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BCU 560, BCU 565 · Edition 02.16

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= To be continued

Contents

Burner control units BCU 560, BCU 565 . . . . . . . . . . . . . . . 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

1.1 Examples of application. . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1.1 Single-stage-controlled burner. . . . . . . . . . . . . . . . . . . . . . . .7

1.1.2 Two-stage-controlled burner . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.3 Modulating-controlled burner . . . . . . . . . . . . . . . . . . . . . . . .9

1.1.4 Flame control using the temperature . . . . . . . . . . . . . . . . .10

1.1.5 menox

mode to reduce NO

formation . . . . . . . . . . . . . . 11

1.1.6 PROFINET connection using bus module BCM . . . . . . . . . . 12

1.1.7 ON/OFF rotary impulse control for burners up to 360 kW . 13

1.1.8 Modulating burner control . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1.1 BCU 560..F3 with ionization control in double-electrode

operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1.2 BCU 560..F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1.3 BCU 560..F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.4 BCU 565..F3 with ionization control in double-electrode

operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.5 BCU 565..F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1.6 BCU 565..F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1.7 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2 BCU 560 program sequence . . . . . . . . . . . . . . . . . . . . 23
3.3 BCU 565 program sequence . . . . . . . . . . . . . . . . . . . . 24

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

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

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

4.1.2 BCU..F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5 menox

low NO

mode . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1 System structure and function. . . . . . . . . . . . . . . . . . . . 28
5.2 BCU..D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6 Valve proving system . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.1 Tightness control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.1.1 Test instant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.1.2 Program sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1.3 Test period t

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.1.4 Opening time t

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.1.5 Measurement time t

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.2 Proof of closure function. . . . . . . . . . . . . . . . . . . . . . . . 38

6.2.1 Program sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7 BCSoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8 Profinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.1 BCU and bus module BCM. . . . . . . . . . . . . . . . . . . . . . 41
8.2 GSD file for PLC configuration. . . . . . . . . . . . . . . . . . . . 42

8.2.1 Modules for cyclic data exchange . . . . . . . . . . . . . . . . . . 43

8.2.2 Indexes for acyclic communication . . . . . . . . . . . . . . . . . 48

9 Program step/status .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 49
10 Fault signalling .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 50
11 Parameters .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 53

11.1 Scanning the parameters. . . . . . . . . . . . . . . . . . . . . . . 58
11.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

11.2.1 Burner 1 FS1 flame signal switch-off threshold. . . . . . . . . 58

11.2.2 Flame control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

11.2.3 High temperature operation . . . . . . . . . . . . . . . . . . . . . . 60

11.3 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . 62

11.3.1 Burner 1 start-up attempts. . . . . . . . . . . . . . . . . . . . . . . . . 62

11.3.2 Burner application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

11.3.3 Safety time 1 t

SA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

11.3.4 Flame proving period 1 t

FS1

. . . . . . . . . . . . . . . . . . . . . . . . 71

11.4 Behaviour during operation. . . . . . . . . . . . . . . . . . . . . 72

11.4.1 Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

11.4.2 Minimum operating time t

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

11.5 Safety limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

11.5.1 Low air pressure protection . . . . . . . . . . . . . . . . . . . . . . . 74

11.5.2 Air pressure cut-out delay . . . . . . . . . . . . . . . . . . . . . . . . 74

11.5.3 Safety time during operation . . . . . . . . . . . . . . . . . . . . . . .75

11.6 Air control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Содержание BCU 560

Страница 1: ...nited burners of unlimited capacity in intermittent or continuous operation Optionally with valve proving system Optionally with menox operating mode to reduce the formation of thermal NOx Flexible range of applications due to parameterization possibilities PROFINET fieldbus connection using optional bus module Assume safety functions pursuant to EN 746 2 EU certified Certified for systems up to S...

Страница 2: ...U F3 27 5 menox low NOx mode 28 5 1 System structure and function 28 5 2 BCU D2 30 6 Valve proving system 31 6 1 Tightness control 31 6 1 1 Test instant 32 6 1 2 Program sequence 33 6 1 3 Test period tP 35 6 1 4 Opening time tL 35 6 1 5 Measurement time tM 35 6 2 Proof of closure function 38 6 2 1 Program sequence 38 7 BCSoft 39 8 Profinet 40 8 1 BCU and bus module BCM 41 8 2 GSD file for PLC conf...

Страница 3: ... 100 11 11 2 Function of terminal 51 100 11 11 3 Function of terminal 65 100 11 11 4 Function of terminal 66 101 11 11 5 Function of terminal 67 102 11 11 6 Function of terminal 68 103 11 12 Password 104 11 13 Fieldbus communication 104 12 Selection 105 12 1 Type code 105 13 Project planning information 106 13 1 Installation 106 13 2 Commissioning 106 13 3 Electrical connection 107 13 3 1 OCU 107 ...

Страница 4: ...art up tSA1 127 20 2 Ignition time tZ 127 20 3 Safety time during operation tSB 127 20 4 Safety interlocks 127 20 5 Safety shut down 127 20 6 Safety shut down with subsequent fault lock out fault lock out 127 20 7 Warning signal 128 20 8 Timeout 128 20 9 Lifting 128 20 10 Air valve 128 20 11 Diagnostic coverage DC 128 20 12 Operating mode 128 20 13 Safe failure fraction SFF 129 20 14 Probability o...

