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BCU 580 · Edition 11.15l

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= To be continued

Contents

Burner control units BCU 580 . . . . . . . . . . . . . . . . . . . . . . . 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1.1 Stage-controlled main burner with alternating

pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.1.2 Stage-controlled main burner with permanent

pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.1.3 Two-stage-controlled main burner with

permanent pilot burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.1.4 Modulating-controlled burner . . . . . . . . . . . . . . . . . . . . . . 12

1.1.5 Flame control using the temperature . . . . . . . . . . . . . . . 13

1.1.6 PROFINET connection using bus module BCM . . . . 14

1.1.7 ON/OFF rotary impulse control . . . . . . . . . . . . . . . . . . . . . 15

1.1.8 Modulating burner control . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.1.1 BCU 580..F1 with ionization control in single-

electrode operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.2 BCU 580..F2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1.3 BCU 580..F3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.1.4 Flame control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2 BCU 580 program sequence . . . . . . . . . . . . . . . . . . . . .23

4 Air control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Capacity control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.1.1 BCU..F1/F2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.1.2 BCU..F3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5 Valve proving system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1 Tightness test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.1.1 Test instant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.1.2 Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5.1.3 Test period t

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.1.4 Opening time t

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.1.5 Measurement time t

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2 Proof of closure function . . . . . . . . . . . . . . . . . . . . . . . . .36

5.2.1 Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6 BCSoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

7 Profinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.1 BCU and bus module BCM. . . . . . . . . . . . . . . . . . . . . . . .39
7.2 GSD file for PLC configuration . . . . . . . . . . . . . . . . . . . . 41

7.2.1 Modules for cyclic data exchange . . . . . . . . . . . . . . . . . . . 42

7.2.2 Indexes for acyclic communication . . . . . . . . . . . . . . . . . 48

8 Program step/status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9 Fault signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

10 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

10.1 Scanning the parameters. . . . . . . . . . . . . . . . . . . . . . . .58
10.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

10.2.1 Switch-off threshold of the flame amplifier . . . . . . . 58

10.2.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

10.2.3 High temperature operation . . . . . . . . . . . . . . . . . . . . . . . 60

10.3 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . .63

10.3.1 Burner 1 start-up attempts . . . . . . . . . . . . . . . . . . . . . . . . 63

10.3.2 Burner 2 start-up attempts . . . . . . . . . . . . . . . . . . . . . . . . 64

10.3.3 Burner application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

10.3.4 Safety time 1 t

SA1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

10.3.5 Flame proving period 1 t

FS1

. . . . . . . . . . . . . . . . . . . . . . . 68

10.3.6 Safety time 2 t

SA2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

10.3.7 Flame proving period 2 t

FS2

. . . . . . . . . . . . . . . . . . . . . . . 69

10.4 Behaviour during operation . . . . . . . . . . . . . . . . . . . . .70

10.4.1 Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

10.4.2 Minimum operating time t

. . . . . . . . . . . . . . . . . . . . . . . 73

10.4.3 Pilot burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

10.5 Safety limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

10.5.1 Safety time during operation. . . . . . . . . . . . . . . . . . . . . . . 74

10.6 Air control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

10.6.1 Capacity control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

10.6.2 Running time selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

10.6.3 Running time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

10.6.4 Low fire over-run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Содержание Krom Schroder BCU 580

Страница 1: ...ating or staged burners for multiple burner applications with a central air supply For directly ignited burners or burners ignited by a pilot burner in intermittent or continuous operation Optionally with valve proving system PROFINET fieldbus connection using optional bus module Burner control units BCU 580 ...

Страница 2: ... sequence 31 5 1 3 Test period tP 33 5 1 4 Opening time tL 33 5 1 5 Measurement time tM 33 5 2 Proof of closure function 36 5 2 1 Program sequence 36 6 BCSoft 37 7 Profinet 38 7 1 BCU and bus module BCM 39 7 2 GSD file for PLC configuration 41 7 2 1 Modules for cyclic data exchange 42 7 2 2 Indexes for acyclic communication 48 8 Program step status 49 9 Fault signalling 51 10 Parameters 54 10 1 Sc...

Страница 3: ...ing information 104 12 1 Installation 104 12 2 Commissioning 104 12 3 Electrical connection 105 12 3 1 OCU 105 12 3 2 Safety current inputs 106 12 3 3 UVD control 107 12 4 Actuators 108 12 4 1 IC 20 108 12 5 Parameter chip card 109 12 6 Protecting the pilot burner from overload 109 12 7 Calculating the safety time tSA 110 12 8 Fifth or switchable gas valve on BCU F3 111 13 Accessories 112 13 1 BCS...

Страница 4: ...A1 127 19 5 Safety time during operation tSB 127 19 6 Safety shut down 128 19 7 Fault lock out 128 19 8 Warning signal 128 19 9 Timeout 128 19 10 Lifting 129 19 11 Air valve 129 19 12 Diagnostic coverage DC 129 19 13 Operating mode 129 19 14 Safe failure fraction SFF 130 19 15 Probability of dangerous failure PFHD 130 19 16 Mean time to dangerous failure MTTFd 130 Feedback 131 Contact 131 Contents...

Страница 5: ...mple it ensures that the burner ignites in a safe condition when it is restarted The air control on the BCU F1 F2 or F3 assists the furnace control for cooling purging and capacity control tasks The burner control unit has an interface via which an air valve or actuator IC 20 IC 40 or RBW can be controlled for staged or modulating burner capacity control The program status the unit parameters and ...

Страница 6: ...arameters for example when replacing the unit The monitored outputs for the actuator and valves are accommodated in a plug in power module This can simply be replaced if necessary Once the plug in power module has been removed the param eter chip card and fuses are accessible The BCU can be installed on a DIN rail in the control cabinet Plug in connection terminal strips on the BCU make it easier ...

