Industrial & Commercial Thermal Burner control units BCU 580 Technical Information · GB 6 Edition 11.15l • For monitoring and controlling modulating or staged burners for multiple burner applications with a central air supply • For directly ignited burners or burners ignited by a pilot burner in intermittent or continuous operation • Optionally with valve proving system • PROFINET fieldbus connection using optional bus module...
Contents Burner control units BCU 580 . . . . . . . . . . . . . . . . . . . . . . . 1 5.2 Proof of closure function .
Contents 10.6.5 Controller enable signal delay time t ... . 86 12.6 Protecting the pilot burner from overload ..109 10.6.6 Air actuator control....... . . 86 12.7 Calculating the safety time t SA.
Application 1 Application The burner control unit has an interface via which an air valve or actuator (IC 20, IC 40 or RBW) can be controlled for staged or modulating burner capacity control. The program status, the unit parameters and the level of the flame signal can be read directly from the unit.
Application Using the BCSoft program, the parameters, analysis and diagnostic information can be read from a BCU via the optionally available opto-adapter. All valid parameters are saved on an integrated parameter chip card. The parameter chip card can be removed from the old unit and inserted into a new BCU to transfer the parameters, for example when replacing the unit.
Application The external 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, flame signal 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.
Application Bogie hearth forging furnace in the met- Intermittent shuttle kiln in the ceramics Walking beam furnace with overhead allurgical industry industry firing BCU 580 · Edition 11.15l...
Application 1 .1 Examples of application 1 .1 .1 Stage-controlled main burner with alternating pilot burner Control: Main burner ON/OFF or High/Low VAS 1 The main burner can be started with reduced capacity after the operat- Process control (PCC) ing signal from the pilot burner has FCU 500 been detected.
Application 1 .1 .2 Stage-controlled main burner with permanent pilot burner Control: Main burner ON/OFF or High/Low The main burner can be started with VAS 1 reduced capacity after the operat- ing signal from the pilot burner has been detected. Pilot and main burn- Process control (PCC) ers can be operated simultaneously.
Application 1 .1 .3 Two-stage-controlled main burner VAS 1 with permanent pilot burner Control: Main burner ON/OFF with ignition via bypass The main burner can be started with minimum capacity after the VAS 1 operating signal from the pilot Process control (PCC) burner has been detected.
Application 1 .1 .4 Modulating-controlled burner Control: Main burner continuous VAS 1 The butterfly valve for air is moved to the position for minimum capac- ity in order to start the main burner. The main burner is started with Process control (PCC) FCU 500 minimum capacity after the operat- ing signal from the pilot burner has...
Application 1 .1 .5 Flame control using the temperature out evaluating the flame signal and their internal flame control is non-functional. FCU 500..H1 If the furnace temperature falls below the spontaneous BCU 580..D ignition temperature (< 750°C), the FCU disconnects µC the HT output from the electrical power supply.
Application 1 .1 .6 PROFINET connection using bus module BCM PROFINET The bus system transfers the control signals from the automation system (PLC) to the BCU/BCM for starting, resetting, controlling the air valve, purging the furnace or for cooling and heating during operation. In the op- posite direction, it sends operating status, the level of the flame signal and the current program status.
Application 1 .1 . 7 ON/OFF rotary impulse control For processes which require a turn- down of more than 10:1 and/or those which require heavy circula- tion of the furnace atmosphere to ensure a uniform temperature, e.g. heat treatment furnaces operating BCU 580..F3 at low and medium temperatures in the metallurgical industry.
Application The ignition and monitoring of the pilot/main burners is ensured by burner control units BCU 580. The centrally checked safety func- tions such as pre-purge, tightness test, flow detector and pressure switch check (gas , gas BCU 580..F3 min. max.
Application 1 .1 .8 Modulating burner control For processes that do not require heavy circulation in the furnace, e.g. aluminium smelting furnaces. This system is suitable for process- es in which infiltrated air may flow BCU 580..F3 into the furnace through switched off burners.