Страница 5: ...via which an air valve or actuator IC 20 IC 40 or RBW can be controlled for staged or modulating burner capacity control The BCU 565 F3 is equipped with air flow monitoring and pre and post ventilation for use on self recuperative burners The program status the unit parameters and the level of the flame signal can be read directly from the unit The burner or a connected control element can be acti...

Страница 6: ...ternal operator control unit OCU is available as an option for the burner control units The OCU can be installed in the control cabinet door instead of standard control units The program status 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 The address for the fieldbus communication i...

Страница 7: ...adjusted to the requirements of the applications using the parameters of pre ventilation and post ventilation The pressure switch monitors the air flow in the air supply line or in the flue gas exhaust PDZ BCU 565 F3 µC VG VG L TZI TGI VR R V1 V2 14 13 9 10 47 38 37 18 17 1 2 3 46 49 50 41 42 ECOMAX FCU 500 Process control PCC ϑ A P HT VMV DG PLC ...

Страница 8: ...e When the operating state is reached the BCU advises the control unit Depending on the parameter set ting the air valve is actuated to open and close by the program or externally via the input at terminal 2 Application Examples of application BCU 560 C0F3 µC VAS VAG TZI TGI VR L V1 V2 14 13 9 7 10 U V S 38 37 18 17 1 2 3 FCU 500 Process control PCC 46 49 50 P HT ϑ 41 42 A PLC ...

Страница 9: ...moves the but terfly valve for air to ignition position The burner starts at low fire rate a three point step controller controls the burner capacity via the butterfly valve for air after the operating state has been signalled BCU 560 C0F1 µC VAS VAG TZI TGI V1 V2 V3 14 15 13 9 7 U V S 38 37 18 17 1 2 3 46 49 50 41 42 M 52 53 54 55 56 VAS 1 Process control PCC ϑ A P DI FCU 500 PLC ...

Страница 10: ...safe HT output that the furnace system is in High tempera ture mode HT When the HT input is activated the burner control units switch to High temperature mode They operate without 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...

Страница 11: ...d by actuator IC 40 and butterfly valve BVH An air pressure switch upstream of the burner monitors the functioning of the butterfly valve In addition air gas ratio monitoring for the zone or the furnace is required As soon as the safety temperature monitor STM signals a furnace temperature of 850 C 1562 F the burner can be switched to flameless combustion menox low NOx mode to significantly reduce...

Страница 12: ...m the auto mation 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 opposite 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...

Страница 13: ...requen cy always maintains full momentum and results in maximum convection in the furnace chamber even with regulated heating The pneumatic ratio control system con trols the gas pressure on the burner pro portionally 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 The ignition and monitoring of the in dividual burner...

Страница 14: ...as 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 monitoring The centrally checked safety functions such as pre purge setting the valve to ignition position via a butterfly valve control system tightness test flow detec tor and pr...

Страница 15: ...nces Directive 2009 142 EC Meets the requirements of the Low Voltage Directive 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 Eurasian Customs Union The products BCU 560 and BCU 565 meet the technical speci fications of the Eurasian Customs Union ...

Страница 16: ... c ϑ 0 V 24 V 41 42 24V DC HT pu 2 GZL PZL P 5 6 9 11 12 10 7 62 61 A P72 P71 c 230V 2AT 53 54 I Z 0 6 IN 3 Function 3 1 Connection diagram 3 1 1 BCU 560 F3 with ionization control in double electrode operation Alternative flame control see page 22 Flame control Electrical connection see page 106 Project planning infor mation Explanation of symbols see page 126 Legend ...

Страница 17: ...u 2 GZL PZL 5 6 9 11 12 10 7 62 61 ϑ A P72 P71 230V mA P40 2 3 51 52 53 54 55 56 P I Z 0 6 IN Function Connection diagram 3 1 2 BCU 560 F1 Alternative flame control see page 22 Flame control Detailed connection diagrams for actuators and frequency converters see from page 78 Capacity control Electrical connection see page 106 Project planning infor mation Explanation of symbols see page 126 Legend...

Страница 18: ...ZL PZL 5 6 9 11 12 10 7 62 61 A P72 P71 230V mA P69 13 52 53 54 55 56 COM HI LO AUTO P I Z 0 6 IN Function Connection diagram 3 1 3 BCU 560 F2 Alternative flame control see page 22 Flame control Detailed connection diagrams for actuators and frequency converters see from page 78 Capacity control Electrical connection see page 106 Project planning infor mation Explanation of symbols see page 126 Le...

Страница 19: ...page 106 Project planning infor mation Explanation of symbols see page 126 Legend Function Connection diagram 1 2 3 17 18 37 38 13 14 15 5 6 9 11 12 10 N L1 V1 V2 V3 max 1A 24VDC 250VAC BCU 565 F3 7 3 15AT µC 88 c 62 61 0 V 24 V 41 42 24V DC 53 54 ϑ A 46 45 48 47 65 66 67 68 49 50 51 P70 P70 P73 P72 P72 44 HT pu 2 GZL PZL P PZL PDZ PZL PDZ P72 P71 52 P69 2AT c I Z Airmin Air 0 6 IN ...

Страница 20: ... connection see page 106 Project planning infor mation Explanation of symbols see page 126 Legend Function Connection diagram 1 2 3 46 45 48 47 65 66 67 68 49 50 51 17 18 37 38 13 14 15 5 6 9 11 12 10 N L1 V1 V2 V3 max 1A 24VDC 250VAC BCU 565 F1 7 3 15AT µC 88 P70 P70 P73 P72 P72 c 62 61 ϑ 0 V 24 V 41 42 24V DC 44 HT pu 2 GZL PZL P c A PZL PDZ PZL PDZ P72 P71 mA 52 P69 P40 2 3 51 53 54 55 56 I Z A...