Страница 7: ...justment the operating points can be approached conveniently in Manual mode using the operator control unit The address for the fieldbus communication is set using three code switches The optional bus module BCM 500 makes it possible to connect the BCU to a PROFINET network via a fieldbus interface Networking via the fieldbus enables multiple BCUs to be controlled and monitored by an automation sy...

Страница 8: ...BCU 580 Edition 11 15l 8 Application Bogie hearth forging furnace in the met allurgical industry Intermittent shuttle kiln in the ceramics industry Walking beam furnace with overhead firing ...

Страница 9: ...s switched off automatically after the main burner has started up When the main burner is switched off the pilot burner automatically switches on again This reduces the main burner start up time The UV sensor monitors the flame signal from pilot and main burners The BCU provides the cooling and purging processes BCU 580 C0F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 U V S 38 37 18 17 1 2 3 FCU 500...

Страница 10: ... signal from the pilot burner has been detected Pilot and main burn ers can be operated simultaneously This reduces the time required by the main burner for starting up The BCU provides the cooling and purging processes BCU 580 C0F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 38 37 18 17 1 2 3 FCU 500 Process control PCC 46 49 50 P HT A ϑ1 9 13 14 57 8 5 4 41 42 43 1 2 ϑ2 t 1 2 04 04 02 04 06 08 06 ...

Страница 11: ...g state is reached the BCU issues the Enable signal for the maximum burner capacity Pilot and main burners can be operated simultaneously This reduces the time required by the main burner for starting up The BCU provides the cooling and purging processes TZI TGI VAS VAS 1 VAG IC 40 BVA V1 V2 V3 V4 VAS 1 4 10 12 7 16 12 M µC BCU 580 C0F2 µC 38 37 18 17 1 2 3 FCU 500 Process control PCC 46 49 50 P H...

Страница 12: ...m the pilot burner has been detected The control system controls the burner capacity via the butterfly valve for air after the oper ating state has been signalled Pilot and main burners can be operated simultaneously This reduces the time required by the main burner for starting up V1 IC 20 BVA BCU 580 C0F1 µC 38 37 18 17 1 2 3 FCU 500 Process control PCC 46 49 50 P HT A ϑ1 13 14 57 TZI TGI 9 8 5 ...

Страница 13: ...tput that the furnace system is in High temperature mode HT When the HT input is activated the burner control units switch to High temperature mode They operate with out evaluating the flame signal and their internal flame control is non functional If the furnace temperature falls below the spontaneous ignition temperature 750 C the FCU disconnects the HT output from the electrical power supply As...

Страница 14: ...on system PLC to the BCU BCM for starting resetting controlling the air valve purging the furnace or for cooling and heating during operation In the op posite direction it sends operating status the level of the flame signal and the current program status Control signals that are relevant for safety such as the safety interlocks purge and HT input are transferred independently of the bus communica...

Страница 15: ...o 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 the same time it acts as ...

Страница 16: ... 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 BCU 580 F3 FCU 500 F0 µC P DG DG DG VAS 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 STM ...

Страница 17: ...pressure on the burner proportionally to the air pressure and thus maintains a con stant air gas ratio At the same time it acts as a low air pressure protec tion device The ignition and monitoring of the pilot main burners is ensured by burner control units BCU 580 The centrally checked safety func tions such as pre purge tightness test flow detector and pressure switch check gasmin gasmax airmin ...

Страница 18: ...tive 2006 95 EC EMC Directive 2004 108 EC FM approved Factory Mutual Research Class 7400 Process Control Valves Designed for applications pursuant to NFPA 85 and 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 and 3335 81 Eurasian Customs Union The product BCU 580...

Страница 19: ...ency converters see from page 75 Capacity con trol Electrical connection see page 104 Project planning information Explanation of symbols see page 126 Legend N BCU 580 F1 µC 88 c c 0 V 24 V 24V DC 9 11 12 10 62 61 230V 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70 P69 P73 P72 P72 HT pu 2 GZL PZL P71 46 45 65 66 67 68 49 50 51 52 5 6 7 8 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 A 53 5...

Страница 20: ...104 Project planning information Explanation of symbols see page 126 Legend N BCU 580 F2 µC 88 c c 0 V 24 V 24V DC 9 11 12 10 62 61 230V mA 53 54 55 56 COM HI LO AUTO 1 2 3 4 L1 ϑ1 P70 ϑ2 P69 13 P70 P73 P72 P72 HT pu 2 GZL PZL P71 46 45 65 66 67 68 49 50 51 52 5 6 7 8 A 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 P P 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14...

Страница 21: ...rol Electrical connection see page 104 Project planning information Explanation of symbols see page 126 Legend N BCU 580 F3 µC 88 c c 0 V 24 V 24V DC 9 11 12 10 62 61 230V 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70 P69 P73 P72 P72 HT pu 2 GZL PZL P71 46 45 65 66 67 68 49 50 51 52 5 6 7 8 A 53 54 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3 V4 P 2 1 I Airmin Air 0 6 IN ...

Страница 22: ...V sensor for continuous operation UVD 1 The 0 20 mA current output can be used to display the flame signal The cable to the control room must be screened The 0 20 mA current output is not required for normal operation Depending on Parameter 79 the following connection diagrams apply see also page 73 Pilot burner Alternating pilot burner Parameter 79 0 BCU 580 F1 µC 88 c c 24 V 24V DC 9 11 12 10 62...

Страница 23: ...h ϑ1 signal Wait until the running time has elapsed P42 02 Safety time 1 tSA1 running ignition in process valves V1 and V4 open If no flame detected max 3 start up attempts or fault lock out 03 Flame proving period 1 tFS1 running P95 In the event of flame failure fault lock out 04 Pilot burner operation signalling contact closes In the event of flame failure restart or fault lock out 05 Main burne...

Страница 24: ...ts P61 In the event of flame failure restart or fault lock out A8 External actuation of the air valve for capacity control 08 Controlled shut down via ϑ signals for pilot and main burners 00 If min operating time tB has elapsed operation signalling contact opens gas valves close and running time P42 starts to elapse ...

