purge 2 Manual mode Heating 3 lock out control box locked Thes...

Page 14: ...R Manual Mode Heating functions are dependant on the current operating mode temperature range Burner in Start Mode Manual Mode Heating functions are dependant on the current operating mode temperature range Burner in Flame Mode ...

Page 15: ...s are dependant on the current operating mode temperature range Burner in FLOX Mode Manual Mode Timeout Operation in manual mode is time limited Once this time is exceeded the CBR is automatically locked out Exiting Manual Mode Return to automatic operation ...

Page 16: ...lt shut down of the firing burner interruption of the gas supply via manual shut off valve interruption of the combustion air supply via manual shut off valve removing the UV sensor head from the burner 3 Safety shut down in FLOX mode The following manipulations must lead to a fault shut down of the firing burner interruption of the combustion air supply via manual shut off valve removing the conn...

Page 17: ...nections e g powering outputs can open gas valves and destroy the CBR fail safe functionality of the unit is no longer guaranteed Most faults can be reset thus restarting the burner by pressing the local reset button for a minimum of second or by activating the remote reset signal In case of reoccurring fault avoid multiple or continuous reset attempts and determine the root cause of the fault by ...

Page 18: ...t reached The CBR is only configured for a FLOX only burner Incorrect configuration of the CBR P 3 Safety chain limits permissives interrupted Upstream combustion safety devices are not on line Burners are not permitted to operate Check the limits and permissives P 4 False flame signal detected by the UV sensor or ionization electrode during a restart attempt see fault F A6 These faults do not cau...

Page 19: ... loss during STS no flame established during start up High Voltage Use caution when removing the spark plug cap Automatic restart attempts will power the ignition transformer Check the gas and air flow volumes Check spark plug connection Is a spark generated transformer OK Is the spark visible through the sight glass Moisture present in the brass ignition head Remove the gas nozzle ceramic tube ig...

Page 20: ... p air min pre adjusted to approx half of delta p of nominal air flow volume Minimum required air volume not achieved Delta p switch defective Air volume flow too low Exhaust suction not present Flexible hose from pressure switch positive side to the measuring orifice lose or leaking Threshold of delta p switch selected too low lower setting Flexible hoses switched High pressure air missing F 5 De...

Page 21: ...xhaust pressure negative deviates from pressure curve Pressure switch defective Threshold of delta p switch selected too low lower setting Moisture in pressure switch F a False flame signal detected by the UV probe during start up similar to F A6 Unusually long residual flare after burner has turned off e g gas valve leakage UV probe defective or aged Burner internals defective Ground connection o...

Page 22: ...ged reset signal present 10 seconds or signal is already present when connecting power F5 flashing Input fault An attempt was made to overwrite a non changeable parameter Button combination locked F7 flashing Burner CBR locked out A burner may be turned off in this fashion The CBR is locked out Comfort Configuration 0 or parameter 10 manual mode is set to 3 For example after long operation in manu...

Page 23: ...r 15 minute interval permitted Wait until new reset is permitted F 0C Configuration error Switching intervals are smaller than the test intervals of the pressure switch or the thermocouple configuration or post air purge post combustion 0 5s F 16 Communication fault TWI Bus Service interface On TWI Bus Only add or remove client with power off F 18 CBR powered down externally The CBR was powered do...

Page 24: ... interrupted Profibus IC defective or missing F 5 Temperature supervision optional Thermocouple fault Burner head exhaust gas temperature Thermocouple not connected properly Positive and negative leads switched Thermocouple defective F 5C Combustion chamber thermocouple fault Dual thermocouple fault Phase correct connection of the CBR is essential Otherwise power my be connected to the compensatin...

Page 25: ...ult Over temperature burner Shut down to protect the burner against excessive ambient temperatures Fault does not auto reset after temperature has dropped Thermocouple fault F 62 Too frequent signal change Flame to FLOX 3 in 30s at the signal inputs of burners with external FLOX flame switching Check switching and signals d Internal faults Other error codes indicate CBR internal faults If reset at...

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