Страница 21: ...apacity control Electrical connection see page 106 Project planning infor mation Explanation of symbols see page 126 Legend 1 2 3 46 45 48 47 65 66 67 68 49 50 51 17 18 37 38 13 14 15 5 6 9 11 12 10 N L1 V1 V2 V3 max 1A 24VDC 250VAC BCU 565 F2 7 3 15AT µC 88 P70 P70 P73 P72 P72 c 62 61 ϑ 0 V 24 V 41 42 24V DC HT pu 2 GZL PZL P c A PZL PDZ PZL PDZ P72 P71 mA P69 13 53 54 55 56 COM HI LO AUTO 52 I Z...

Страница 22: ...1 42 24V DC 5 6 9 11 12 10 7 62 61 ϑ 230V mA 52 53 54 55 56 UVS 1 2 3 Z N L1 UVD control 1 2 3 46 45 65 66 67 68 49 50 51 17 18 37 38 13 14 15 L1 V1 V2 V3 max 1A 24VDC 250VAC BCU 560 F1 3 15AT µC 88 P70 P69 P70 P73 P72 P72 c c 24 V 41 42 24V DC HT pu 2 GZL PZL 5 6 9 11 12 10 7 62 61 ϑ A P72 P71 230V m P40 2 3 51 52 53 54 55 56 P 0 V 24 V 0 20 mA UVD1 1 2 4 3 5 6 Z N L1 0 6 IN A voltage supply of 2...

Страница 23: ... the running time has elapsed P42 02 Safety time 1 tSA1 P94 running ignition in process valves for 1st gas stage open If no flame detected max 3 start up attempts P07 or fault lock out 03 Flame proving period 1 tFS1 running P95 In the event of flame failure fault lock out 04 Operation signalling contact closes valve for 2nd gas stage opens and min operating time tB starts to elapse P61 In the even...

Страница 24: ...n time tVL running P36 air actuator opens A2 Safety time 1 tSA1 running P94 ignition in process valves for 1st gas stage open If no flame detected max 3 start up attempts P07 or fault lock out A3 Flame proving period 1 tFS1 running P95 In the event of flame failure fault lock out A4 Operation signalling contact closes valve for 2nd gas stage opens and min operating time tB starts to elapse P61 In ...

Страница 25: ...U F3 valve are actuated for this purpose 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 M FCU 500 F0 µC P DG DG DG VAS VAS VCG VCG VR L VR L DG DG DGmin DGmax 49 15 13 14 50 45 47 48 58 750 pu 2 DLmin DLPurge BCU 5xx...

Страница 26: ...at terminal 1 The control element can be activated to control the burner s capacity dependent on parameters 48 and 49 Modulating control Parameter 48 3 After the operating signal has been received from the burner and after expiry of the delay time for the controller enable signal parameter 44 the BCU issues the controller enable signal via the output at terminal 56 Access to the control ele ment i...

Страница 27: ...rts the pre purge time if there is adequate air flow After the elapse of the pre purge time the air valve closes for ignition 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 the ...

Страница 28: ...pressure regulator e g VAD The gas volume is set using a fine adjusting valve e g VMV The air volume for the operating modes is set by adjusting the butterfly valve e g BVH The air pressure is monitored on each burner by a pressure switch to check the functioning of the butterfly valve In addition air gas ratio monitoring for the zone or the furnace is required since the air pres sure switch is no...

Страница 29: ...e combustion chamber The oxidation reactions take place without a visible flame Compared to traditional flame mode the reaction zone is considerably larger and the reaction density considerably lower This prevents the occurrence of peak temperatures which are responsible for high NOx values Emissions of NOx are drastically reduced 850 1050 1250 1200 1150 1100 900 1000 950 0 100 200 300 400 Furnace...

Страница 30: ...eters of menox pre ventilation time burner application and settings for the control element coordinated for menox mode Parameter settings for switching between flame mode and menox mode see pages 63 Burner application 95 menox pre ventilation time tVLM and 95 Switchover to menox operating mode BCU 565 C0F1 µC 49 FCU 500 Process control PCC HT 38 37 18 17 1 2 3 46 50 41 44 42 ϑ A P 44 SPS If there ...

Страница 31: ...etails see pages 31 Tightness control and 38 Proof of closure function 6 1 Tightness control The aim of the tightness control is to identify an inadmissible leak on one of the gas solenoid valves and to prevent burner start Gas solenoid valves V1 and V2 are tested as is the pipe work between the valves V2 pu Vp1 V1 PZ pu 2 European standards EN 746 2 and EN 676 stipulate tightness controls for cap...

Страница 32: ...valve during this check The burner is ignited 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 tight ness of the gas solenoid valves and the pipework between them Once the test has been carried out successfully the next burner start is enabled The BCU immediately conducts a tightness test if mains ...

Страница 33: ...lf 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 tightness test can only be performed i...

Страница 34: ...1 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 down stream 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...

Страница 35: ...he tightness control in the BCU can be ad justed for each individual system by adapting the measure ment time tM The longer the measurement time tM the greater the sensitivity of the tightness control The measurement time is set using parameter 56 to a value between 3 and 3600 s see page 97 Measurement time Vp1 The required measurement time tM is calculated from Inlet pressure pu mbar Leakage rate...

