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Kromschroder FCU 500 Technical Information

Protective system controls
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Protective system controls FCU 500, FCU 505

Technical Information · GB
6 Edition 02.17
• For monitoring and controlling central safety functions in multiple
burner systems on industrial furnaces
• Valve proving system for a valve system leak tightness check
(optional)
• Safety temperature monitor (STM) or safety temperature limiter
(STL) (optional)
• Long service life due to replaceable power module for fail-safe
outputs
• Visualization and adaptation to the specific application via the PC
programming and diagnostic software BCSoft to simplify logistics
management

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  • Page 1: Protective System Controls Fcu 500, Fcu 505

    Protective system controls FCU 500, FCU 505 Technical Information · GB 6 Edition 02.17 • For monitoring and controlling central safety functions in multiple burner systems on industrial furnaces • Valve proving system for a valve system leak tightness check (optional) •...

  • Page 2: Table Of Contents

    3.2.1 FCU 500..F0........
  • Page 3 15 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 12.6.3 Filling time before start-up ..... . .113 FCU 500, FCU 505 · Edition 02.17 ▼...
  • Page 4 21 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 FCU 500, FCU 505 · Edition 02.17 ▼...

  • Page 5: Application

    All valid pa- rameters are saved on an integrated parameter chip Protective system control FCU 500 is designed to mon- card. The parameter chip card can be removed from the itor and control central safety functions, e.g. gas min.
  • Page 6 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 is set using three code switches. FCU 500, FCU 505 · Edition 02.17...
  • Page 7 Application Roller hearth kiln in the ceramics Shaft melting furnace Smelting and holding furnace industry FCU 500, FCU 505 · Edition 02.17...

  • Page 8: Application Examples

    VR..L 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. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 9 The centrally checked safety func- tions such as pre-purge, tightness test, flow detector and pressure switch check (gas , gas BCU 460..L min. max. ) are provided by the FCU 500. min. ϑ VR..L µC BCU 460..L >750° FCU 500..F0...

  • Page 10: Modulating Burner Control

    (gas , gas min. max. ) are provided by the FCU 500. min. FCU 500, FCU 505 · Edition 02.17...

  • Page 11: Safety Limits (Lds) For Modulating Burner Control

    BCU 560..F0 sure switch check (gas , gas min. max. ) are provided by the FCU 500. min. The capacity can be adjusted con- tinuously by activating the control element (analogue or 3-point step signal).

  • Page 12: Flame Control Using The Temperature

    High temperature mode (HT). When the HT in- put is activated, the burner control units switch to High temperature mode. They operate without evaluation of the flame signal and their internal flame control system is non-functional. FCU 500, FCU 505 · Edition 02.17...

  • Page 13: Furnace And Zone Control

    FCU 505 via their safety interlock input that the central tem leak tightness check and pre-purge. FCU 500 has issued the enable signal for the burners. It signals to the FCU 505 in the zones that the butterfly valves can be moved to the purge position. Signals are...

  • Page 14: Certification

    PL e. Eurasian Customs Union EU certified pursuant to The product FCU 500 meets the technical specifica- – Gas Appliances Directive (2009/142/EC) in conjunc- tions of the Eurasian Customs Union. tion with EN 298, EN 1643 Meets the requirements of the –...

  • Page 15: Function

    91 (Capacity con- trol) STM/ k11 k21 × 0.6 ϑ 62 61 5 6 7 8 11 12 3,15AT µC FCU 505 FCU 500 0.6 × I +24 V FCU 500, FCU 505 · Edition 02.17...

  • Page 16: Fcu 505

    Electrical connection, see page 120 (Project planning information) Explanation of symbols, see page 144 (Legend) STM/ k11 k21 × 0.6 ϑ 62 61 5 6 7 8 11 12 3,15AT µC FCU 505 0.6 × I +24 V FCU 500, FCU 505 · Edition 02.17...

  • Page 17: Assignment Of Connection Terminals

    24 V DC output Operating signal Operation signalling output, 24 V DC, max. 0.1 A 24 V DC input Fan ready for operation Feedback signal from fan indicating readiness for operation, see Parameter 31 ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 18 55, 56 see Parameter 40 to 47 V AC output Connection for fan control. Alternatively, this output can be used to activate a valve to check the function of the air pressure switch. FCU 500, FCU 505 · Edition 02.17...

  • Page 19: Program Sequence

    Function 3 .2 Program sequence 3 .2 .1 FCU 500 . .F0 Example of application, see page 8 (ON/OFF rotary impulse control) Switch on the FCU ▼ In the event of fault signal: reset ▼ Start-up position/standby ▼ Start-up with ϑ signal ▼...

  • Page 20: Fcu 500

    Function 3 .2 .2 FCU 500 . .F1, FCU 500 . .F2 Example of application, see page 10 (Modulating burner control) Switch on the FCU ▼ In the event of fault signal: reset ▼ Start-up position/standby ▼ Start-up with ϑ signal ▼...