Certification 2 Certification American National Standards Institute/Canadian Standards Association – ANSI Z21.20/CSA C22.2 No. Certified to SIL and PL www.csagroup.org – Class number: 3335-01 and 3335-81. For systems up to SIL 3 pursuant to EN 61508 and PL e pursuant to ISO 13849 Eurasian Customs Union EU certified pursuant to The product BCU 580 meets the technical specifica- –...
Function 3 Function Detailed connection diagrams for actuators and fre- quency converters, see from page 75 (Capacity con- 3 .1 Connection diagram trol) 3 .1 .1 BCU 580 . .F1 with ionization control in single- Electrical connection, see page 104 (Project planning electrode operation information) Alternative flame control, see page 22 (Flame con-...
Function 3 .1 .4 Flame control UVD control A voltage supply of 24 V DC is required to operate the Ionization control in double-electrode operation UV sensor for continuous operation UVD 1. The 0 – 20 mA current output can be used to display the flame signal.
Function 3 .2 BCU 580 program sequence Flame proving period 1 t running (P95) Parameters 48 and 49 = 0: High/Low control during op- ▼ In the event of flame failure: eration, cooling in standby fault lock-out Example of application, see page 11 (Two-stage- ▼...
Function Main burner operation signalling contact closes, minimum operating time t starts (P61) ▼ In the event of flame failure: restart or fault lock-out ▼ External actuation of the air valve for capacity control Controlled shut-down via ϑ signals for pilot and main burners ▼...
Air control 4 Air control A central protective system such as the FCU 500 takes over air control. It monitors the static air pressure as well as the air volume required for pre-purge, start-up and after the furnace has been shut down. The air ac- tuators (BCU..F1 = actuators IC 20/40, BCU..F2 = RBW actuators, BCU..F3 = valve) are actuated for this pur- pose by the capacity control system of the BCU.
Air control 4 .1 Capacity control As soon as there is a purge signal at terminal 50 of BCU..F1/F2, the control element is activated by the 4 .1 .1 BCU . .F1/F2 outputs for capacity control to approach the position for pre-purge.
Air control Modulating control Parameter 48 = 3 After the operating signal has been received from the burner and after expiry of the delay time for the control- ler enable signal (parameter 44), the BCU issues the controller enable signal via the output at terminal 56. Access to the control element is thus transferred to an external temperature controller (3-point step).
Air control 4 .1 .2 BCU . .F3 interlocks) has issued the enable signal, the burner can be started by the start-up signal at terminal 1. The gas valves for the 1 stage are opened and the burner is ignited (on the BCU..C1 after a successful valve check). VAS 1 After the operating signal has been received from the burner, the gas valve for the 2...
Valve proving system 5 Valve proving system 5 .1 Tightness test The BCU 500..C1 is fitted with an integrated valve prov- The aim of the tightness control is to identify an inad- ing system. This allows either the tightness of the gas missible leak on one of the gas solenoid valves and to solenoid valves and the pipework between them to be prevent burner start.
Valve proving system 5 .1 .1 Test instant Depending on the parameter setting, the tightness control checks the tightness of the pipework and the gas solenoid valves before each start-up and/or after VAS 1 each shut-down of the burner, see page 95 (Valve proving system).
Valve proving system 5 .1 .2 Program sequence The tightness test starts by checking the external pres- sure switch. If pressure p > p /2, program A starts. START If pressure p < p /2, program B starts, see page 32 –...
Valve proving system Program B Valve V2 opens for the set opening time t . V2 closes again. During the measurement time t , the tightness START control checks the pressure p between the valves. – p Z > If pressure p >...
Valve proving system 5 .1 .3 Test period t time t , the greater the sensitivity of the tightness con- Depending on the burner capacity, the tightness of the trol. The measurement time is set using parameter 56 gas solenoid valves must be checked in accordance to a value between 3 and 3600 s –...
Valve proving system Leakage rate VG 50/VK 50 The BCU tightness test ensures that the leakage rate Q VG 65/VK 65 VG 80/VK 80 is < 0.1% of the maximum flow rate Q (N)max. VK 100 VK 125 13.6 max. [m /h] x 1000 [l/h] VK 150 Leakage rate QL [l/h] =...
Valve proving system Calculation examples Measurement time for one test volume V 2 valves VAS 665, Parameter 70 = 0 distance L = 9.5 m, 2 x 50 mbar x 32.45 l [ s ] = = 16.23 s inlet pressure p = 50 mbar, 200 l/h max.
