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PFU 780 · Edition 02.12

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= To be continued

Table of contents

Burner control unit PFU 780 . . . . . . . . . . . . . . . . . . . . . . . . . 1

Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Examples of application. . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1.1 Stage-controlled main burner with alternating pilot burner 6

1.1.2 Stage-controlled main burner with permanent pilot burner 7

1.1.3 Modulating-controlled burner . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.4 PFU 780..D:

High temperature equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.1.1 PFU 780 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1.2 PFU 780..K2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 PFU 780 program sequence . . . . . . . . . . . . . . . . . . . . 13
3.3 Program status and fault messages . . . . . . . . . . . . . . 16

4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Flame control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.1 Flame signal, pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.2 Flame signal, main burner . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.3 Program status when the most recent fault occurred. . . 20

4.2.4 Switch-off threshold of the flame amplifier . . . . . . . . . . . 20

4.2.5 High temperature operation with PFU..D. . . . . . . . . . . . . . 21

4.2.6 UVS check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.3 Pilot and main burner monitoring . . . . . . . . . . . . . . . . 25

4.3.1 Permanent pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.3.2 Interrupted pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.4 Behaviour in start-up position/standby. . . . . . . . . . . . 28

4.4.1 Flame simulation check in start-up position/standby . . . 28

4.4.2 Minimum burner pause time t

. . . . . . . . . . . . . . . . . . . 29

4.5 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . 30

4.5.1 Safety time on start-up t

. . . . . . . . . . . . . . . . . . . . . . . . . 30

4.5.2 Flame proving period t

. . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.5.3 Minimum combustion time t

. . . . . . . . . . . . . . . . . . . . . . 31

4.5.4 Burner start-up attempts . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.6 Behaviour during operation . . . . . . . . . . . . . . . . . . . . . 34

4.6.1 Safety time during operation t

for pilot and main

burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.6.2 Fault lock-out or restart, pilot burner . . . . . . . . . . . . . . . . 34

4.6.3 Fault lock-out or restart, main burner. . . . . . . . . . . . . . . . 36

4.7 Air valve control PFU..L . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.7.1 Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.7.2 Cooling in start-up position/standby . . . . . . . . . . . . . . . . 38

4.7.3 Burner start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.7.4 Air valve opens in the case of external activation (not

during start-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.7.5 Air valve opens in the case of external activation (even

during start-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.7.6 Air valve opens with valve V2 . . . . . . . . . . . . . . . . . . . . . . . 41

4.7.7 Air valve opens with operating signal . . . . . . . . . . . . . . . 42

4.7.8 Low fire over run time t

after a normal shut-down . . . 43

4.7.9 Behaviour of the air valve in the event of a fault lock-out 44

4.8 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.8.1 Manual mode limited to 5 minutes. . . . . . . . . . . . . . . . . . 45

4.9 Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1 Calculating the safety time t

. . . . . . . . . . . . . . . . . . . 47

5.2 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.2.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6 Project planning information . . . . . . . . . . . . . . . . . . . . . 49

6.1 Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.1.1 Ignition cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.1.2 Ionisation cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.1.3 UV-Leitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.2 Ignition electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.2.1 Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.2.2 Star electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.3 Minimum combustion time . . . . . . . . . . . . . . . . . . . . . 50
6.4 Safety interlocks (Limits) . . . . . . . . . . . . . . . . . . . . . . . . 50
6.5 Emergency stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Содержание PFU 780

Страница 1: ...and main burner by UV ionisation or a further option of using the furnace chamber temperature Display of the program status unit parameters and flame signal Manual mode for burner adjustment and for...

Страница 2: ...ur during start up 30 4 5 1 Safety time on start up tSA 30 4 5 2 Flame proving period tFS 31 4 5 3 Minimum combustion time tB 31 4 5 4 Burner start up attempts 32 4 6 Behaviour during operation 34 4 6...

Страница 3: ...ed parameters stickers 55 8 5 Radio interference suppressed electrode adapters 56 8 6 Socket connectors 56 8 7 Module subrack 56 8 8 Power supply PFP 700 57 8 9 Relay module PFR 704 58 8 10 Field bus...

Страница 4: ...rial furnaces the PFU 780 reduces the load on the central furnace control by taking over tasks that only relate to the burner for example it ensures that the burner always ignites in a safe condition...

Страница 5: ...PFU 780 Edition 02 12 5 Application Bogie hearth forging furnace in the metallurgical industry Intermittent shuttle kiln in the ceramics industry Walking beam furnace with overhead firing...