  • Page 21: Fcu 505

    ▼ FCU 500 pre-purge time t running Tightness test (if equipped with TC) ▼ Actuator moves to the position for ignition capacity ▼ Controller enabler signal delay time t running ▼ Operation/controller enable FCU 500, FCU 505 · Edition 02.17...

  • Page 22: Animation

    (as load it from the document library (www.docuthek.com) on a DVD player). as an independent application. To play the animation, you will need Adobe Reader 9 or a FCU 500, FCU 505 · Edition 02.17...

  • Page 23: Temperature Monitoring

    The safety temperature monitor and safety temperature limiter functions can be adjusted to the requirements of the system using parameters 20, 22, 23, 24 and 25, see page 82 (High temperature operation). FCU 500, FCU 505 · Edition 02.17...

  • Page 24: High Temperature Operation With Safety Temperature Monitor Function (Stm Function)

    H1 or an external safety temperature monitor (STM) can be used for High temperature mode. Pre-purge can be disabled for both versions in High temperature mode, see page 86 (Pre-purge during high tempera- ture operation). FCU 500, FCU 505 · Edition 02.17...

  • Page 25: With External Stm

    (Pre-purge during high temperature operation). then be monitored at two different points in the furnace. FCU 50x..H1 FCU 50x..H0 FCU 50x..H1 BCU 4xx..D BCU 4xx..D µC µC BCU 4xx..D BCU 4xx..D µC µC FCU 500, FCU 505 · Edition 02.17...

  • Page 26: Maximum Temperature Monitoring With (Flue Gas) Safety Temperature Limiter

    The temperature module integrated in the FCU..H1 or an external safety temperature limiter (STL) can be used for this function. 4 .2 .2 With external STL/FSTL FCU 50x..H0 FCU 50x..H1 BCU 4xx..D BCU 4xx..D BCU 4xx..D FCU 500, FCU 505 · Edition 02.17...

  • Page 27: Air Control

    Air control 5 Air control The capacity control function provided by the FCU 500.. F1/F2 and FCU 505..F1/F2 allows an additional cen- Acting as the furnace protective system, the FCU 500 tral actuator or a frequency-controlled fan to be con- assumes the task of central air control on a furnace.

  • Page 28: Controlled Air Flow

    The FCU starts the fan depending on the functions defined using parameters, see also page 81 (Low air On FCU 500, actuation of the input at terminal 2 acti- pressure protection), page 88 (Air monitoring during vates the controlled air flow function. The fan (termi- controlled air flow) and page 89 (Air flow monitoring nal 58) is started in standby (with no start-up signal).

  • Page 29: Capacity Control

    As soon as a start-up signal has been received by the safety interlocks and the LDS output are active. FCU..F1/F2 (terminal 1), the fan of an FCU 500..F1/F2 is started via terminal 58 after the switch-on delay time has elapsed. The air volume for pre-purge is requested via the outputs for central capacity control (terminals (BCU..F0)
  • Page 30 Depending on parameter 40, actuators IC 20 and IC 40, an actuator with an RBW interface or a fan controlled by a frequency converter can be actuated via the out- puts for central capacity control, see page 91 (Ca- pacity control). FCU 500, FCU 505 · Edition 02.17...

  • Page 31: Furnace Zone Control

    The furnace FCU (FCU 500) performs central tasks such as checking the central safety functions, fan con- For furnace zone control, one FCU 500 is used to trol, system leak tightness check and pre-purge. control the furnace and several FCU 505 are used to control the individual modulating zones (FCU 505..F1...
  • Page 32 46 that burner start is enabled. When they receive this signal, the zone FCUs move the valves to ignition position for starting the burners and then issue the enable signal to the burner control units to start the burners. FCU 500, FCU 505 · Edition 02.17...

  • Page 33: Valve Proving System

    By checking the closed position using the proof of clo- sure function, the FCU complies with the requirements of NFPA 85 (Boiler and Combustion Systems Hazards Code) and NFPA 86 (Standard for Ovens and Furnaces). FCU 500, FCU 505 · Edition 02.17...

  • Page 34: Tightness Control

    2. The system tightness of a complete gas inlet section The valves and the pipework between the valves are with one test volume and pressure reduction using a tested. relief valve (parameter 53 = 2): V p1 FCU 500, FCU 505 · Edition 02.17...

  • Page 35: Test Instant

    When pre-purge is finished and the tightness has been checked suc- cessfully, the safety valves for operating the system are opened after the safety interlocks have been enabled. FCU 500, FCU 505 · Edition 02.17...