Страница 36: ...etre 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 measurement time required for the test volume Vp1 must be set ...

Страница 37: ...570 C1 µC 13 14 15 47 58 48 TC PZL PDZ M 750 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 36 Test volume Vp1 Measurement time for one test volume Vp1 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 97 Measurement...

Страница 38: ... function the BCU complies with the requirements of NFPA 85 Boiler and Combustion Systems Hazards Code and NFPA 86 Standard for Ovens and Furnaces 6 2 1 Program sequence When the start up signal ϑ is received at terminal 1 the BCU 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 V1 ...

Страница 39: ...e to set device parameters on Windows based PCs in order to adjust the BCU to the specific application In addition BCSoft provides extended access to the individual statistics and protocol func tions 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 113 BCSoft ...

Страница 40: ...finet also provides acyclic data exchange for events which are not constantly repeated such as sending parameter settings and configu ration data when the IO devices start up or sending a diag nostic 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 communication The...

Страница 41: ...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 Negotiation and Auto Crossover are satisfied Safety related signals and interlocks e g safety interlock must be wired independently of the fieldbus communication direct to the BCU and the protective system e g FCU ...

Страница 42: ...le contains the device image and communications properties of the BCU Modules defined in the GSD file may be selected for configuration to integrate the BCU see page 43 Modules for cyclic data exchange 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 ...

Страница 43: ...ontrol units BCU 560 and BCU 565 are shown in the following table The modules are assigned to the slots Module Slot Input ad dress Output ad dress Inputs outputs 1 n n 2 n Burner 1 flame signal 2 n Free 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 informa tion 9 n n 2 BCU output terminal in...

Страница 44: ...ontroller device The output byte describes the digital signals which are output by the PLC IO controller to the BCU IO device The digital sig nals to control the burner control unit BCU occupy 1 byte 8 bits Parallel to the bus communication terminals 1 to 3 44 and 50 of the BCU can be wired This allows the BCU to be con trolled using the digital signals of the bus communication or the inputs at th...

Страница 45: ...table BCU56x_GSD_Codetabelle xlsx Bit Byte n Data type Format Value 0 Status signals Byte DEC 0 255 see code table BCU56x_ GSD_Codetabelle xlsx at www docuthek com 1 2 3 4 5 6 7 Fault and warning signals module device controller slot 5 The fault and warning signals are transferred from the BCU to the PLC using this module The fault and warning signals oc cupy one byte each 0 to 255 The allocation ...

Страница 46: ... 7 Remaining times of the valve proving system module device controller slot 7 Only for BCU C1 The module in BCU C0 contains no information This module transfers the remaining time of the valve prov ing system from the BCU C1 to the PLC The remaining time occupies 2 bytes The valve check runs parallel to other time related processes e g pre purge To display the remaining time of the valve proving ...

Страница 47: ...states of the digital inputs on the BCU 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 Free 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 BCU output t...

Страница 48: ...y on an event basis e g using system function block Siemens FSB 52 RDREC The available data records differ in terms of their indexes Index Description 1001 Parameters 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 index...

Страница 49: ...k A Approaching minimum capacity2 A Approaching maximum capacity2 P0 Pre purge P1 Pre purge A Approaching ignition capacity2 H2 Delay Valve check 02 Safety time 1 03 Flame proving period 1 tFS1 04 Burner 1 operation controller enable 09 Over run up to minimum capacity P9 Post purge U I Remote control with OCU Data transfer programming mode Device Off 1 In Manual mode two dots blink on the display ...

Страница 50: ...52 21 Maximum capacity and Ignition capacity posi tion feedback from butterfly valve set simultane ously Actuator wiring terminals 52 55 22 Faulty wiring of terminals 52 55 Actuator feedback terminal 52 23 Maximum or ignition capacity is not constantly signalled back to terminal 52 Simultaneous Min Max bus command 24 Open actuator and Close actuator bus signals set simultaneously Non fail safe par...

Страница 51: ... 44 57 menox mode without HT signal Internal error 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 a...

Страница 52: ...address 1 Invalid or incorrect address set on bus module Invalid configuration 2 The bus module has received an incorrect con figuration from the controller Invalid network name 3 Invalid network name or no address allocated in the network name Controller in STOP position 4 Controller in STOP position Burner 1 flame simulation F1 Burner 1 flame simulation during multi flame control No flame after ...

Страница 53: ...nuous operation with ionization UVD menox intermittent 0 Burner 1 start up attempts 07 1 2 3 1 start up attempt 2 start up attempts 3 start up attempts 1 Restart 09 0 1 4 Off Burner 1 Max 5 for burner 1 in 15 min 0 Low air pressure protection 15 0 1 2 Off With safety shut down With fault lock out 2 Air pressure cut out delay 16 0 1 Off On Safety time during operation 19 0 1 2 Time in seconds 1 men...

Страница 54: ...tion 41 0 1 2 3 Off checking the positions for minimum maximum capacity On for approaching the positions for mini mum maximum capacity On for approaching the position for maxi mum capacity On for approaching the position for mini mum 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 ...

Страница 55: ...d externally 1 Valve proving system 51 0 1 2 3 4 Off Tightness test before start up Tightness test after shut down Tightness test before start up and after shut down Proof of closure function 0 Relief valve VPS 52 2 3 V2 V3 2 Measurement time Vp1 56 3 5 25 30 3600 Time in seconds in 5 s steps in 10 s steps 10 Valve opening time tL1 59 2 25 Time in seconds 2 Minimum operating time tB 61 0 250 Time ...