Страница 6: ...er Control Main burner ON OFF The main burner can be started with reduced capacity after the operating signal from the pilot burner has been detected The pilot burner is switched off automatically aft...

Страница 7: ...06 08 04 2 1 1 2 C 1 2 26a Application Examples of application 1 1 2 Stage controlled main burner with permanent pilot burner Control Main burner ON OFF The main burner can be started with reduced cap...

Страница 8: ...Control Main burner continuous The butterfly valve for air BV is moved to ignition position in order to start the main burner The main burner can be started at low fire rate after the operat ing sign...

Страница 9: ...ature equipment The flame is controlled indirectly on the basis of the temperature During the start up process as long as the wall temperature is below auto ignition tem perature the flame must be con...

Страница 10: ...certified pursuant to Gas Appliances Directive 2009 142 EC in conjunction with EN 298 2004 01 Meets the requirements of the Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC PFU T is FM appr...

Страница 11: ...V c2 10c 12c 10a 12a 30e 22a P DI A 2 1 1 N 2 28c 26a 1 2 14a 14e 10e 12e 24c 20c 18a l 20c 18a N 26a 26a N 28c 28c 18a Z I UVS 1 2 3 24c L N M V2 V1 C C SK A S PFU 780 3 Function 3 1 Connection diag...

Страница 12: ...c1 24 V 0 V c2 10c 12c 10a 12a 30e 22a P DI A 2 1 1 N 2 28c 26a 1 2 14a 14e 10e 12e 24c 20c 18a l 20c 18a N 26a 26a N 28c 28c 18a Z I UVS 1 2 3 24c L N M V2 V1 C C SK A S PFU 780 K2 Function Connecti...

Страница 13: ...pilot burner has been started suc cessfully and its flame has stabilised the burner control unit issues the Enable signal for main burner operation The operation signalling contact for the pilot burne...

Страница 14: ...inals 14a and 14e the PFU 780 opens valve V2 The main burner is ignited by the pilot burner If a flame is detected during the safety time tSA2 the flame proving period tFS2 starts after the safety tim...

Страница 15: ...ils during operation either an immediate fault lock out occurs or a restart occurs This procedure can be set via the optical interface parameter 13 Main burner restart Function PFU 780 program sequenc...

Страница 16: ...e on start up main burner 6 Start up without flame signal main burner Flame proving period main burner 7 Flame failure during flame proving period main burner Operation main burner 8 Flame failure dur...

Страница 17: ...6 Short circuit on ignition or valve output 51 Safety interlock failure 52 Permanent reset 53 Time between two start ups is too short In Manual mode two dots will blink on the display in program statu...

Страница 18: ...burner 13 0 1 0 Safety time during operation for V1 and V2 tSB 14 1 2 s 1 s Flame simulation check in start up position standby 15 0 1 1 Permanent pilot burner 16 0 1 1 Minimum combustion time tB 20 2...

Страница 19: ...ive 1 Function active On parameterisation ensure that the program sequence started matches the application Select the parameters so that the burner can restart as intended in all operating phases 4 1...

Страница 20: ...gram position the unit was in when the fault was detected waiting time 01 or standby 00 Result A flame simulation was detected during the waiting time or standby 4 2 4 Switch off threshold of the flam...

Страница 21: ...fety function of the device internal flame control system is placed out of operation In High temperature mode the gas valves are opened without flame control The precondition for high temperature oper...

Страница 22: ...re FA When High temperature mode is ended the PFU switches off the burner and restarts with flame simulation check recom mended in the case of UV control with UVS Parameter 33 2 06 07 08 08 t tSA2 tFS...

Страница 23: ...t 04 04 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e 22a V1 1 V2 2 1 2 2 1 DI Fault main burner 08 t 08 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e 22a V1 1 V2 2 1 2 2 1 DI P...

Страница 24: ...ach time the start up signal is applied Parameter 35 0 Unlimited burner operation Parameter 35 1 An automatic restart is activated once every 24 hours It must be ensured in this case that the program...

Страница 25: ...pilot burner t 1 2 1 2 88 02 04 06 08 04 06 08 04 For applications which require a high system availability or where a continuously burning flame is necessary The pilot burner is ignited once and rema...

Страница 26: ...d main burner monitoring Operating mode Intermittent pilot burner Start up as in the illustration Permanent pilot burner with the difference being that the start up signal for pilot and main burners i...

Страница 27: ...as elapsed In this setting the flame signal can be connected to terminals 18a or 26a The pilot burner is switched off after the main burner safety time tSA2 has elapsed Parameters Pilot and main burne...