  • Page 36: One Test Volume Between 2 Gas Solenoid Valves

    7 .1 .2 One test volume between 2 gas solenoid valves ϑ µC The tightness control checks the tightness of the test >750° volume V between gas solenoid valves V1 and V2. FCU 500..C1 ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 37 M = P56 t M = P56 The tightness test can only be performed if pressure p downstream of V2 is around atmospheric pressure. – p Z > p Z > ▼ – FCU 500, FCU 505 · Edition 02.17...
  • Page 38 Z > downstream of V2 is around atmospheric pressure. – t L = P59 t L = P59 t M = P56 t M = P56 – p Z > p Z > – FCU 500, FCU 505 · Edition 02.17...

  • Page 39: One Test Volume For System Tightness

    V between the central shut-off valve V1, relief valve V3 and the burner valves. The opening times of the relief valve V3 and the shut-off valve V1 are identical. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 40 V1 is tight. t M = P56 t M = P56 The tightness test can only be performed if pressure p downstream of V3 is around atmospheric pressure. – > > ▼ – FCU 500, FCU 505 · Edition 02.17...
  • Page 41 The tightness test can only be performed if pressure p – > > downstream of V3 is around atmospheric pressure. – t L = P59 t L = P59 t M = P56 t M = P56 – > > – FCU 500, FCU 505 · Edition 02.17...

  • Page 42: Two Test Volumes For System Tightness

    If pressure p < p /2, program B starts, see page 44 (Program B). t L = P59 t L = P59 ▼ Test of valve 2 t M = P56 t M = P56 FCU 500, FCU 505 · Edition 02.17...
  • Page 43 (Checking the first and second test volumes (V Test of valve 2 ▼ t M = P56 t M = P56 – p Z > p Z > – V p1 Wait for 1 s FCU 500, FCU 505 · Edition 02.17...
  • Page 44 (Checking the first and second test volumes (V Test of valve 2 ▼ t M = P56 t M = P56 – p Z > p Z > – V p1 Wait for 1 s FCU 500, FCU 505 · Edition 02.17...
  • Page 45 > p /2, test volume V has been – successfully checked for tightness. p Z > Valves V1, V2 and V3, the burner valves and the pipe- V p2 V p2 work are tight. FCU 500, FCU 505 · Edition 02.17...

  • Page 46: Large Test Volumes With Reduced Testing Time

    , the second one to ¾ of the inlet pressure. see page 47 (Program B (reduced testing time)). Parameter 70 must be set to 1 for this purpose, see page 116 (Function of terminal 65). ϑ µC ▼ >750° FCU 500..C1 FCU 500, FCU 505 · Edition 02.17...
  • Page 47 – 3p u If pressure p < 3p /4, valve V2 is leaking. p Z > p Z > If pressure p > 3p /4, valve V2 is tight. – FCU 500, FCU 505 · Edition 02.17...

  • Page 48: Test Period T

    >750° [s] = 2 x t + 2 x t – Opening times t for V1 and V2, FCU 500..C1 – Measurement times t for V1 and V2. [s] = 2 x t + 2 x t FCU 500, FCU 505 · Edition 02.17...

  • Page 49: For Two Test Volumes For System Tightness

    (Two test volumes for system tightness), – Measurement times t for V1 and V2 to check the test volume V (parameter 56), see page 110 (Measurement time V – Waiting time 1 s, FCU 500, FCU 505 · Edition 02.17...

  • Page 50: Extended Valve Opening Time 1 T

    VAS 1 VAS 1 VAS 1 VAS 1 Current rating of safety interlock output (terminal 57): max. 0.5 A, see also page 127 (Safety interlock output in the case of higher power requirement) ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 51 112 (Valve opening time 1 t (l/h) = 100,000 l/h × 0.05% = 50 l/h Calculation module for calculating the opening time t see page 52 (Calculating the extended valve open- ing time) ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 52 Nominal flow rate Q 3531 SCFH Max. gas volume 13,2 Gallon in combustion chamber V VAS 1 on main valve VAS 6 bis 9 or orifice diameter d 0,70 inch Opening time t FCU 500, FCU 505 · Edition 02.17...

  • Page 53: Measurement Time T

    [s] =   Leakage rate Q [l/h] = 1000 x 1 [m For a large test volume V with reduced testing time ▼ Adjustable using parameter 56 0.9 × p [s] =   FCU 500, FCU 505 · Edition 02.17...
  • Page 54 VG 15 0.07 VG 20 0.12 12.3 VG 25 17.7 VG 40/VK 40 31.4 VG 50/VK 50 VG 65/VK 65 VG 80/VK 80 VK 100 VK 125 13.6 VK 150 VK 200 VK 250 FCU 500, FCU 505 · Edition 02.17...
  • Page 55 = 1.1 l + 9.5 m x 3.3 l/m = 32.45 l see page 110 (Measurement time V and Vp2). see page 54 (Test volume Vp) ▼ Test volume V = 300 l (assumed as an example) FCU 500, FCU 505 · Edition 02.17...
  • Page 56 0.9 x 50 mbar x (32.45 l + 300 l) [s] =  = 74.8 s 200 l/h Set the next highest value (80 s) using parameter 57, see page 110 (Measurement time V and Vp2). FCU 500, FCU 505 · Edition 02.17...