Страница 25: ...ated for this pur pose by the capacity control system of the BCU After being enabled by the protective system the BCU can start the burners The capacity is controlled during operation by an external temperature control system VAS M PZL PZH PZ PZL PDZ TE BCU 580 F3 FCU 500 F0 µC P DG 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 B...

Страница 26: ...levant operat ing situation As soon as there is a purge signal at terminal 50 of BCU F1 F2 the control element is activated by the outputs for capacity control to approach the position for pre purge The protective system e g FCU 500 starts the pre purge time if there is adequate air flow After the elapse of the pre purge time the control ele ment moves to the ignition position Once the protec tive...

Страница 27: ...capacity air volume on the basis of the required temperature De pending on the wiring of the temperature controller the actuator may be adjusted between maximum capacity and ignition capacity or minimum capacity Depending on parameter 40 an actuator IC 20 IC 40 IC 50 or an actuator with an RBW interface can be ac tuated via the outputs for capacity control Detailed information about parameter 40 s...

Страница 28: ...arts the pre purge time if there is adequate air flow After the elapse of the pre purge time the air valve closes for ig nition Once the protective system terminal 46 safety interlocks has issued the enable signal the burner can be started by the start up signal at terminal 1 The gas valves for the 1st stage are opened and the burner is ignited on the BCU C1 after a successful valve check After th...

Страница 29: ...l is issued For details see following chapter Tightness test and page 36 Proof of closure function 5 1Tightness test The aim of the tightness control is to identify an inad missible leak on one of the gas solenoid valves and to prevent burner start Gas solenoid valves V1 and V2 are tested as is the pipework between the valves V2 pu Vp1 V1 PZ pu 2 European standards EN 746 2 and EN 676 stipulate ti...

Страница 30: ...e during this check The pilot burner is ig nited when pre purge is ended and the tightness has been checked successfully After burner shut down After the burner has been shut down the BCU checks the tightness of the gas solenoid valves and the pipe work between them Once the test has been carried out successfully the next burner start is enabled The BCU always conducts a tightness test if mains vo...

Страница 31: ...t 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 tightness test can only be performed if pressure ...

Страница 32: ...g 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 and the volume downstream of V2 is at least 5 higher than the volume between the valves tL P59 tM P56 pZ pu 2 OK V1 V1 V1 OK V2 ...

Страница 33: ...e is opened the gas volume must not exceed 0 083 of the maximum flow rate 5 1 5 Measurement time tM The sensitivity of the tightness control in the BCU can be adjusted for each individual system by adapting the measurement time tM The longer the measurement time tM the greater the sensitivity of the tightness con trol The measurement time is set using parameter 56 to a value between 3 and 3600 s s...

Страница 34: ... VV L x VR Valves Pipework Type Volume VV l DN Volume per metre VR l m VAS 1 0 25 10 0 1 VAS 2 0 82 15 0 2 VAS 3 1 8 20 0 3 VAS 6 1 1 25 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 mea...

Страница 35: ...PZL PDZ M 750 ϑ 1 2 3 Vp1 VAS 665 VAS 665 pu 50 mbar Q N max 200 m3 h DN65 9 5 m Leakage rate QL 200 m3 h x 1000 l h 200 l h 1000 x 1 m3 h Test volume Vp1 1 1 l 9 5 m x 3 3 l m 32 45 l see page 34 Test volume Vp1 Measurement time for one test volume Vp1 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 96 Measurement time Vp1 ...

Страница 36: ...on the BCU complies with the requirements of NFPA 85 Boiler and Combustion Systems Hazards Code and NFPA 86 Standard for Ovens and Furnaces 5 2 1 Program sequence When the start up signal ϑ1 is received at terminal 1 the BCU checks that valve V1 is in its closed position using the POC switch After a timeout time of 10 s a signal from the POC switch valve V1 is closed must be received at terminal 4...

Страница 37: ...e pa rameters on Windows based PCs in order to adjust the BCU 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 112 BC Soft ...

Страница 38: ...ofinet also pro vides acyclic data exchange for events which are not constantly repeated such as sending parameter set tings and configuration data when the IO devices start up or sending a diagnostic message from the IO device to the IO controller during operation The data read or written acyclically by read write services are specified by an index see page 48 Indexes for acyclic com munication T...

Страница 39: ...via the bus module between the BCU IO device and PLC IO controller Bus module BCM 500 has two RJ45 connection sock ets for connection to the fieldbus on its front The con nection sockets are combined with an internal 2 port switch This allows the BCM 500 together with the BCU to be integrated in various network topologies star tree or line topology Requirements such as Auto Negotia tion and Auto C...

Страница 40: ...e controller PLC All network components which connect the automation system and the field devices must be certified for Profi net use For information on planning and the structure of a Profibus network and the components to be used e g cables lines and switches see Profinet Installation Guide at www profibus com ...

Страница 41: ...tains the device image and communi cations properties of the BCU Modules defined in the GSD file may be selected for configuration to integrate the BCU see page 42 Modules for cyclic data ex change The GSD file for the bus module can be ordered at www docuthek com The steps required to integrate the file are described in the instructions for the engineering tool for your automation system For para...

Страница 42: ...0 are shown in the following table The modules are assigned to the slots Module Slot Input address Output address Inputs outputs 1 n n 2 n Burner 1 flame signal 2 n Burner 2 flame signal 3 n Status signal 4 n Fault and warning signals 5 n n 1 Remaining times 6 n n 1 TC remaining times1 7 n n 1 PLC output information 8 n BCU input terminal information 9 n n 2 BCU output terminal information 10 n n ...

Страница 43: ...tput byte describes the digital signals which are output by the PLC IO controller to the BCU IO device The digital signals to control the burner control unit BCU occupy 1 byte 8 bits Parallel to the bus communication terminals 1 to 4 44 and 50 of the BCU can be wired This allows the BCU to be controlled using the digital signals of the bus com munication or the inputs at the terminals In the event...