Страница 28: ...ected by the main burner Parameter 15 0 The flame simulation check is conducted after applying the start up signal during the waiting time tW Parameter 15 1 The flame simulation check is conducted pro...

Страница 29: ...he pause time After the pause time the burner is started if the start up signal is applied The minimum burner pause time tBP serves to adapt the pro gram sequence to the requirements of the applicatio...

Страница 30: ...02 03 00 t tFS 26a 16c 18e 2c 4c 88 10e 26e 30a 28c 2e 4e V1 1 V2 1 1 Safety time on start up tSA1 for the pilot burner Main burner Parameter 24 tSA1 tZ 04 06 07 08 02 03 00 t tFS1 tSA2 tFS2 26a 16c 1...

Страница 31: ...25 s This time elapses before the PFU starts the next program step so as to give the flame time to stabilise 4 5 3 Minimum combustion time tB Parameter 20 Programmable time to maximum 25 s during whic...

Страница 32: ...by FM Approval see type label it is only possible to select one start up attempt 1 start up attempt Parameter 10 1 tSA tZ 02 00 t 02 26a 16c 18e 2c 4c 88 10e 26e 30a 28c 2e 4e V1 V2 1 If no flame for...

Страница 33: ...empt Parameter 11 1 tSA1 tZ 04 06 02 03 00 t tFS1 tSA2 06 26a 16c 18e 2c 4c 18a 14a 88 10e 26e 30a 28c 2e 4e 6a 6e V1 1 V2 2 1 2 2 1 If no flame forms during the start up of the main burner a fault lo...

Страница 34: ...ock out or restart pilot burner Parameter 12 This parameter determines whether the PFU starts a one off restart or performs an immediate fault lock out for the burner after an installation fault such...

Страница 35: ...he burner does not function a fault lock out occurs The display blinks and shows the cause of the fault In accordance with EN 746 2 a restart may be conducted only if the safety of the installation is...

Страница 36: ...within the safety time during operation tSB This in volves disconnecting the power from the gas valves and the ignition transformer The fault signalling contact closes the display blinks and shows the...

Страница 37: ...urner once If the burner does not function a fault lock out occurs The display blinks and shows the cause of the fault In accordance with EN 746 2 a restart may be conducted only if the safety of the...

Страница 38: ...r a normal shut down 4 7 1 Purge Parameter 42 0 The air valve is closed when voltage is applied to terminal 30e Parameter 42 1 The air valve is opened when voltage is applied to terminal 30e In the ca...

Страница 39: ...The air valve remains closed during start up even if it is activated externally These settings are required on burners on which the gas air ratio is controlled via a pneumatic link and which also nee...

Страница 40: ...2 1 2 2 1 VAG PFU 780 L A P L1 1 2 VAS TZI 2 1 UV VAS 1 Parameter 30 0 The air valve opens if it is activated externally via input 10a Parameter 31 1 The air valve can be activated even during start u...

Страница 41: ...6a 6e V1 1 V2 2 1 2 2 1 PFU 780 L A P L1 1 2 VR R VAG VBY TZI 2 1 SPS PLC CPE Parameter 30 2 The air valve opens simultaneously with valve V2 Application Single stage controlled main burner is switch...

Страница 42: ...2 1 2 2 1 PFU 780 L A P L1 1 2 VR R VAG VBY TZI 2 1 SPS PLC CPE Parameter 30 3 The air valve opens simultaneously with the operating signal Application Two stage controlled main burner is switched ON...

Страница 43: ...during the closing time increases the O2 content in the com bustion chamber Parameter 36 3 5 10 15 25 or 60 low fire over run time tKN 3 5 10 15 25 or 60 s The air valve closes slowly after the activa...

Страница 44: ...ther the air valve can be activated in the case of a fault lock out Parameter 32 0 The air valve is closed in the event of a fault It cannot be activated externally via terminal 10a Parameter 32 1 The...

Страница 45: ...xt section of the program sequence and stops there After approx 3 s the flame signal will be displayed instead of the program parameter Briefly pressing the Reset Informa tion button 1 s displays the...

Страница 46: ...parameter settings a password is stored in parameter 50 Changes to parameter settings can only be made once this number has been entered The password can be changed using BCSoft Note the effect of pa...

Страница 47: ...PFU 780 Edition 02 12 47 5 Selection 5 1 Calculating the safety time tSA...

Страница 48: ...rd available Order example PFU 780LT 5 2 1 Type code Code Description L Air valve control Mains voltage T 220 240 V 15 10 50 60 Hz N 110 120 V 15 10 50 60 Hz D Digital input to interrupt flame control...