  • Page 57: Proof Of Closure Function

    By checking the closed position using the proof of clo- µC >750° sure function, the FCU complies with the requirements BCU 560..C1 of NFPA 85 (Boiler and Combustion Systems Hazards Code) and NFPA 86 (Standard for Ovens and Furnaces). FCU 500, FCU 505 · Edition 02.17...

  • Page 58: Bcsoft

    In addition to the engineering tool BCSoft, an opto- adapter or Bluetooth adapter is required to read the device parameters in and out, see also page 131 (BC- Soft). FCU 500, FCU 505 · Edition 02.17...

  • Page 59: Fieldbus Communication Via Ethernet

    BCM..B2 = PROFINET BCM..B4 = Modbus TCP The basic function of Profinet and Modbus TCP is the exchange of process and required data between a controller (e.g. PLC) and several distributed devices (e.g. BCU/FCU). FCU 500, FCU 505 · Edition 02.17...

  • Page 60: Fcu And Bus Module Bcm

    For information on planning and the structure of a net- work and the components to be used (e.g. cables, lines and switches) for Profinet, see Profinet Installation Guide at www.profibus.com, for Modbus TCP, see www.modbus.org. FCU 500, FCU 505 · Edition 02.17...

  • Page 61: Configuration, Planning

    GSD file may be selected for configura- tion to integrate the device. The GSD file for the bus module can be ordered at www.docuthek.com. The steps required to integrate the file are described in the FCU 500, FCU 505 · Edition 02.17...

  • Page 62: Modules/Registers For Process Data

    All modules (Profinet) and registers (Modbus TCP) re- Example of “Inputs” register: quired for data exchange between the PLC and the pro- Modbus address tective system controls FCU 500/FCU 505 are shown Format Word in the following table. Byte n...
  • Page 63 Byte n Format The digital input and output signals from the protective Reset BOOL Start BOOL system controls FCU 500 and FCU 505 are included in Controlled air flow BOOL this module/register. Burner operation BOOL Input bytes (FCU ➔ PLC)
  • Page 64 Format Value Status signals Byte 0 – 255 Fault signals Byte 0 – 255 See code table “GSD Codes FCU 500” or “Modbus Profile FCU 50x” at www.docuthek.com Byte n+1 Data type Format Value Warning signals Byte 0 – 255 See code table “GSD Codes FCU 500”...
  • Page 65 To display the remaining time of the valve proving system separately, it is transferred separately. Byte n Byte n+1 Data type Format Value Remaining times of the 0 – 6554 Word valve proving system (0 to 6554 s) ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 66 Terminal 50 Free BOOL Terminal 4 Terminal 51 Free BOOL Terminal 44 Terminal 52 Free BOOL Terminal 45 Terminal 65 Free BOOL Terminal 46 Terminal 66 Free BOOL Terminal 47 Terminal 67 Free BOOL FCU 500, FCU 505 · Edition 02.17...
  • Page 67 STL/STM temperature values. Byte n+4 Format STM, temperature valid BOOL STL, temperature valid BOOL Free BOOL Free BOOL Free BOOL Free BOOL Free BOOL Free BOOL ▼ FCU 500, FCU 505 · Edition 02.17...

  • Page 68: Device Parameters And Statistics

    Power module statistics The available data records differ in terms of their in- dexes. The contents and description of the indexes are described in the code table “GSD Codes FCU 500” (download from www.docuthek.com). FCU 500, FCU 505 · Edition 02.17...

  • Page 69: Program Step/Status

    Delay Operation/controller enable Post-purge Controlled air flow Remote control (with OCU) Data transfer (programming mode) X. X. High temperature operation – – Device Off In Manual mode, two dots blink on the display. FCU 500, FCU 505 · Edition 02.17...

  • Page 70: Fault Signalling

    ) cannot be supplied or vented; faulty pressure Pressure switch/gas valve wiring switch/gas valve wiring Gas valve wiring Reversed valve connection Interruption of signal at the “Controller enable/Emergency stop” input Controller enable/emergency stop (terminal 46) ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 71 Purge position not reached after 250 s Ignition capacity not reached Ignition position not reached after 250 s Communication with bus module (display bE) Internal communication with bus module has suffered a fault ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 72 No input signal from pressure switch at terminal 50 during program step 0, (display o0, o1, o2, o3, o4, o5, o6, o7, o8 or o9) 1, 2, 3, 4, 5, 6, 7, 8 or 9 Bus (display Pb) Bus fault ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 73 No input signal from pressure switch at terminal 49 during program step 1, (display u1, u2, u3, u4, u5, u6, u7, u8 or u9) 2, 3, 4, 5, 6, 7, 8 or 9 FCU 500, FCU 505 · Edition 02.17...