Страница 44: ...r 2 is transferred from the BCU to the PLC as an analogue value using this module The flame signal occupies one byte with values from 0 to 255 flame signal from 0 to 25 5 µA Bit Byte n Data type Format Value 0 Burner 2 flame signal Byte DEC 0 255 0 25 5 μA 1 2 3 4 5 6 7 Status signal module device controller slot 4 This module transfers the status signals from the BCU to the PLC The status signals...

Страница 45: ... to the fault signals and the warning signals Bit Byte n Data type Format Value 0 Fault signals Byte DEC 0 255 see Code table GSD_Codes_ BCU580 xlsx at www docuthek com 1 2 3 4 5 6 7 Bit Byte n 1 Data type Format Value 0 Warning signals Byte DEC 0 255 see Code table GSD_Codes_ BCU580 xlsx at www docuthek com 1 2 3 4 5 6 7 Remaining times module device controller slot 6 This module transfers the re...

Страница 46: ...t is transferred separately Bit Byte n Byte n 1 Data type Format Value 0 Remaining times of the valve proving system Word DEC 0 6554 0 6554 s 1 2 3 4 5 6 7 PLC output information module device controller slot 8 This module transfers information on signals which the PLC uses to control the BCU back to the PLC This al lows the signal transfer from the PLC to the BCU to be checked Bit Byte n Format 0...

Страница 47: ...erminal 45 Terminal 65 Free BOOL 6 Terminal 46 Terminal 66 Free BOOL 7 Terminal 47 Terminal 67 Free BOOL BCU output terminal information module device controller slot 10 This module transfers the signal states of the digital outputs on the BCU output terminals to the PLC Bit Byte n Byte n 1 Format 0 Terminal 9 Terminal 42 BOOL 1 Terminal 10 Terminal 43 BOOL 2 Terminal 13 Terminal 531 BOOL 3 Termin...

Страница 48: ...e g using system func tion block Siemens FSB 52 RDREC The available data records differ in terms of their in dexes Index Description 1001 Parameter 1002 Device statistics counter 1003 Device statistics faults warnings 1004 Operator statistics counter 1005 Operator statistics faults warnings 1006 Fault history 1007 Power module statistics The contents and description of the indexes are de scribed i...

Страница 49: ... tBP A1 Pre ventilation2 H1 Delay A Approaching minimum capacity2 A Approaching maximum capacity2 A Approaching ignition capacity2 Valve check 02 Safety time 1 A2 Safety time 1 H2 Delay 03 Flame proving period 1 tFS1 A3 Flame proving period 1 tFS1 04 Burner 1 operation A4 Burner 1 operation H4 Delay H5 Delay 06 Safety time 2 A6 Safety time 2 07 Flame proving period 2 ...

Страница 50: ...ogram step status A7 Flame proving period 2 08 Burner 2 operation A8 Burner 2 operation H8 Delay U I Remote control with OCU Data transfer programming mode Device Off 1 In Manual mode two dots blink on the display 2 Air actuator control element valve is open ...

Страница 51: ...rts for burner 2 12 5 restarts in 15 minutes Controller enable output terminal 56 20 Controller enable output incorrectly connected supplied with power from an external source Simultaneous activation terminals 51 and 52 21 Maximum capacity and Ignition capacity position feedback from butterfly valve set simultaneously Actuator wiring terminals 52 55 22 Faulty wiring of terminals 52 to 55 Actuator ...

Страница 52: ...or 80 Flame amplifier error device error Internal error 89 Error in processing internal data Internal error 94 Error at digital inputs Internal error 95 Error at digital outputs Internal error 96 Error when checking the SFR Internal error 97 Error when reading the EEProm Internal error 98 Error when writing to the EEProm emBoss 99 Shut down without application error Minimum capacity not reached A ...

Страница 53: ...llocated in the network name Controller in STOP position 4 Controller in STOP position Burner 1 flame simulation A1 Burner 1 flame simulation while air valve open No flame after safety time 1 A2 No flame during safety time 1 while air valve open Flame failure during flame proving period 1 A3 Flame failure during flame proving period 1 while air valve open Flame failure during burner 1 operation A4...

Страница 54: ...ion UVS UVD Ionization1 and UVS 2 Ionization1 and UVD 2 UVS 1 and ionization 2 UVD 1 and UVD 2 UVD 1 and ionization 2 UVD 1 and UVS 2 0 High temperature operation 06 0 2 3 Off Intermittent operation with UVS Continuous operation with ionization UVD 0 Burner 1 start up attempts 07 1 2 3 1 start up attempt 2 start up attempts 3 start up attempts 1 Burner 2 start up attempts 08 1 2 3 1 start up attem...

Страница 55: ...ity On for approaching the position for maximum capacity On for approaching the position for minimum capacity 0 Running time 42 0 250 Running time in seconds if parameter 41 1 2 or 3 30 Low fire over run 43 0 1 2 3 4 5 6 7 8 9 10 Off Up to minimum capacity 1 s 2 s 3 s 4 s 5 s 10 s 20 s 30 s 40 s 1 Controller enable signal delay time tRF 44 0 250 Time in seconds 0 Air actuator control 48 0 1 2 3 4 ...

Страница 56: ... Valve opening time 1 tL1 59 2 25 Time in seconds 2 Minimum operating time tB 61 0 250 Time in seconds 0 Minimum pause time tBP 62 0 3600 Time in seconds 0 Operating time in Manual mode 67 0 1 Unlimited 5 minutes 1 Function of terminal 50 68 23 24 Purge with Low signal Purge with High signal 24 Function of terminal 51 69 0 8 13 Off AND with emergency stop trm 46 Max capacity position feedback IC 4...

Страница 57: ...n CLOSED position burner quick start 0 Password 77 0000 9999 Four digit number code 1234 Burner application 78 0 1 2 3 4 5 Burner 1 Burner 1 with pilot gas Burner 1 and burner 2 Burner 1 and burner 2 with pilot gas Two stage burner 1 Burner 1 and two stage burner 2 2 Pilot burner 79 0 1 With shut down In continuous operation 0 Fieldbus communication 80 0 1 2 Off With address check No address check...