Valve proving system 5 .2 Proof of closure function As soon as the BCU has opened valve V1, it queries the open position of the valve via the POC switch. If a signal The proof of closure function monitors the function of is still received at terminal 45 from the POC switch after the gas solenoid valve V1.
BCSoft 6 BCSoft The BCSoft engineering tool provides extended access to the BCU. BCSoft makes it possible to set device pa- rameters on Windows-based PCs in order to adjust the BCU to the specific application. In addition, BCSoft pro- vides extended access to the individual statistics and protocol functions.
Profinet 7 Profinet constantly repeated such as sending parameter set- tings and configuration data when the IO devices start Profinet is a manufacturer-independent, open standard up or sending a diagnostic message from the IO device for industrial Ethernet. It covers the requirements for to the IO controller during operation.
Profinet 7 .1 BCU and bus module BCM The optional bus module BCM 500 is required to inte- grate the BCU in the Profinet system. Control signals (for start, reset and air actuator control), signal states from the device inputs and outputs and information about the device status (operating states, flame signal and current program step), warnings and faults can be transferred via the bus module between...
Profinet PROFINET Temperature controller ϑ All network components which connect the automation system and the field devices must be certified for Profi- net use. For information on planning and the structure of a Profibus network and the components to be used (e.g. cables, lines and switches), see Profinet Installation Guide at www.profibus.com.
Profinet 7 .2 GSD file for PLC configuration Before commissioning, the Profinet system must be configured for data exchange using an engineering tool. The device master data file (GSD) is required for the integration of the BCU in the configuration of the PLC. The GSD file contains the device image and communi- cations properties of the BCU.
Profinet 7 .2 .1 Modules for cyclic data exchange The modules for cyclic data exchange are defined in the GSD file for the bus module BCM 500. All modules re- quired for cyclic data exchange between the controller and the burner control units BCU 580 are shown in the following table.
Profinet “Inputs/outputs” module – slot 1 Output byte (controller ➔ device) The digital input and output signals from the burner The output byte describes the digital signals which are control units BCU 560, BCU 565 and BCU 580 are in- output by the PLC (IO controller) to the BCU (IO device). cluded in this module.
Profinet “Burner 1 flame signal” module (device ➔ controller) – slot 2 The flame signal for burner 1 is transferred from the “Status signal” module (device ➔ controller) – slot 4 BCU to the PLC as an analogue value using this module. This module transfers the status signals from the The flame signal occupies one byte with values from 0 BCU to the PLC.
Profinet “Fault and warning signals” module (device ➔ “Remaining times” module (device ➔ controller) – controller) – slot 5 slot 6 The fault and warning signals are transferred from the This module transfers the remaining times of various BCU to the PLC using this module. The fault and warn- processes from the BCU to the PLC.
Profinet “Remaining times of the valve proving system” “PLC output information” module (device ➔ module (device ➔ controller) – slot 7 controller) – slot 8 Only for BCU..C1. This module transfers information on signals which the PLC uses to control the BCU back to the PLC. This al- The module in BCU..C0 contains no information.
Profinet “BCU input terminal information” module (device ➔ controller) – slot 9 This module transfers the signal states of the digital in- puts on the BCU (input terminals) to the PLC. Bit Byte n Byte n+1 Byte n+2 Format Terminal 1 Terminal 48 Terminal 68 BOOL...
Profinet 7 .2 .2 Indexes for acyclic communication With the help of acyclic communication between the PLC (IO controller) and BCU/FCU (IO devices), it is pos- sible to read information on parameters, statistics and fault history on an event basis (e.g. using system func- tion block Siemens FSB 52 RDREC).
Program step/status 8 Program step/status DISPLAY Program step/status Initializing Cooling Pre-purge Delay Burner pause time t Pre-ventilation Delay Approaching minimum capacity Approaching maximum capacity Approaching ignition capacity Valve check Safety time 1 Safety time 1 Delay Flame proving period 1 t Flame proving period 1 t Burner 1 operation Burner 1 operation...