Страница 56: ...n trm 47 AND with air flow monitoring trm 48 0 Function of terminal 66 71 0 8 9 10 20 Off AND with emergency stop trm 46 AND with airmin trm 47 AND with air flow monitoring trm 48 LDS ignition position check 0 Function of terminal 67 72 0 8 9 10 21 Off AND with emergency stop trm 46 AND with airmin trm 47 AND with air flow monitoring trm 48 Multi flame control MFC start up condi tions 0 Function o...

Страница 57: ...ition 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 Burner application 78 0 1 4 11 12 13 Burner 1 Burner 1 with pilot gas Two stage burner 1 1 0 in menox and 1 0 in flame mode 1 0 in menox and L H O in flame mode 1 0 in menox mode with 2 gas paths 1 Fieldbus communication 80 0 1 2 Off W...

Страница 58: ...1 flame signal switch off threshold Parameter 01 The sensitivity at which the burner control unit detects a flame can be set 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 During start up If the measured flame signal falls below the set value 2 to 20 µA during the start up after elapse of the saf...

Страница 59: ...estart does not meet the requirements of EN 298 for UV sensor continu ous operation because the required self test at least once per hour is not performed while the burner is operating This shut down and subsequent restart are performed in the same way as a normal controlled shut down Depending on the parameterization the burner is started with or without pre purge This process is controlled indep...

Страница 60: ...rol unit reverts to High temperature mode i e the BCU operates without evaluation of the flame signal The safety function of the device internal flame control system is deactivated In High temperature mode the gas valves are opened and the burners are started as usual without monitoring the pres ence of a flame The precondition for this operating mode is that an external flame supervision device e...

Страница 61: ... check recommended in the case of UV control with UVS Parameter 06 3 BCU D1 88 04 04 ϑ t 1 46 11 L1 9 5 13 V1 14 V2 49 HT 42 41 The burner remains in operation and the BCU performs flame control again recommended in the case of ionization control or UV control with UVD Parameter 06 5 BCU D2 tSA1 tZ 88 02 03 04 ϑ t tVLM 1 46 11 L1 9 5 13 V1 14 V2 01 49 44 04 tFS1 HT 42 41 The BCU switches off the b...

Страница 62: ...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 subsequent fault lock out The fault message 04 will flash in the BCU display depending on the burner operating mode Parameter 07 2 3 2 or 3 start up attempts tSA1 tZ 02 00 t tSA1 tZ 88 ϑ 1 46 11 L1 9 5 42 13 V1 14 V2 41 If no flame is formed during the s...

Страница 63: ... 15 13 52 55 54 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 th...

Страница 64: ...ner These are con nected to the valve outputs terminals 13 14 and 15 BCU 570 µC V1 V2 V3 14 15 13 52 55 54 53 56 47 48 58 03 02 01 04 2 1 3 9 14 15 13 5 17 18 t tFS1 tSA1 tBP Valves V1 and V3 open to start the burner The burner is started with a limited ignition capacity using gas valve V3 After the flame proving period tFS1 has elapsed valve V2 opens to en able the 2nd gas stage ...

Страница 65: ...me mode and in menox FCU Process Control PCC PZL DG BCU 565 F1 µC V1 V2 14 13 49 44 53 47 55 IC 40 BVH M 51 52 HT PLC STM In flame mode 850 C the burner is started conventionally as when P78 0 with the pre ventilation time defined in parameter 36 The air control valve is in the high position for flame mode 03 02 04 2 1 9 14 55 53 52 51 13 49 1 44 47 t tFS1 tSA1 PZL HT ϑ M ...

Страница 66: ...rmer takes place during safety time tSA The gas valves V1 and V2 are opened at the start of the safety time tSA 03 02 04 2 1 9 14 55 53 52 51 13 49 1 44 47 t tFS1 tSA1 PZL HT ϑ M An IC 40 with operating mode 06 is used as the actuator The relevant position is approached via terminals 53 and 55 of the BCU The air pressure switch and the position of the IC are checked by terminals 48 51 and 52 of th...

Страница 67: ...M 51 52 PLC STM In flame mode 850 C the burner is started conventionally as when P78 4 with the pre ventilation time defined in parameter 36 The air control valve is set to the low position Valves V1 and V3 then open The burner is started with a limited ignition capacity using gas valve V3 After the flame proving period tFS1 has elapsed valve V2 opens to enable the 2nd gas stage and the air contro...

Страница 68: ... ignition transformer takes place during safety time tSA1 Gas valves V1 V2 and V3 are opened at the start of the safety time tSA1 03 02 04 2 1 9 14 3 15 13 49 1 44 t tFS1 tSA1 HT ϑ 55 53 52 51 47 PZL M An IC 40 with operating mode 6 is used as the actuator The relevant position is approached via terminals 53 and 55 of the BCU The positions are checked by terminals 51 and 52 of the BCU The BCU sign...

Страница 69: ...ths in flame and in menox mode FCU Process Control PCC PZL BCU 565 F1 µC 53 47 55 M 51 52 V3 V4 15 57 13 49 44 HT V3 IC 40 BVH V1 PLC STM In flame mode 850 C the burner is started conventionally with the pre ventilation time defined in parameter 36 The air control valve is set to the high position for this purpose 03 02 04 3 1 9 15 4 57 13 49 1 44 t tFS1 tSA1 55 53 52 51 47 PZL M HT ϑ ...