Страница 58: ...et using parameter 01 In the case of UV control this value can be increased should the burner to be monitored be influenced by other burners for example Burner 2 flame signal switch off threshold FS2 Parameter 02 The sensitivity at which the burner control unit detects a flame at burner 2 can be set using parameter 02 In the case of UV control this value can be increased should the burner to be mo...

Страница 59: ...r for continuous operation UVD Burner 2 flame control is performed with an ionization electrode Parameter 04 8 burner 1 flame control is performed with a UV sensor for continuous operation UVD Burn er 2 flame control is performed with a UV sensor for intermittent operation UVS UV sensor for intermittent operation For intermittent operation the operating state of the complete system is limited to 2...

Страница 60: ... perature mode 750 C the flame may be controlled via the temperature using a safety temperature moni tor STM in order to increase the system s availability This means that no incorrect flame signals e g signals from a UV sensor which interprets reflected UV radia tion as extraneous signals may lead to faults FCU 500 H1 M HT 18 HT HT BCU 580 D 49 5 8 µC BCU 580 D 49 5 8 µC 5 8 STM When the HT input...

Страница 61: ...rature mode tSA1 tZ 04 06 02 03 00 t tFS1 tSA2 07 08 tFS2 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 41 42 L1 1 43 2 49 HT If the temperature in the furnace chamber drops below 750 C the HT input must be disconnected from the electrical power supply and the furnace must then be operated with flame control The BCU then responds depending on setting Parameter 06 0 The High temperature mode function is...

Страница 62: ...eration The BCU performs flame control again recom mended in the case of ionization control or UV control with UVD If no flame signal is present when High temperature mode is deactivated the burner control unit performs a fault lock out regardless of parameter 06 Fault pilot burner t 04 04 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 88 1 46 11 9 41 42 49 L1 HT Fault main burner t 08 08 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4...

Страница 63: ...8 1 46 11 9 41 42 L1 If no flame is formed during the start up so that at the end of the safety time tSA1 no flame signal is detected this will result in a BCU safety shut down with subse quent fault lock out The fault message 04 will flash in the BCU display depending on the burner operating mode Parameter 07 2 3 two or three start up attempts tSA1 tZ tSA1 tZ t 00 02 5 13 V1 1 14 V2 2 ϑ1 ϑ2 8 4 8...

Страница 64: ...flame is formed during the start up so that at the end of the safety time tSA1 no flame signal is detected this will result in a BCU safety shut down with subse quent fault lock out The fault message 06 will flash in the BCU display depending on the burner operating mode Parameter 08 2 3 two or three start up attempts tSA2 tSA2 tSA2 tSA1 tZ 04 06 02 03 00 t tFS1 06 tW 06 06 05 05 tW 5 13 V1 1 14 V...

Страница 65: ... 53 56 47 48 58 03 02 01 04 2 1 3 9 14 15 13 5 17 18 t tFS1 tSA1 tBP Parameter 78 1 burner 1 with pilot gas Three valves V1 V2 and V3 are included for a burner with a pilot gas valve These are connected to the valve outputs terminals 13 14 and 15 Valves V1 and V3 open to start the burner The burner is started with a limited ignition capacity using gas valve V3 After the elapse of the safety time t...

Страница 66: ...ot gas In this application the burner has an additional pilot gas valve V3 The valves are connected to the valve outputs terminals 13 14 15 and 57 Valves V1 and V4 open to start the pilot burner The burner is started with a limited ignition capacity using gas valve V3 After the elapse of the safety time tSA2 program step 06 valve V2 opens terminal 14 Pilot gas valve V3 is closed again after the el...

Страница 67: ...48 58 03 02 01 04 2 1 3 9 14 15 13 5 17 18 t tFS1 tSA1 tBP 1 Parameter 78 5 burner 1 and two stage burner 2 In this application the burner has an additional pilot gas valve V3 The valves are connected to the valve outputs terminals 13 14 15 and 57 Valves V1 and V4 open to start the pilot burner The burner is started with a limited ignition capacity using gas valve V3 Valve V2 terminal 14 can be op...

Страница 68: ...k out P07 1 or with one or two additional start up attempts P07 2 or 3 The BCU will complete a maximum of three start up attempts Safety time 1 must be determined on the basis of cur rent national standards and regulations The burner ap plication and the burner capacity are the main criteria for this If the ϑ1 signal terminal 1 drops out during safety time 1 the valves will not be switched off unt...

Страница 69: ...t lock out P08 1 or with one or two additional start up attempts P08 2 or 3 The BCU will complete a maximum of three start up attempts Safety time 2 must be determined on the basis of cur rent national standards and regulations The burner ap plication and the burner capacity are the main criteria for this If the ϑ1 signal terminal 1 drops out during safety time 2 the valves will not be switched of...

Страница 70: ...on ducted only if the safety of the installation is not im paired A restart is recommended for burners which oc casionally display unstable behaviour during operation The precondition for an automatic restart is that the burner can restart as intended in all operating phases In this case it must be ensured that the program se quence started by the BCU matches the application Parameter 09 0 Off 04 ...

Страница 71: ...not function a safety shut down with fault lock out occurs The display blinks and shows the fault message Parameter 09 2 burner 2 06 05 07 08 08 t tSA2 tFS2 1x tW2 tSB 2 s 88 5 13 V1 57 V4 1 14 V2 2 ϑ1 ϑ2 8 4 1 46 11 9 41 42 L1 1 43 2 17 18 If a flame failure occurs during operation minimum op erating time of 2 s valve 2 is closed and the operation signalling contact is opened within the safety ti...

Страница 72: ...ously without a safety shut down with subsequent fault lock out being performed The BCU has a safety shut down with subsequent fault lock out option if more than 5 restarts are performed within a period of 15 minutes Taking into account national standards and require ments it must be clarified whether the option may be used Parameter 09 5 max 5 in 15 min for burner 2 Parameter 09 6 max 5 in 15 min...