Program step/status DISPLAY Program step/status Flame proving period 2 Burner 2 operation Burner 2 operation Delay Remote control with OCU Data transfer (programming mode) – – Device Off In Manual mode, two dots blink on the display. Air actuator (control element/valve) is open. BCU 580 ·...
Fault signalling 9 Fault signalling DISPLAY Fault message (blinking) Description Burner 1 flame simulation Flame simulation/flame signal before ignition No flame after safety time 1 No flame formation to end of 1 safety time Flame failure during flame proving period 1 t Flame failure during burner 1 operation Flame failure during operation Burner 2 flame simulation...
Fault signalling DISPLAY Fault message (blinking) Description Inlet valve(s) leaking Leak found on inlet valve Outlet valve(s) leaking Leak found on outlet valve Pressure switch/gas valve wiring Gas valve wiring Reversed valve connection Safety interlock failure Permanent remote reset Remote reset input activated > 25 s Timing cycle too short Minimum timing cycle not observed Waiting for ignition position (LDS)
Fault signalling DISPLAY Fault message (blinking) Description Air monitor “no flow” state Fault Air monitor “no flow” state check Low air pressure Fault Air monitor operating check Low air pressure Low air pressure during program step 2, 3, 4, 5, 6, 7 or 8 Air flow during pre-purge Air flow failure during pre-purge Waiting for connection...
Parameters 10 Parameters Any changes to parameters will be saved to the parameter chip card. Factory default Name Parameter Value range Description settings Burner 1 FS1 flame signal switch-off Burner 1 FS1 flame signal switch-off threshold in µA 0 – 20 threshold (5 when P04 = 1) Burner 2 flame signal switch-off Burner 2 FS2 flame signal switch-off threshold in µA...
Parameters Factory default Name Parameter Value range Description settings BCU..F0 = 0 With IC 20 BCU..F1 = 1 Capacity control With IC 40 BCU..F2 = 3 With RBW BCU..F3 = 5 With air valve Off; checking the positions for minimum/maximum capacity On;...
Parameters Factory default Name Parameter Value range Description settings Air actuator can be activated externally on Cannot be activated start-up Can be activated externally Cannot be activated Air actuator in the event of fault Can be activated externally Tightness test before start-up Valve proving system Tightness test after shut-down Tightness test before start-up and after shut-down...
Parameters Factory default Name Parameter Value range Description settings MIN. to MAX. capacity; standby in position for MIN. capacity MIN. to MAX. capacity; standby in CLOSED position IGNITION to MAX. capacity; standby in CLOSED Capacity control (bus) position MIN. to MAX. capacity; standby in position for MIN. capacity;...
Parameters 10 .1 Scanning the parameters Burner 2 flame signal switch-off threshold FS2 Parameter 02 During operation, the 7-segment display shows the pro- The sensitivity at which the burner control unit detects gram step/status. a flame at burner 2 can be set using parameter 02. All the parameters of the BCU can be scanned in nu- In the case of UV control, this value can be increased, merical order by repeatedly pressing the Reset/Infor-...
Parameters 10 .2 .2 Flame control Parameter 04 = 8: burner 1 flame control is performed Parameter 04 with a UV sensor for continuous operation (UVD). Burn- er 2 flame control is performed with a UV sensor for Parameter 04 = 0: flame control is performed with an intermittent operation (UVS).
Parameters 10 .2 .3 High temperature operation FCU 500..H1 Parameter 06 BCU 580..D Operation of firing systems at temperatures above µC 750°C The BCU..D1 and BCU..D2 have a fail-safe input with the function “High temperature operation”. If firing sys- BCU 580..D tems are operated above 750°C, the system is consid- µC ered to be an item of high temperature equipment (see...
Parameters The precondition for this operating mode is that an Parameter 06 = 0 external flame supervision device ensures the pres- The High temperature mode function is switched off. ence of the flame in a fail-safe manner indirectly via the Flame control takes place dependent on the setting in temperature.
Parameters Parameter 06 = 3 (BCU..D1) Fault, main burner ϑ1 ϑ1 ϑ2 ϑ2 Despite the HT input having been disconnected from the electrical power supply, the burner remains in op- eration. The BCU performs flame control again (recom- mended in the case of ionization control or UV control with UVD).