Страница 70: ...akes place during safety time tSA1 The gas valves V1 and V4 are opened at the start of the safety time tSA1 03 02 04 3 1 9 15 4 57 13 49 1 44 t tFS1 tSA1 HT ϑ 55 53 52 51 47 PZL M An IC 40 with operating mode 6 is used as the actuator The relevant position is approached via terminals 53 and 55 of the BCU The air pressure switch and the position of the IC are checked by terminals 48 51 and 52 of th...

Страница 71: ...wn with fault lock 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 current na tional standards and regulations The burner application and the burner capacity are the main criteria for this If the ϑ signal terminal 1 drops out during safety time 1 the valves will not be s...

Страница 72: ...ce in the event of flame failure during operation Parameter 09 1 burner 1 The restart function is active tSA tZ 04 04 02 03 01 t tFS tW tSB 1x 2 s 88 ϑ 1 46 9 5 13 V1 14 V2 11 L1 42 41 If a flame failure occurs during operation minimum operating time of 2 s the valves are closed and the operation signalling contact is opened within the safety time during operation tSB The burner control unit then ...

Страница 73: ...ed until the set time has elapsed even if the start up signal fails The minimum operating time starts as soon as the program step for operation controller enable display 04 has been reached If the start up signal drops out before the start of operation controller enable e g during pre purge the burner control unit reverts directly to the start up position standby and the burner is not ignited The ...

Страница 74: ... safety shut down will be performed if there is no signal at the airmin input ter minal 47 Parameter 15 2 with fault lock out A safety shut down with fault lock out will be performed if there is no signal at the airmin input terminal 47 BCU 565 µC P pe 2 TC ϑ 1 2 3 47 PDZ If air flow monitoring during pre purge is active P35 1 or 2 the no flow state of the air flow monitoring pressure switch PDZ i...

Страница 75: ...ts terminals 45 to 51 and 65 to 68 The safety time can be set to 1 or 2 s Prolong ing 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 accordance with EN 746 2 the safety time of the installation during operat...

Страница 76: ... purging see page 74 Low air pres sure protection 11 6 2 Air flow monitoring during pre purge Parameter 35 Function of the air flow input terminal 48 The air flow is monitored during pre purge by the differential pressure switch connected to terminal 48 If the air volume and therefore the differential pressure on the air pressure switch falls below the set value the BCU will perform a safety shut ...

Страница 77: ...k and no flow state check have been conducted successfully the air valve is opened Start up of the burner commences with no interruption of the air supply after expiry of the programmable pre ventilation time tVL Parameter setting for this example sequence P23 0 P48 1 P36 0 see also page 74 Air pressure cut out delay The gas valve does not open until the pressure switch has switched 11 6 4 Post ve...

Страница 78: ...actuators IC 20 IC 40 RBW or air valve Parameter 40 0 Off no capacity control no air actuator Parameter 40 1 with IC 20 The interface is configured to the requirements of actuators 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 65 66 67 68 49 50 51 17 13 14 15 BCU 560 F1 3 15AT µC 88 24V DC PE L1 N 3PS 3 2 1 16 6 7 4 8 12 11 15 1...

Страница 79: ...oller enable out put 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 actuator is between the positions for maximum and ignition capacity 53 54 55 56 52 1 2 3 46 45 65 66 67 68 49 50 51 17 18 37 38 13 14 15 BCU 560 F1 3 15AT µC 88 c c 41 42 24V DC 5 6 9 11 12 10 7 62 61 PE L1 N 3 2 1 16 6 7 4 8 12 11 15...

Страница 80: ...l be displayed see page 50 Fault signalling In addition the actuator will be moved to the set position for minimum capacity using the output at terminal 54 The control system is enabled during operation via the control ler enable output terminal 56 During the controller enable procedure the actuator can be adjusted infinitely between the positions for maximum and minimum capacity by a controller 0...

Страница 81: ...erminal 52 checks the position for ignition 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 fault message A A or A will be displayed see page 50 Fault signalling If a controller enable is active the control system is enabled for operation via the outputs at terminals 53 and 55 Operating mode 11 Operating mode 11 allows cycl...

Страница 82: ...ty OFF ON Purge Maximum capacity Fault In the event of a fault there will be no signal at terminals 53 and 55 so that the actuator moves to the closed position When approaching the closed position 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...

Страница 83: ...a fault lock out of the BCU If parameter 41 0 the system monitors the movement to the positions for maximum and minimum capacity with a timeout time of 255 s Reaching the relevant position imme diately triggers the program continue switch conditions If reaching the position is not signalled within the timeout time of 255 s a safety shut down of the BCU will be performed A fault message A or A will...

Страница 84: ... igni tion capacity is reached if it is open the maximum capacity is reached BCU 560 F3 µC VAS VAG TZI TGI VR L V1 V2 14 13 9 7 10 U V S Parameter 42 Running time can be used to adjust the behav iour of slow opening and closing air valves so that the system can be set to ignition position before a start up is initiated see page 85 Running time Parameter 41 Running time selection must be set to 1 t...

Страница 85: ...tiate the next program step Approaching the position for minimum capacity is signalled and monitored Parameter 41 3 On for approaching the position for mini mum capacity No signal is returned that the position for mini mum capacity has been reached The running time set using parameter 42 is activated for approaching the position for minimum capacity see page 85 Running time After this time has ela...

Страница 86: ... flame fails or the position for minimum capacity is reached If the flame is extinguished this does not result in a fault Parameter 43 2 3 4 5 10 20 30 or 40 only for FCU F3 time in seconds During this time the gas valve remains open The air valve is closed with deactivated start up signal ϑ BCU 560 F3 µC VAS VAG TZI TGI VR L V1 V2 14 13 9 7 10 U V S This means that the burner is initially adjuste...