Страница 73: ...al drops out before the start of op eration controller enable e g during pre purge the burner control unit reverts directly to the start up posi tion standby and the burner is not ignited The minimum operating time can be cancelled by switching off the BCU or if a safety shut down occurs 10 4 3 Pilot burner Parameter 79 tSA1 04 06 07 08 02 03 00 t tFS1 tSA2 tFS2 13 V1 14 V2 15 V3 57 V4 ϑ1 ϑ2 4 88 ...

Страница 74: ...peration or an interruption at the safety current inputs terminals 45 to 51 and 65 to 68 The safety time can be set to 1 or 2 s Prolonging the safety time during operation increases the installation availability in the case of brief duration signal fades e g fades of the flame signal In accordance with EN 298 the maximum reaction time to a flame failure must not exceed 1 s In accord ance with EN 7...

Страница 75: ...uators IC 20 IC 40 RBW or air valve Parameter 40 0 Off no capacity control no air actua tor 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 53 54 55 56 52 6 65 66 67 68 49 50 51 17 1 13 14 15 BCU 580 F1 3 15AT µC 88 24V DC PE L1 N 3PS 3 2 1 16 6 7 4 8 12 11 1...

Страница 76: ... controller en able output terminal 56 has a different function The wiring between the BCU and the 3 point step controller can be adjusted so that the control range of the actua tor is between the positions for maximum and ignition capacity 53 54 55 56 52 65 66 67 68 49 50 51 13 14 15 BCU 580 F1 µC 88 PE L1 N 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 0 90 S1 Min Max 3PS...

Страница 77: ...r enable output terminal 56 During the con troller enable procedure the actuator can be adjusted infinitely between the positions for maximum and mini mum capacity by a controller 0 4 20 mA 0 10 V using the setpoint device on terminals 17 and 18 or the bus signal There is no timeout active in this case If bus control is active parameter 75 the controller en able output terminal 56 has a different ...

Страница 78: ...5 BCU 580 F1 3 15AT µC 88 c c 41 42 24V DC 5 6 9 11 12 10 7 62 61 The 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 safety shut down of the BCU will be performed A ...

Страница 79: ... Minimum Ignition capacity ON ON High fire rate High fire rate OFF ON Purge Maximum capacity Operating mode 27 During the controller enable procedure the actuator IC 40 can be adjusted infinitely between the positions for maximum and minimum capacity using its ana logue input terminals 18 and 19 There is no timeout active in this case t s t s t1 t2 t3 t4 t5 t6 0 20 mA DI 1 DI 2 Purge Closed Igniti...

Страница 80: ...ion 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 BCU are non functional and are not activated Manual mode In Manual mode no external controller is enabled The actuator can be moved to the positions for maximum capacity or ignition capacity by the u...

Страница 81: ...hed 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 BCU 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 triggers the program continue switch conditions If reaching the positi...

Страница 82: ... 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 ...

Страница 83: ...is open the maximum capacity is reached BCU 580 F3 µC VAS VAS 1 VAG TZI TGI VR L V1 V2 V4 10 9 13 14 57 8 5 Parameter 42 Running time can be used to adjust the behaviour of slow opening and closing air valves so that the system can be set to ignition position before a start up is initiated Parameter 41 Running time selection must be set to 1 to adjust this behaviour See page 84 Running time and 84...

Страница 84: ...step Approaching 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 BCU will initiate the next program ste...

Страница 85: ... Parameter 43 1 only for BCU F1 F2 up to minimum capacity The burner is not immediately switched off af ter the start up signal ϑ terminal 1 has been removed During low fire over run the control element is moved to the position for minimum capacity and the gas valves remain open until the flame fails or the position for min imum capacity is reached If the flame is extinguished this does not result...

Страница 86: ...ter 48 In cyclic operation parameters 48 and 49 on BCU F1 F2 and F3 determine the behaviour of the air actuator during burner start Parameter 48 0 opens on external activation tSA1 tZ 04 02 03 00 A0 t tFS1 tSA2 tFS2 A8 06 07 2 10 53 A 88 ϑ1 46 1 ϑ2 4 11 9 5 37 38 13 V1 1 2 14 V2 14 V3 57 V4 17 18 8 M This setting together with parameter 49 0 see page 89 Air actuator can be activated externally on ...

Страница 87: ...ting signal tSA1 tZ 04 02 03 00 A0 t tFS1 tSA2 tFS2 00 A0 00 A8 06 07 2 10 53 A 88 ϑ1 46 1 ϑ2 4 11 9 5 37 38 13 V1 1 2 14 V2 14 V3 57 V4 17 18 8 M This setting is required in the case of two stage main burners which are switched ON OFF via the ϑ2 input The air valve opens simultaneously with the operating signal for the main burner The air valve can be acti vated externally via the input at termin...

Страница 88: ...air actuator can be opened in standby via the input at terminal 2 for this purpose Cooling is then only pos sible in the start up position standby The controller enable signal is suspended during cooling tSA1 tZ 04 02 03 00 A0 t tFS1 tSA2 tFS2 00 A0 00 08 06 07 2 53 A 17 18 M 56 mA 88 Parameter 48 4 opens with V4 pilot burner tSA1 tZ A4 A2 A3 00 A0 t tFS1 tSA2 tFS2 00 A0 00 A8 A6 A7 2 10 53 A 88 ϑ...

Страница 89: ...A1 tZ tFS1 A000 A3 ϑ1 ϑ2 53 M The air actuator can be activated externally via the input at terminal 2 during start up Parameter 48 must be set to 0 for this purpose see also page 86 Air actuator control 10 6 8 Air actuator in the event of fault Parameter 50 This parameter decides whether the air actuator can be activated externally via the input at terminal 2 in the event of a fault lock out Para...

Страница 90: ...BW or alternatively with a comparable three point step actuator If the air supply is stopped on a heated furnace with the burner switched off the controls may be dam aged 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 standby S1 for...