Parameters 10 .3 Behaviour during start-up If no flame is formed during the start-up so that at the end of the safety time t no flame signal is detected, 10 .3 .1 Burner 1 start-up attempts this will result in a BCU safety shut-down with subse- Parameter 07 quent fault lock-out.
Parameters 10 .3 .2 Burner 2 start-up attempts this will result in a BCU safety shut-down with subse- quent fault lock-out. The fault message 06 will flash in Parameter 08 the BCU display depending on the burner operating Up to three start-up attempts are possible in certain mode.
Parameters 10 .3 .3 Burner application start the burner. The burner is started with a limited Parameter 78 ignition capacity using gas valve V3. After the elapse of the safety time t (program step 02), valve V2 opens. This parameter enables the BCU to be adjusted to vari- Valve V3 limits the ignition capacity.
Parameters Parameter 78 = 2: burner 1 and burner 2. Three valves the elapse of the safety time t (program step 06), (V1, V2 and V4) are included for a modulating burner valve V2 opens (terminal 14). Pilot gas valve V3 is closed with a pilot burner.
Parameters Parameter 78 = 4: two-stage burner 1. Three valves (V1, Parameter 78 = 5: burner 1 and two-stage burner 2. In V2 and V3) are included for a two-stage-controlled this application, the burner has an additional pilot gas burner. These are connected to the valve outputs (ter- valve V3.
Parameters 10 .3 .4 Safety time 1 t If the ϑ1 signal (terminal 1) drops out during safety Parameter 94 time 1, the valves will not be switched off until the end During the safety time 1 t , the flame (pilot flame) is of safety time 1.
Parameters 10 .3 .6 Safety time 2 t If the ϑ1 signal (terminal 1) drops out during safety Parameter 96 time 2, the valves will not be switched off until the end During the safety time 2 t , the flame on burner 2 of safety time 2.
Parameters 10 .4 Behaviour during operation Parameter 09 = 0: Off. 10 .4 .1 Restart Parameter 09 This parameter determines whether the BCU initiates ϑ an immediate safety shut-down with fault lock-out or an automatic restart after a flame failure during opera- tion.
Parameters Parameter 09 = 1: burner 1. The restart function is ac- Parameter 09 = 2: burner 2. tive. ϑ1 ϑ ϑ2 >2 s >2 s 17-18 If a flame failure occurs during operation (minimum op- erating time of 2 s), the valves are closed and the opera- If a flame failure occurs during operation (minimum op- tion signalling contact is opened within the safety time erating time of 2 s), valve 2 is closed and the operation...
Parameters Parameter 09 = 4: max. 5 × in 15 min. for burner 1. The restart function is active and is also monitored. In cer- tain conditions, it is possible that the restart function is repeated continuously without a safety shut-down with subsequent fault lock-out being performed.
Parameters 10 .4 .2 Minimum operating time t 10 .4 .3 Pilot burner Parameter 61 Parameter 79 A minimum operating time (0 to 250 s) may be defined to ensure that the heating equipment operates stably. ϑ1 ϑ2 If the minimum operating time is active, burner opera- tion will be maintained until the set time has elapsed P79 = 1 even if the start-up signal fails.
Parameters 10 .5 Safety limits Parameter 19 can be used to adjust the safety limits (safety time during operation) to the system require- ments. 10 .5 .1 Safety time during operation Parameter 19 Parameter 19 = 1; 2: time in seconds. The safety time during operation is the time that the BCU needs to stop the fuel supply after a flame failure during operation or an interruption at the safety current...
3,15AT Parameters 10 .6 Air control IC 20 10 .6 .1 Capacity control Parameter 40 µC The BCU is fitted with an interface for connecting air actuators. BCU 580..F1 The BCU..F1/F2 activates a control element via the out- puts for capacity control (terminals 53 to 56) for purg- ing, cooling or starting the burner.
Parameters In the event of a fault, the actuator is moved to the posi- tion set via cam S4 for minimum capacity via the output at terminal 54. µC 0° 90° BCU 580..F1 Burner control range Butterﬂy valve setting range The minimum position which can be reached is the Control range closed position.