Страница 87: ...ich need to be started at low fire rate e g on two stage controlled burn ers see page 8 Two stage controlled burner In this case activation of the air actuator during burner start via the input at terminal 2 must be prevented External control allows switchover between low fire and high fire during operation Parameter 48 1 opens with valve V1 1st stage tSA tZ A4 A2 A3 00 A000 t tFS A0 2 10 53 A 88 ...

Страница 88: ...andby This parameter is used to activate modulating capacity control on BCU F1 and F2 The controller enable signal is issued via the output at terminal 56 in the start up position standby and during operation Cooling is then only possible in the start up position standby The air actuator can be opened via the input at terminal 2 for this purpose ...

Страница 89: ...ternally via the input at terminal 2 during start up Parameter 48 must be set to 0 for this purpose see also page 87 Air actuator control 11 6 12 Air actuator in the event of fault Parameter 50 This parameter decides whether the air actuator can be ac tivated externally via the input at terminal 2 in the event of a fault lock out Parameter 50 0 cannot be activated The air actuator re mains closed ...

Страница 90: ...or IC 20 RBW or alternatively 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 stan...

Страница 91: ...ted from the hot furnace atmosphere as a 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 ignition capacity of the burner S2 for minimum capacity of the burner S3 for maximum capacity of th...

Страница 92: ...rols are protected from the hot furnace atmosphere as a 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 ...

Страница 93: ... as a result of the 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 ap proach the position for ignition capacity S1 for ignition capacity of the burner S2 for r...

Страница 94: ...he burner can cope 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 burn er S2 for reversing the direction of rotation to approach the ...

Страница 95: ...er expiry of the running time P42 the BCU performs a shut down depending on parameter 15 Low air pressure protection 11 7 2 Switchover to menox operating mode Parameter 64 As soon as there is a signal at the menox input terminal 44 the BCU can switch to flame or menox mode immediately or upon the next burner start Switchover from flame mode to menox mode Parameter 64 0 on next burner start As long...

Страница 96: ...n Parameter 51 3 tightness test before start up and after shut down An additional bypass valve must be installed in gas sections with an air gas ratio control This 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 µC P 49 13 14 50 TC 750 ϑ 1 2 3 V1 V2 45 GZL A signal is sent to the BCU via the POC switch on t...

Страница 97: ...teps See also page 35 Measurement time tM 11 8 4 Valve opening time tL1 Parameter 59 This parameter is used to define the opening time for the valves 2 to 25 s which are opened to fill or discharge the test volume between the gas valves If the preset opening time tL 2 s is inadequate e g if slow opening valves are used to fill the test volume or reduce the pressure between the valves bypass valves...

Страница 98: ...e stable operation of the burners If the post ventilation time set using parameter 39 has elapsed and no signal ϑ is received at terminal 1 burner shut down a restart and cooling are prevented for the duration of the minimum pause time tBP 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: ...d as required By holding the button the actuator is first opened further 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 direction takes place each time the button is released and pressed a...

Страница 100: ...re ventilation is supplied by a central fan controlled by a separate automation system The automation system sends a signal to terminal 50 during purg ing At this point the BCU opens the air actuator actuator air valve regardless of the status of the other inputs The display shows P0 Parameter 68 23 purge with Low signal Parameter 68 24 purge with High signal 11 11 2 Function of terminal 51 Parame...

Страница 101: ...D with input at terminal 48 air flow pressure switch Parameter 71 20 LDS ignition position check The BCU does not perform a burner start up restart or start up attempt until the butterfly valve is in ignition position To 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 s...

Страница 102: ...er 72 8 AND with input at terminal 46 emergency stop Parameter 72 9 AND with input at terminal 47 airmin pres sure switch Parameter 72 10 AND with input at terminal 48 air flow pressure switch Parameter 72 21 Multi flame control MFC start up condi tions 1 2 3 46 45 65 66 67 68 49 50 51 5 6 9 11 12 10 BCU 56x 7 3 15AT µC 88 c c 62 61 24V DC 44 0 6 IN IFW IFW L1 ...

Страница 103: ...er 73 8 AND with input at terminal 46 emergency stop Parameter 73 9 AND with input at terminal 47 airmin pres sure switch Parameter 73 10 AND with input at terminal 48 air flow pressure switch Parameter 73 22 Multi flame control MFC operating con ditions 1 2 3 46 45 65 66 67 68 49 50 51 5 6 9 11 12 10 BCU 56x 7 3 15AT µC 88 c c 62 61 24V DC 44 0 6 IN IFW IFW L1 ...

Страница 104: ... using parameter 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 example for the BCU 560 is not assigned bcu 560 xxx...

Страница 105: ...C 50 60 Hz 230 V AC 50 60 Hz C0 C1 No valve proving system With valve proving system F0 F1 F2 F3 Capacity control none with interface for actuator IC with interface for RBW actuators with air valve control U0 Ionization or UV control in case of operation with gas D0 D1 D2 Digital input none for high temperature operation for menox K0 K1 K2 No plug in terminals Plug in terminals with screw connecti...

Страница 106: ...ed vertically end clamps are required 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 13 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 complies with th...

Страница 107: ...cabling of the safety circuits e g pressure switches gas valves outside enclosed instal lation spaces must be protected from mechanical damage and stress e g vibration or bending and from 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 du...