Страница 91: ...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 standby 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 th...

Страница 92: ... result 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 standby 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 ...

Страница 93: ...e 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 rotation to approach the position for ignition capacity S1 for ignition capacity of the burner S2 for reversing the direct...

Страница 94: ...e without cooling If pre 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 for minimum capacity and ignition capacity of the burner S2 for reversing the direction of rotation to approach the position for ignit...

Страница 95: ...rameter 51 1 tightness test before start up Parameter 51 2 tightness test after shut down With this setting a tightness test is also performed after a fault is reset and after mains on Parameter 51 3 tightness test before start up and after shut down An additional bypass valve must be installed in gas sec tions with an air gas ratio control The valve allows the closed air gas ratio control to be b...

Страница 96: ... volume is discharged via the valve connected to terminal 15 Parameter 52 4 V4 The test volume is discharged via the valve connected to terminal 57 10 7 3 Measurement time Vp1 Parameter 56 The required measurement time must be determined according to the requirements of the appropriate appli cation standards e g EN 1643 BCU 56x C1 µC P 13 14 45 pu 2 TC PZ 750 ϑ 1 2 3 pu 2 PZ Vp1 V1 V2 The required...

Страница 97: ...es If the preset opening time tL 2 s is inadequate e g if slow opening valves are used to fill the test volume or re duce the pressure between the valves bypass valves can be used instead of the main valves The opening time may be longer than the 3 s permitted by the standard EN 1643 2000 if the gas volume which flows into the combustion chamber is equal to or less than 0 083 of the maximum flow r...

Страница 98: ... 1 Minimum pause time tBP Parameter 62 A minimum pause time tBP 0 to 3600 s can be defined to achieve stable operation of the burners If a signal is applied to terminal 1 burner start up or terminal 2 cooling during the minimum pause time status display Delay H0 will appear ...

Страница 99: ...an be opened and closed as required By holding the button the actuator is first opened fur ther The BCU indicates A with blinking 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 BCU indicates A with blinking dots A change of direc tion takes place each time the button i...

Страница 100: ...or post purge In the case of multiple burner applications burners with mechanical combustion air supply are used The air for combustion and pre venti lation is supplied by a central fan controlled by a sepa rate automation system The automation system sends a signal to terminal 50 during purging At this point the BCU opens the air actuator actuator air valve regard less of the status of the other ...

Страница 101: ...ensure that the burners only start with the start up fuel rate the FCU issues an enable signal to start the burner via terminal 66 to the BCU with setting P71 20 In addition the safety interlocks must have been enabled by the FCU BCU BCU FCU µC 54 55 53 24V M L1 L1 54 55 53 M 66 66 10 10 5 Function of terminal 67 Parameter 72 Parameter 72 0 Off Parameter 72 8 AND with input at terminal 46 emer gen...

Страница 102: ...ed using pa rameter 80 when bus module BCM 500 is connected A device name must be entered in the automation system for the unique identification of the control unit BCU FCU in the Profinet IO system Parameter 80 0 Off Parameterization access using BCSoft via Ethernet is still possible Parameter 80 1 with address check The device name on delivery for the BCU 580 is not assigned bcu 580 xxx The expr...

Страница 103: ...W Mains voltage 120 V AC 50 60 Hz 230 V AC 50 60 Hz C0 C1 No valve proving system With valve proving system F1 F2 F3 Capacity control interface for actuator IC interface for RBW actuators air valve control U0 Ionization or UV control in case of operation with gas D0 D1 Digital input none for high temperature operation K0 K1 K2 No plug in terminals Plug in terminals with screw connection Plug in te...

Страница 104: ...l is aligned vertically end clamps are re quired e g Clipfix 35 by Phoenix Contact to prevent the BCU from slipping Environment Install in a clean environment e g a control cabinet with an enclosure IP 54 whereby no condensation is permitted 12 2 Commissioning Do not start the BCU until the parameter settings and wiring are correct and the faultless processing of all input and output signals compl...

Страница 105: ...ng of the safety circuits e g pressure switches gas valves 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 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 BCU cables in the same cable duct a...

Страница 106: ...rrent inputs the fuse must 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 24 V 62 61 1 2 3 4 L1 ϑ1 P70 ϑ2 P70 P70 P69 P73 P72 P72 HT pu 2 GZL PZL P71 0 6 IN 46 45 65 66 67 ...

Страница 107: ...peration The 0 20 mA current output can only be used to display the flame signal If it is used for the dis play in a control room for example then the cable to the control room must be screened Alternating pilot burner Parameter 79 0 µC 88 c c 24V DC 9 11 12 10 62 61 230V 1 2 3 4 ϑ1 P73 72 72 46 45 65 66 67 68 49 50 51 52 5 6 7 8 17 18 37 38 max 1A 24VDC 250VAC 3 15AT 42 41 43 13 14 15 57 V1 V2 V3...

Страница 108: ... 02 04 06 08 06 08 ϑ1 ϑ2 PLC 12 4 1 IC 20 The BCU 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 129 Lift ing To ensure this check is possible BCU F1 and actuator IC 20 or equivalent three point step actuators must be wired as shown in the connection diagram I 17 18 37 38 N max 1A 24VDC 250VAC BCU 580 3...

Страница 109: ...ctrical power supply for this purpose The valid parameters are then adopted by the new BCU The old device and the new BCU must have an identical type code 12 6 Protecting the pilot burner from overload To protect the unit against overload by frequent cycling only a specific number of pilot burner start up attempts can be carried out by the BCU The maximum number of start up attempts per minute dep...

Страница 110: ...BCU 580 Edition 11 15l 110 Project planning information 12 7 Calculating the safety time tSA ...

Страница 111: ...a fifth gas valve To do this the output of a gas valve must be used as auxiliary en ergy e g V2 as a result of the required flame control BCU F3 13 14 15 N V2 V3 V1 53 54 V5 57 V4 The following application describes a two stage con trolled burner without a pneumatic air gas ratio control system V2 and the air valve are activated simultane ously V2 must not be activated during purging BCU 580 F3 V1...