  • Page 74: Parameters

    Temperature in °C Pre-purge during high temperature operation Fan in the event of fault Fan run-up time tGV 0 – 6000 Time in seconds Fan ready for operation With safety shut-down With fault lock-out ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 75 Actuator in ignition position, waiting for Minimum enable time 0 – 250 enable signal, time in seconds 0 (if P40 = 0) Burner operating signal On; controller enable 1 (if P40 ≠ 0) ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 76 0 – 3600 Time in seconds Switch-on delay time tE 0 – 250 Time in seconds Filling time before start-up 0 – 25 Time in seconds Unlimited Operating time in Manual mode 5 minutes ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 77 AND with emergency stop (trm. 46) Function of terminal 68 AND with air min. (trm. 47) AND with air flow monitoring (trm. 48) AND with gas min. (trm. 49) AND with gas max. (trm. 50) ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 78 MIN. capacity; burner quick start IGNITION to MAX. capacity; standby in CLOSED position; burner quick start. Password 0000 – 9999 Four-digit number code 1234 Fieldbus communication With address check No address check FCU 500, FCU 505 · Edition 02.17...

  • Page 79: Scanning The Parameters

    Parameter 10 = 2: with fault lock-out and safety time during operation) to the system re- A fault lock-out will be performed if there is no signal quirements. at the controller enable/emergency stop input (termi- nal 46). FCU 500, FCU 505 · Edition 02.17...

  • Page 80: High Gas Pressure Protection

    A fault lock-out will be performed if there is no signal at max. Parameter 12 = 2: with fault lock-out the gas input (terminal 49). min. A fault lock-out will be performed if there is no signal at the gas input (terminal 50). max. FCU 500, FCU 505 · Edition 02.17...

  • Page 81: Low Air Pressure Protection

    Parameter 15 = 1: with safety shut-down A safety shut-down will be performed if there is no input signal. Parameter 15 = 2: with fault lock-out A fault lock-out will be performed if there is no input signal. FCU 500, FCU 505 · Edition 02.17...

  • Page 82: High Temperature Operation

    The required double thermocouple must be positioned exceeded. at the coldest point in the combustion chamber for this function so that it can reliably detect whether the spontaneous ignition temperature (> 750°C) has been exceeded. FCU 500, FCU 505 · Edition 02.17...

  • Page 83: Thermocouple

    It is not permitted to use single thermocouples and connect the inputs in parallel using wire straps. If sepa- rate sensor fittings are used, they must be installed next to each other so that they both record the same temperature. FCU 500, FCU 505 · Edition 02.17...

  • Page 84: Stm Limit Value (High Temperature Operation)

    HT output from the electrical power supply. High temperature mode is deactivated on the burner control units. The furnace is operated with flame control – see also page 123 (High temperature operation). FCU 500, FCU 505 · Edition 02.17...

  • Page 85: Temperature Hysteresis

    BCU 4xx..D ceeded (excessive temperature in furnace), the FCU will µC perform a lock-out. The fault lock-out cannot be reset until the temperature falls below the STL limit value and the defined temperature hysteresis. FCU 500, FCU 505 · Edition 02.17...

  • Page 86: Pre-Purge During High Temperature Operation

    Parameter 27 = 0: OFF; no pre-purge is performed upon furnace start-up Parameter 27 = 1: ON; a pre-purge is performed at every start regardless of the furnace temperature FCU 500, FCU 505 · Edition 02.17...

  • Page 87: Air Control

    Parameter 31 = 2: with fault lock-out The fan run-up time can be parameterized in a range A fault lock-out will be performed if there is no input between 0 and 250 s. signal. FCU 500, FCU 505 · Edition 02.17...

  • Page 88: Air Monitoring During Controlled Air Flow

    The duration of the pre-purge started by the FCU 505 Parameter 32 = 2: OFF; controller enable. is determined by the FCU 500 (furnace FCU). The The controller enable signal (terminal 56) is issued. The FCU 505 opens the zone’s butterfly valve for purging,...

  • Page 89: Air Flow Monitoring During Pre-Purge

    A fault lock-out will be performed if there is no input signal. Air flow monitoring is to be set on the basis of the rel- evant application standard (e.g. EN 676, EN 746-2, NFPA 85 or NFPA 86). FCU 500, FCU 505 · Edition 02.17...

  • Page 90: Air Flow Monitoring During Post-Purge

    The air flow is not monitored. Parameter 38 = 3: OFF; control element controller en- able. FCU 500, FCU 505 · Edition 02.17...