Страница 49: ...o not lay UV ionisation cable and ignition cables together and lay them as far apart as possible 6 1 2 Ionisation cable Use unscreened high voltage cable see page 55 Acces sories Cable length max 100...

Страница 50: ...on time only has an effect on the behaviour of the main burner The minimum combustion time for the pilot burner is limited to the safety time on start up tSA1 Background The pilot burner is only used...

Страница 51: ...The malfunction can not be remedied by changing the method of activation 6 6 4 Burner start A furnace start may only be initiated if it has been ensured using an appropriate procedure that there is n...

Страница 52: ...tion is permitted Cable length between PFU and burner max 100 m 6 10 Wiring The PFU is suitable for hard wiring only Do not reverse phase and neutral conductor Different phases of a three phase curren...

Страница 53: ...with EN 50156 it does allow the burner to be isolated functionally from the central control system This function is required for manual operation and in the case of PROFIBUS units to switch off the un...

Страница 54: ...ust be interrupted at least once every 24 hours This can be programmed using parameter 35 For further information see brochure UVS The burner control unit PFU U is prepared for UV sensor UVD 1 This en...

Страница 55: ...17 5 mm Colour silver 8 4 Changed parameters stickers D 49018 Osnabr ck Germany Achtung ge nderte Parameter Die Angaben auf dem Typenschild gelten nicht mehr in vollem Umfang Aktuelle Parameter direkt...

Страница 56: ...printed circuit board with rear terminal strip function tested standard documentation guide rails without partial front plates screw terminals at the rear single zone operation for MPT 700 operating m...

Страница 57: ...wer supply PFP 700 For supplying the control inputs of burner control unit PFU or for supplying the auxiliary voltage to relay module PFR 704 Operating status display on the front plate PFP switches o...

Страница 58: ...230 V 24 V 115 V 230 V 24 V 115 V 230 V 24 V 8 9 Relay module PFR 704 For contact multiplication e g if several air valves are activated via a single control signal for pre purge or for heating cool...

Страница 59: ...FU 19c 17b 30e 26e PFU 24 V L1 PROFIBUS DP Accessories 8 10 Field bus interface PFA 700 For connection of up to nine automatic burner control units PFU 760 to industrial communication networks using P...

Страница 60: ...lated thanks to intermittent operation and thereby constant temperature distribution and shorter heating up periods for all gas fired heat treatment furnaces are ensured Mains voltage 95 240 V AC 10 5...

Страница 61: ...20 V 0 40 V Frequency 50 60 Hz 50 60 Hz Rated value 24 V DC Signal 1 24 V 10 Signal 0 1 V Inherent current Signal 1 typ 5 mA Output voltage for voltage related outputs mains voltage Contact rating Gas...

Страница 62: ...ursuant to IEC 127 2 5 Ambient temperature 20 to 60 C 4 to 60 00 C Climate no condensation permitted Enclosure IP 00 pursuant to IEC 529 after installing in a 19 module subrack according to the in str...

Страница 63: ...e PFHD 1 34 x 10 8 l h Mean time to dangerous failure MTTFd Safe failure fraction SFF 99 2 The specified values apply for the combination with ionization electrode sensor and PFU 780 logic Relationshi...

Страница 64: ...3 HE 133 4 5 3 8 TE 40 6 1 6 9 2 Operating controls A 2 digit 7 segment display B Reset Information button to reset the system after a fault or to scan parameters on the display C Mains switch D Optic...

Страница 65: ...PFU 780 Edition 02 12 65 10 Maintenance cycles Burner control unit PFU requires little servicing...

Страница 66: ...ilot burner 2 Operating signal main burner Fault signal Reset Input signal Output signal Flame simulation check tW Waiting time 2 s tSA Safety time on start up 3 s 5 s or 10 s tSB Safety time during o...

Страница 67: ...starts to elapse Voltage is supplied to the pilot gas valve V1 and the ignition transformer and the burner is ignited The duration of the ignition time is either 2 3 or 7 seconds depending on safety...

Страница 68: ...e voltage supply 12 9 Pilot gas valve V1 The start fuel flow rate for the pilot burner is released by pilot gas valve V1 It opens when the safety time on start up tSA1 starts to elapse It remains open...

Страница 69: ...High demand mode or continuous mode Operating mode where the frequency of demands for opera tion made on a safety related system is greater than one per year or greater than twice the proof test frequ...

Страница 70: ...the product To choose a product Planning To look for information My scope of functions Technical department Sales No answer Remarks Adobe Reader 7 or higher required www adobe com Elster GmbH Postfac...

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