Страница 108: ...ensor 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 and from short circuits short circuits to ground and cross circuits 1 2 3 46 45 65 66 67 68 49 50 51 17 18 37 38 13 14 15 N L1 V1 V2 V3 max 1A 24VDC 250VAC BCU 560 F0 3 15AT µC 88 P70 P69 P70 P73 P72 P72 c c ϑ 0 V 24 V 4...

Страница 109: ...oltage supply of 24 V DC is required to operate the UV sensor for continuous operation UVD 1 in conjunction with burner control unit BCU 560 or BCU 565 The 24 V DC voltage supply and the 0 20 mA current output of the UV sensor must be wired separately The 0 20 mA current output is not required for normal opera tion The 0 20 mA current output can only be used to display the flame signal If it is us...

Страница 110: ...Z BCU 560 F3 only 13 5 Parameter chip card The parameter chip card must be installed in the unit for the BCU to operate The parameter chip card contains the valid parameter settings for the BCU If a BCU is replaced the parameter chip card can be removed from the old unit and inserted into the new BCU The BCU must be disconnected from the electrical power supply for this purpose The valid parameter...

Страница 111: ...BCU 560 BCU 565 Edition 02 16 111 Project planning information 13 7 Calculating the safety time tSA ...

Страница 112: ...ate a fourth gas valve To do this the output of a gas valve must be used as auxiliary energy e g V2 as a result of the required flame monitoring BCU F3 13 14 15 N V2 V3 V1 53 54 V4 The following application describes a two stage controlled burner without a pneumatic air gas ratio control system V2 and the air valve are activated simultaneously V2 must not be activated during purging BCU F3 V1 VAS ...

Страница 113: ...4960617 14 2 OCU For installation in the control cabinet door in standard grid dimensions The program step status or fault messages 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 115 OCU OCU 500 1 Order No 84327030 OCU 500 2 Order No 84327031 14 3 Connection plug set For wiring the BCU Connection plugs with scr...

Страница 114: ...nschild 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 valables dans leur intégralité Veuillez vous référer directement aux paramètres actu...

Страница 115: ...CU 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 val ues statistics flame signal intensities or parameter values to change settings on the OCU or to control or adjust connected butterfly valves in Manual mode ...

Страница 116: ...lay you can use the OK key to change to Service mode OK Back In Service mode you can use the Back key to switch from one setting level to the next higher one By holding down the key for a certain time you can change directly to the status display OK Navigation UP DOWN In Service mode the navigation keys can be used to select individual functions on one level In Manual mode those keys can be used t...

Страница 117: ...ation 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 15 5 Selection The OCU can be supplied with various language kits Type Languages Order No OCU 500 1 German English French Dutch Spanish Italian 84327030 OCU 500 2 English Danish Swedish Nor wegian Turkish Portuguese 84327031 OCU 500 3 English US English S...

Страница 118: ... 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 cross section AWG kcmil min 24 wire cross section AWG kcmil max 22 AWG to UL CUL min 24 AWG to UL CUL max 22 Cable length inside control cabinet max 10 m ...

Страница 119: ...ds operating status the level of the flame signal and the current program step 16 3 Electrical connection Use only cable and plug components which comply with the appropriate Profinet specifications Use shielded RJ45 plugs Cable length between 2 Profinet stations max 100 m Profinet installation guidelines see www profibus com 16 4 Installation Installation position vertically upright horizontal or...

Страница 120: ...s Order No 74960663 16 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 Environment Ambient temperature 20 to 60 C 4 to 140 F Storage temperature 20 to 60 C 4 to 140 F Climate no condensation permitted Enclosure IP 20 pursuant to IEC 529 Installation location min IP 54 for installation in a control cabinet ...

Страница 121: ...als 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 and 15 of the actuator 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 outputs valve outputs V1 V2 and V3 are...

Страница 122: ...il 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 17 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 5...

Страница 123: ...essure protection with optional input 5 4 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 Multi flame control 6 6 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 ...

Страница 124: ...BCU 560 BCU 565 Edition 02 16 124 Technical data 17 6 Converting units See www adlatus org ...

Страница 125: ... shut down method 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 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 BCSoft for fur ther diagnostics and troubleshooting The user statistics can be rese...

Страница 126: ...e 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 Input Output safety circuit IN Current consumption of sensor contactor tL Tightness control opening time tM Measurement ...

Страница 127: ...miters in the safety interlock linking of all the relevant safety control and switching equipment for the use of the ap plication e g safety temperature limiter minimum maximum gas pressure must isolate input from the voltage supply 20 5 Safety shut down After an installation fault e g flame or air pressure failure the burner control unit performs a safety shut down The display blinks and displays...

Страница 128: ... not detect a signal at the feedback input 20 10 Air valve The air valve can be used for cooling for purging to control the burner capacity in ON OFF mode and in High Low mode when using a pneumatic air gas ratio control system 20 11 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 th...

Страница 129: ...d to appear from EN 13611 A2 2011 20 14 Probability of dangerous failure PFHD Value describing the likelihood of dangerous failure per hour of a component for high demand mode or continuous mode Unit 1 h from EN 13611 A2 2011 20 15 Mean time to dangerous failure MTTFd Expectation of the mean time to dangerous failure from EN ISO 13849 1 2008 ...

Страница 130: ... No answer 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 T 49 541 1214 0 F 49 541 1214 370 info kromschroeder com www kromschroeder com The current addresses of our international agents are available on the Interne...

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