3,15AT Parameters IC 20 . .E The control system is enabled during operation via the controller enable output (terminal 56). During the con- troller enable procedure, the actuator can be adjusted infinitely between the positions for maximum and mini- µC mum capacity by a controller (0(4) –...
Parameters IC 40 been reached. Terminal 52 checks the position for igni- Parameter 40 = 2: with IC 40. tion capacity. If the position is not reached within the timeout time of 255 s, a safety shut-down of the BCU To ensure that the actuator IC 40 can be operated on will be performed.
Parameters Operating mode 11 Operating mode 27 Operating mode 11 allows cyclic operation (ON/OFF During the controller enable procedure, the actuator and OFF/Low/High/OFF). IC 40 can be adjusted infinitely between the positions for maximum and minimum capacity using its ana- The actuator IC moves to the “High fire”...
Parameters Fault In the event of a fault, there will be no signal at ter- minals 53 and 55 so that the actuator moves to the closed position. When approaching the closed posi- tion, no timeout of 255 s is active since no feedback input is checked.
Parameters 62 61 11 12 The RBW actuator reports that it has reached the posi- Parameter 40 = 3: with RBW. tion for maximum capacity via a signal to terminal 51. The actuator reports that it has reached the position The actuator can be moved to the positions for maxi- for minimum capacity via a signal to terminal 52.
Parameters Manual mode In Manual mode, no external controller is enabled dur- ing the controller enable procedure. The actuator can be moved to the positions for maximum capacity or ig- nition capacity by the user. 3-point step operation is not possible.
Parameters Parameter 40 = 5: with air valve. The positions for maximum capacity and ignition ca- pacity can be set using the air valve. If the air valve is closed, the ignition capacity is reached, if it is open, the maximum capacity is reached.
Parameters 10 .6 .2 Running time selection 10 .6 .3 Running time Parameter 41 Parameter 42 This parameter can be used to adjust the behaviour of Parameter 41 = 0: Off; checking the positions for mini- mum/maximum capacity. A signal that the positions for slow opening and closing air valves.
Parameters 10 .6 .4 Low fire over-run imum capacity is reached. If the flame is extinguished, Parameter 43 this does not result in a fault. The low fire over-run (t ) is applicable to systems with Parameter 43 = 2, 3, 4, 5, 10, 20, 30 or 40 (only for BCU.. a pneumatic air/gas ratio control system and On/Off F3): time in seconds.
Parameters 10 .6 .5 Controller enable signal delay time t Parameter 44 (only on BCU..F1/F2) ϑ1 The controller enable signal is delayed by 0, 10, 20 or 30 ϑ2 up to 250 s using parameter 44. If the BCU has successfully started the burner, after the elapse of the safety time and the flame proving period, if parameterized, the controller enable signal to the ∨...
Parameters Parameter 48 = 1: opens with gas stage 1. Parameter 48 = 2: opens with operating signal. ϑ1 ϑ1 ϑ2 ϑ2 ∨ 53 ∨ 53 17-18 17-18 37-38 37-38 The air actuator opens at the same time as safety This setting is required in the case of two-stage main time t begins and the main burner starts.
Parameters Parameter 48 = 3: controller enable following operating Parameter 48 = 4: opens with V4 pilot burner. signal or in standby. This parameter is used to activate modulating capacity control on BCU..F1 and F2. The controller enable signal ϑ1 ϑ2 is issued via the output at terminal 56 in the start-up position (standby) and during operation.
Parameters 10 .6 . 7 Air actuator can be activated externally on start-up The air actuator can be activated externally via the input Parameter 49 at terminal 2 during start-up. Parameter 48 must be set to 0 for this purpose, see also page 86 (Air actuator Parameter 49 = 0: cannot be activated.
Parameters 10 .6 .9 Capacity control (bus) 0° 90° 62 61 11 12 Parameter 75 Burner control range Controlling the burner capacity using the fieldbus is Butterﬂy valve setting range only possible with bus module BCM 500 connected Control range and enabled (P80 = 1 or 2).