  • Page 91: Capacity Control

    255 s, the FCU will display fault message A , A or A    (minimum, maximum or igni- tion capacity not reached), see page 70 (Fault sig- nalling). ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 92 3-point step operation. No timeout is active when ap- ignition capacity. proaching these positions. The controller enable output (terminal 56) is not active and not checked. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 93 255 s, a fault lock- out of the FCU will be performed and a fault message (A , A or A    ) will be displayed, see page 70 (Fault sig- nalling). FCU 500, FCU 505 · Edition 02.17...
  • Page 94 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- FCU 500, FCU 505 · Edition 02.17...
  • Page 95 3-point step Closed Closed operation is not possible. No timeout is active when ap- Ignition Minimum/Ignition capacity Any position between minimum and proaching these positions. 0 – 20 mA maximum capacity Open Maximum capacity ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 96 100 (Running time). The program continue µC switch conditions are then controlled dependent on this time. FCU 500..F2 If a fault occurs, the actuator is moved to the position for minimum capacity. + F - ▼ 0° 90° FCU 500, FCU 505 · Edition 02.17...
  • Page 97 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. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 98 The FCU bridges the connections at terminals 53 and 54 (COM – HI bridge) for pre-purge. The frequency converter accelerates the fan to the speed for maxi- ▼ mum capacity with a timeout of 255 s. FCU 500, FCU 505 · Edition 02.17...
  • Page 99 In Manual mode, the frequency converter can be set to the speed for maximum air volume or minimum air volume (pilot air volume). Adjustment by the control system is not possible. No timeout is active when accel- erating to these speeds. FCU 500, FCU 505 · Edition 02.17...

  • Page 100: Running Time Selection

    3-point step operation is not pos- sible. No timeout is active when approaching these positions. FCU 500, FCU 505 · Edition 02.17...

  • Page 101: Controller Enable Signal Delay Time T Rf

    Parameter 46 = 1: On; controller enable; parameter 47 is The burner operating signal (terminal 4) is not evaluated activated. until the minimum enable time has elapsed if param- eter 46 = 1. FCU 500, FCU 505 · Edition 02.17...

  • Page 102: Controller Enable Time Limit

    If no feedback signal is received during this time, the FCU performs a fault lock-out. The time does not start until the mini- mum enable time has elapsed. FCU 500, FCU 505 · Edition 02.17...

  • Page 103: Capacity Control (Bus)

    S4 . IC 20 Switching cam setting for ignition capacity, minimum and maximum capacity as well as pre-purge and stand- S1: for ignition capacity of the burner. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 104 S1: for ignition capacity of the burner. S2: for minimum capacity of the burner. S3: for maximum capacity of the burner and pre-purge. S4: for the closed position of the butterfly valve and standby. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 105 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 butterfly valve and ▼ standby. FCU 500, FCU 505 · Edition 02.17...
  • Page 106 S1: for ignition capacity of the burner. S2: for reversing the direction of rotation to approach the position for ignition capacity. S3: for maximum capacity of the burner and pre-purge. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 107 S1: for minimum capacity and ignition capacity of the burner. S2: for reversing the direction of rotation to approach the position for ignition capacity. The actuator will move to the position for ignition capacity without reaching the position for maximum burner capacity. FCU 500, FCU 505 · Edition 02.17...

  • Page 108: Valve Check

    15. tightness test. Parameter 52 = 4: V4. The test volume is discharged via the valve connected to terminal 57. FCU 500, FCU 505 · Edition 02.17...

  • Page 109: Tightness Control Test Volume

    The system tightness is checked with one test volume (V between two safety valves. The relief valve V3 is opened to re- duce the pressure in the test volume by venting to a safe area. V p2 V p1 V p1 FCU 500, FCU 505 · Edition 02.17...

  • Page 110: Pressure Reduction

    56. The possible set- tings are 3 s, 5 to 25 s (in 5 s steps) or 30 to 3600 s (in 10 s steps). See also page 53 (Measurement time t FCU 500, FCU 505 · Edition 02.17...
  • Page 111 “Input for 3p /4 pressure switch for tight- ness test”. Terminal 45 is thus assigned the function “Input for p /4 pressure switch for tightness test”. ϑ µC >750° FCU 500..C1 FCU 500, FCU 505 · Edition 02.17...

  • Page 112: Valve Opening Time 1 T

    The opening time to be set is then calculated on the ba- sis of this restrictor or orifice. Current rating of safety interlock output (terminal 57): max. 0.5 A, see also page 127 (Safety interlock output in the case of higher power requirement) FCU 500, FCU 505 · Edition 02.17...

  • Page 113: Behaviour During Start-Up

    2 contactors with forced-guided contacts, see also page 127 (Safety in- terlock output in the case of higher power requirement). FCU 500, FCU 505 · Edition 02.17...