Страница 112: ...g BCSoft CD ROM Order No 74960625 13 1 2 Bluetooth adapter PCO 300 Including BCSoft CD ROM Order No 74960617 13 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 114 OCU OCU 500 1 Order No 8432...

Страница 113: ...rameters stickers 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 n...

Страница 114: ... 500 BCU 500 series The external operator control unit OCU may be installed in the door of a control cabinet for example Thus the control cabinet does not need to be opened to read out process values statistics flame signal intensities or parameter values to change set tings on the OCU or to control or adjust connected but terfly valves in Manual mode ...

Страница 115: ...you can operate connected control units in Manual mode There are five control keys for the OCU and the control unit connected to it 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 can use the...

Страница 116: ...of the con troller enable emergency stop input terminal 46 is retained The positions for maximum capacity minimum capacity 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 comple...

Страница 117: ...gs provided Required signal and control line cable length max 10 m 4 pin min 0 25 mm2 AWG 24 max 0 34 mm2 AWG 22 Wire each conductor on both plugs to the same contact 14 4 Installation The threaded adapters of the OCU are suitable for 23 mm boreholes which are drilled at intervals of 30 mm 60 mm 90 mm 23 mm 15 mm 90 mm OK ...

Страница 118: ...ussian Polish Croatian Romanian Czech 84327033 14 6 Technical data for OCU Ambient temperature 20 to 60 C Relative humidity 30 to 95 no condensation permitted Enclosure IP 65 when fitted control cabinet door Dimensions of the operator control unit 90 x 90 x 18 mm W x H x D Electrical connection Connection data wire cross section flexible min 0 25 mm wire cross section flexible max 0 34 mm wire cro...

Страница 119: ...rol signals for start ing resetting and for controlling the air valve to purge the furnace or kiln or for cooling in start up position and heating during operation from the 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 15 3 Electrical connection Use only cable and plug components which comply with the...

Страница 120: ... e g a control cabinet with an enclosure IP 54 whereby no condensation is permitted 15 5 Selection Code Description BCM Bus module 500 Series 500 S0 Standard communication B2 Profinet 3 Two RJ45 sockets 3 Three point step control via bus Order No 74960663 15 6 Technical data Electrical data Power consumption 1 2 VA Power loss 0 7 W Mechanical data Dimensions W H D 32 5 115 100 mm Weight 0 3 kg Env...

Страница 121: ...ts terminals 53 54 and 55 max 1 A each cos ϕ 1 Ignition transformer terminal 9 max 2 A Total current for the simultaneous activation of the valve outputs terminals 13 14 15 and 57 the actu ator terminals 53 56 and the ignition transformer max 2 5 A Signalling contact for operating and fault signals max 1 A external fuse required Number of operating cycles The fail safe valve outputs V1 V2 V3 and V...

Страница 122: ...max 12 Spring force terminal nominal cross section 2 x 1 5 mm wire cross section min 0 2 mm wire cross section AWG min 24 wire cross section AWG max 16 wire cross section max 1 5 mm rated current 10 A 8 A UL to be observed in case of daisy chain 16 3 Environment Ambient temperature 20 to 60 C 4 to 140 F no condensation permitted Enclosure IP 20 pursuant to IEC 529 Installation location min IP 54 f...

Страница 123: ...x 10 9 1 h Air flow monitoring 7 2 x 10 9 1 h Air flow monitoring with optional input 7 1 x 10 9 1 h Flame control 6 5 x 10 9 1 h Approaching position for ignition capacity with F1 IC 20 5 6 x 10 9 1 h Approaching position for ignition capacity with F2 RBW 5 9 x 10 9 1 h Approaching position for ignition capacity with F3 5 3 x 10 9 1 h SIL 3 is only achieved in conjunction with actuators IC 20 or ...

Страница 124: ...BCU 580 Edition 11 15l 124 Technical data 16 6 Converting units See www adlatus org ...

Страница 125: ... method isolation of the valve outputs from the mains In the event of a de fect 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 stati...

Страница 126: ...aximum pressure PZL Pressure switch for minimum pressure PDZ Differential pressure switch Pxx Input signal depending on parameter xx M Actuator with butterfly valve TC Tightness test pu 2 Half of the inlet pressure pu Inlet pressure pd Outlet pressure Vp1 Test volume GZL Valve with proof of closure switch Fan Three point step switch Emergency stop Input Output safety circuit IN Current consumption...

Страница 127: ...t safety control and switching equipment for the use of the application e g safety temperature limiter minimum maximum gas pressure must isolate input from the voltage supply 19 4 Safety time on start up tSA1 This refers to the period of time between switching on and switching off of the gas valve when no flame signal is detected The safety time on start up tSA1 2 3 5 or 10 s is the minimum operat...

Страница 128: ...tem cannot be reset by mains failure In the event of a fault lock out of the BCU the fault sig nalling contact closes the display blinks and shows the current program step see page 51 Fault signalling The gas valves are disconnected from the electrical power supply The fault signalling contact opens if the mains voltage fails In order to restart the BCU can only be reset manually using the button ...

Страница 129: ...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 automation system and or control elements Unit from EN ISO 13849 1 2008 19 13 Operating mode IEC 61508 describes tw...

Страница 130: ... appear from EN 13611 A2 2011 19 15 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 19 16 Mean time to dangerous failure MTTFd Expectation of the mean time to dangerous failure from EN ISO 13849 1 2008 ...

Страница 131: ...swer Use To get to know the product To choose a product Planning To look for information My scope of functions Technical department Sales No answer Remarks Elster GmbH Postfach 2809 49018 Osnabrück Strotheweg 1 49504 Lotte Büren Germany Tel 49 541 1214 0 Fax 49 541 1214 370 info kromschroeder com www kromschroeder com Contact The current addresses of our international agents are available on the I...

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