Parameters Parameter 75 = 2: MIN. to MAX. capacity; standby in 0° 90° 62 61 11 12 CLOSED position. The control range while the burner Burner control range is operating is between the positions for minimum ca- CLOSED Butterﬂy valve setting range OPEN pacity (S2) and maximum capacity (S3).
Parameters Parameter 75 = 3: IGNITION to MAX. capacity; standby 0° 90° 62 61 11 12 in CLOSED position. Burner control range The control range while the burner is operating is be- CLOSED Butterﬂy valve setting range OPEN tween the positions for minimum capacity (S1) and IGNITION Control range maximum capacity (S3).
Parameters Parameter 75 = 4: MIN. to MAX. capacity; standby in 0° 90° position for MIN. capacity; burner quick start. 62 61 Burner control range 11 12 The control range while the burner is operating is be- Butterﬂy valve setting range OPEN tween the positions for minimum capacity (S4) and Control range...
Parameters Parameter 75 = 5: IGNITION to MAX. capacity; standby S4: for the closed position of the butterfly valve and standby. in CLOSED position; burner quick start. 0° 90° The control range while the burner is operating is be- 62 61 11 12 Burner control range tween the positions for ignition capacity (S1) and maxi-...
Parameters 10 . 7 Valve check Parameter 51 = 4: proof of closure function (POC). 10 . 7 .1 Valve proving system Parameter 51 Parameter 51 is used to define whether and at what time in the BCU program sequence the valve check is activated.
Parameters 10 . 7 .2 Relief valve (VPS) 10 . 7 .3 Measurement time V Parameter 52 Parameter 56 One of the valves connected to terminal 14, 15 or 57 The required measurement time must be determined can be selected to discharge the test volume during a according to the requirements of the appropriate appli- tightness test.
Parameters 10 . 7 .4 Valve opening time 1 t Parameter 59 This parameter is used to define the opening time for the valves (2 to 25 s) which are opened to fill or dis- charge the test volume between the gas valves. If the preset opening time t = 2 s is inadequate (e.g.
Parameters 10 .8 Behaviour during start-up 10 .8 .1 Minimum pause time t Parameter 62 A minimum pause time t (0 to 3600 s) can be defined to achieve stable operation of the burners. If a signal is applied to terminal 1 (burner start-up) or terminal 2 (cooling) during the minimum pause time, status display Delay H0 will appear.
Parameters 10 .9 Manual mode 10 .9 .1 Operating time in Manual mode Parameter 67 If the Reset/Information button is pressed for 2 s dur- Parameter 67 determines when Manual mode is termi- ing switch-on, the BCU reverts to Manual mode. Two nated.
Parameters 10 .10 Functions of terminals 50, 51, 65, 66, 67 10 .10 .2 Function of terminal 51 Parameter 69 and 68 Parameter 69 = 0: Off. The BCU is informed via terminal 50 by a separate au- Parameter 69 = 8: AND with input at terminal 46 (emer- tomation system that purging is currently being per- gency stop).
Parameters 10 .11 Password Parameter 77 The password is designed to protect the parameter settings. To prevent unauthorized changes to param- eter settings, a password is stored in parameter 77 (0000 to 9999). Changes to parameter settings can only be made once this number has been entered. The password can be changed using BCSoft.
Project planning information 12 Project planning information Environment Install in a clean environment (e.g. a control cabinet) 12 .1 Installation with an enclosure ≥ IP 54, whereby no condensation is Installation position as required. permitted. The BCU mounting is designed for horizontally aligned 12 .2 Commissioning 35 × 7.5 mm DIN rails.
Project planning information 12 .3 Electrical connection 12 .3 .1 OCU The BCU is designed for connection to a 1-phase sys- tem. All inputs and outputs have a one-phase mains supply. Other connected burner control units must use the same phase of the mains supply. The national standards and safety requirements must be satisfied.
Project planning information 12 .3 .2 Safety current inputs Actuation of the safety current inputs only with switch- ϑ1 gear featuring mechanical contacts. If switchgear with 62 61 semi-conductor contacts is used, the safety current ϑ2 inputs must be connected using relay contacts. To safeguard the safety current inputs, the fuse must be designed so that the sensor with the lowest switching capacity is protected.