  • Page 114: Manual Mode

    FCU indicates A with blinking dots. A change of direc- tion takes place each time the button is released and pressed again. When the actuator has reached its final position, the dots disappear. FCU 500, FCU 505 · Edition 02.17...

  • Page 115: Functions Of Terminals 51, 65, 66, 67 And

    Parameter 69 = 4: AND with air flow monitoring (termi- nal 48) Parameter 69 = 5: AND with gas (terminal 49) min. Parameter 69 = 6: AND with gas (terminal 50) max. FCU 500, FCU 505 · Edition 02.17...

  • Page 116: Function Of Terminal 65

    Parameter 70 = 4: AND with air flow monitoring (terminal 48) Parameter 70 = 5: AND with gas (terminal 49) min. Parameter 70 = 6: AND with gas (terminal 50) max. FCU 500, FCU 505 · Edition 02.17...

  • Page 117: Function Of Terminal 67

    145 (Safety shut-down). Parameter 72 = 2: BCU ready; if not, fault lock-out If there is no feedback signal, a fault lock-out will be performed, see page 145 (Fault lock-out). FCU 500, FCU 505 · Edition 02.17...

  • Page 118: Password

    Parameter 80 = 0: OFF. Parameterization access using Parameter 80 = 2: no address check. The device name/ BCSoft via Ethernet is still possible. network name can be selected as specified by the auto- mation system. FCU 500, FCU 505 · Edition 02.17...

  • Page 119: Selection

    POC Capacity control: none modulating with interface for actuator IC modulating with interface for RBW Temperature monitoring: none with temperature monitoring Connection terminals: none screw terminals spring force terminals FCU 500, FCU 505 · Edition 02.17...

  • Page 120: Project Planning Information

    If the DIN rail is aligned vertically, end clamps are re- quired (e.g. Clipfix 35 by Phoenix Contact) to prevent the FCU from slipping. FCU 500, FCU 505 · Edition 02.17...

  • Page 121: Electrical Connection

    EN 60204-1, Chapter 12. tors: External electrical interference must be avoided. Cable length max. 10 m, 4-pin, min. 0.25 mm (AWG 24), max. 0.34 mm (AWG 22). FCU 500, FCU 505 · Edition 02.17...

  • Page 122: Safety Current Inputs

    0.6 × I L1 +24 V Calculation = current of the sensor/contactor with the lowest switching capacity Suitable fuse = 0.6 × I FCU 500, FCU 505 · Edition 02.17...

  • Page 123: High Temperature Operation

    Sensor discontinuity, sensor short-circuit, failure of a component or mains failure must set the installation to a safe state. Voltage may be applied to the HT input of a burner control unit so as to activate High temperature FCU 500, FCU 505 · Edition 02.17...

  • Page 124: Safety Temperature Limiter (Stl)

    0 to 1200°C. Type N thermocou- Type S -50 to +1768 0 to +1600 ples are the highest quality thermocouples among the * Can be used as a substitute for Type K. non-precious types. ▼ FCU 500, FCU 505 · Edition 02.17...
  • Page 125 Compensating cables KCA, KCB, NC, SCA or SCB are made of a substitute material which is not identical to the thermocouple material but has similar properties in certain temperature ranges. FCU 500, FCU 505 · Edition 02.17...

  • Page 126: Pfhd

    D STM/STL temperature module = 5.84 × 10 D STM/STL temperature module See also page 141 (Mean probability of danger- ous failure PFHD of individual safety functions) and page 147 (Probability of dangerous failure PFHD) FCU 500, FCU 505 · Edition 02.17...

  • Page 127: Safety Interlock Output

    The two NC contacts in the contactors are con- nected in series to the safety interlock check signal input (terminal 68); the contacts must be protected with a factor ≤ 0.6 x I , see page 122 (Safety current inputs). ▼ FCU 500, FCU 505 · Edition 02.17...

  • Page 128: Bcu With Power Supply For Valves And Ignition Transformer Via Safety Interlocks

    253 V ▼ In the event that a higher output current is required, the ϑ L1 (L1) output current can be increased by means of a contact N (L2) multiplier using 3 contactors. FCU 500, FCU 505 · Edition 02.17...

  • Page 129: Actuators

    IC 20 must be wired as shown in the connection dia- gram. µC FCU 500 14 . 7 Air control Starting the fan with the butterfly valve closed reduces the start-up current of the fan motor. FCU 500, FCU 505 · Edition 02.17...

  • Page 130: Parameter Chip Card

    A pressure switch DG can be connected between V3 and terminal 15 of the FCU for the controlled pressure reduction of the test volume V via a relief valve. FCU 500, FCU 505 · Edition 02.17...

  • Page 131: Accessories

    For details, see from page 133 (OCU). Including BCSoft CD-ROM, OCU 500-1, Order No.: 84327030, Order No.: 74960625. OCU 500-2, Order No.: 84327031. 15 .1 .2 Bluetooth adapter PCO 300 Including BCSoft CD-ROM, Order No.: 74960617. FCU 500, FCU 505 · Edition 02.17...

  • Page 132: Connection Plug Set

    100 pcs, Order No.: 74921492. F C U 5 0 0 Z o n For printing with laser printers, plotters or engraving machines, 27 × 18 mm or 28 × 17.5 mm. Colour: silver. FCU 500, FCU 505 · Edition 02.17...

  • Page 133: Ocu

    16 .1 Application The OCU is an external operator-control unit which can be connected to a control unit of the FCU 500/ BCU 500 series. The external operator-control unit OCU is installed in the door of a control cabinet. Thus,...

  • Page 134: Function

    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 to open and close an activated valve. FCU 500, FCU 505 · Edition 02.17...

  • Page 135: Manual Mode

    After start-up has been completed, the navigation keys can be used, for example, to open or close a valve in program step 08. Wire each conductor on both plugs to the same contact. FCU 500, FCU 505 · Edition 02.17...

  • Page 136: Installation

    German, English, French, Dutch, Spanish, OCU 500-1 84327030 Italian English, Danish, Swedish, Norwegian, OCU 500-2 84327031 Turkish, Portuguese English, US English, Spanish, Brazilian OCU 500-3 84327032 Portuguese, French English, Russian, Polish, Croatian, OCU 500-4 84327033 Romanian, Czech FCU 500, FCU 505 · Edition 02.17...

  • Page 137: Bcm 500

    For Profinet see www.profibus.com, for Modbus TCP, see www.modbus.org The bus module BCM 500 is used as a communica- tion interface for devices of the BCU/FCU 500 product family for connection to a fieldbus communication system (Profinet or Modbus TCP). Networking via the fieldbus enables the FCU or BCU to be controlled and monitored by an automation system (e.g.

  • Page 138: Installation

    Install in a clean environment (e.g. a control cabinet) Enclosure: IP 20 pursuant to IEC 529. with an enclosure ≥ IP 54, whereby no condensation is Installation location: min. IP 54 (for installation in a permitted. control cabinet). FCU 500, FCU 505 · Edition 02.17...

  • Page 139: Technical Data

    F2: T 5A H, pursuant to IEC 60127-2/5. – 24 V DC signalling contact for fault/operation (termi- nal 41, 42): max. 0.1 A. – Fan: max. 3 A (start-up current: 6 A < 1 s). FCU 500, FCU 505 · Edition 02.17...

  • Page 140: Mechanical Data

    Terminals 5, 6, 7 and 8: Maximum voltage: ± 5 V, input voltage range for double thermocouples: Type K: 0 to 54.9 mV, Type N: 0 to 47.5 mV, Type S: 0 to 18.7 mV. FCU 500, FCU 505 · Edition 02.17...

  • Page 141: Safety-Specific Characteristic Values

    * see page 126 (PFHD value for STM/STL temperature module and thermocouple) SIL 3 is not achieved in conjunction with actuators IC 20 or RBW because there are no PFH values for the actuators. FCU 500, FCU 505 · Edition 02.17...

  • Page 142: Converting Units

    Technical data 18 . 7 Converting units See www.adlatus.org FCU 500, FCU 505 · Edition 02.17...

  • Page 143: Maintenance

    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 statistics can be reset using engineering tool BC- Soft. FCU 500, FCU 505 · Edition 02.17...

  • Page 144: Legend

    Pressure switch for minimum pressure Differential pressure switch P xx Input signal depending on parameter xx Control element with butterfly valve Tightness control Half of the inlet pressure A quarter of the inlet pressure FCU 500, FCU 505 · Edition 02.17...

  • Page 145: Glossary

    The display blinks and shows the corresponding warning message. The warning signal ends once the cause has been eliminated. The program sequence continues. No safety shut-down or fault lock-out occurs. FCU 500, FCU 505 · Edition 02.17...

  • Page 146: Timeout

    In high demand mode or continu- ous mode, the frequency of demands for operation made on a safety-related system is greater than one per year or greater than twice the proof-test frequency. See also EN 61508-4 FCU 500, FCU 505 · Edition 02.17...

  • Page 147: Safe Failure Fraction Sff

    Unit: 1/h. from EN 13611/A2:2011 21 .10 Mean time to dangerous failure MTTF Expectation of the mean time to dangerous failure from EN ISO 13849-1:2008 FCU 500, FCU 505 · Edition 02.17...

  • Page 148: Feedback

    Strotheweg 1 · 49504 Lotte (Büren) Germany Tel +49 541 1214-0 We reserve the right to make technical Fax +49 541 1214-370 modifications in the interests of progress. hts.lotte@honeywell.com Copyright © 2017 Elster GmbH www.kromschroeder.com All rights reserved. FCU 500, FCU 505 · Edition 02.17...

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