Project planning information 12 .3 .3 UVD control An additional voltage supply of 24 V DC is required to operate the UV sensor for continuous operation UVD 1 in conjunction with burner control unit BCU 580. The 24 V DC voltage supply and the 0 – 20 mA current out- put of the UV sensor must be wired separately.
Project planning information ϑ1 12 .4 Actuators 12 .4 .1 IC 20 The BCU..F1 checks the position to which the actuator 62 61 5 6 7 8 11 12 If actuators are used, the start gas rate of the burners ϑ2 IC 20 has moved using terminal 52 (feedback) by lifting must be limited for SIL 3 applications in compliance...
Project planning information 12 .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.
Project planning information 12 .8 Fifth or switchable gas valve on BCU . .F3 The following application describes a two-stage-con- trolled burner without a pneumatic air/gas ratio control Units with air valve control have an additional contact system. V2 and the air valve are activated simultane- (terminal 53/54), which closes at the same time as the ously.
Accessories 13 Accessories 13 .2 OCU 13 .1 BCSoft The current software can be downloaded from our In- ternet site at www.docuthek.com. To do so, you need to register in the DOCUTHEK. 13 .1 .1 Opto-adapter PCO 200 For installation in the control cabinet door in standard grid dimensions.
Accessories 13 .3 Connection plug set 13 .5 “Changed parameters” stickers For wiring the BCU. D-49018 Osnabrück, Germany Achtung, geänderte Parameter! Die Angaben auf dem Typenschild gelten nicht mehr in vollem Umfang. Aktuelle Parameter direkt auslesen. Important, changed parameters! The details on the type label are no longer completely accurate.
14 OCU 14 .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 may be installed in the door of a control cabinet, for example.
14 .2 Function Back The OCU features an illuminated plain-text display. The In Service mode, you can use the Back key to lighting is switched on when a control key is pressed switch from one setting level to the next higher and switches off automatically after 5 minutes.
14 .2 .1 Manual mode In Manual mode, the control unit works with capac- ity control (FCU..F1/F2 or BCU..F1/F2) regardless of the status of its inputs. The inputs for start-up signal (terminal 1), controlled air flow (terminal 2) and remote reset (terminal 3) are ignored.
14 .3 Electrical connection 14 .4 Installation The OCU is to be connected to the control unit using The threaded adapters of the OCU are suitable for the two plugs provided. 23 mm boreholes which are drilled at intervals of 30 mm.
14 .5 Selection 14 .6 Technical data for OCU Ambient temperature: -20 to +60°C. The OCU can be supplied with various language kits. Relative humidity: Type Languages Order No. 30% to 95% (no condensation permitted). German, English, French, Dutch, OCU 500-1 84327030 Spanish, Italian Enclosure: IP 65 when fitted (control cabinet door).
BCM 500 15 BCM 500 15 .3 Electrical connection Use only cable and plug components which comply 15 .1 Application 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. The bus module BCM 500 is used as a communications interface for devices of the BCU/FCU 500 product family for connection to a Profinet network.
BCM 500 15 .4 Installation 15 .5 Selection Installation position: vertically upright, horizontal or Code Description tilted to the left or right. Bus module Series 500 The BCM mounting is designed for horizontally aligned Standard communication 35 × 7.5 mm DIN rails. Profinet Two RJ45 sockets Three-point step control via bus...
Technical data 16 Technical data – Ignition transformer (terminal 9): max. 2 A. 16 .1 Electrical data – Total current for the simultaneous activation of the valve outputs (terminals 13, 14, 15 and 57), the actu- Mains voltage ator (terminals 53 – 56) and the ignition transformer: BCU..Q: 120 V AC, -15/+10%, 50/60 Hz, ±5%, max.
Technical data 16 .5 Safety-specific characteristic values Relationship between the Performance Level (PL) and the Safety Integrity Level (SIL) Suitable for Safety Integrity Level Up to SIL 3 Diagnostic coverage DC 97.2 % – Type of subsystem Type B to EN 61508-2:2010 High demand mode pursuant to EN Operating mode 61508-4:2010...
Maintenance 17 Maintenance The fail-safe outputs (valve outputs V1, V2, V3 and V4) of the power module are monitored for correct func- tioning. In the event of a fault, the system is set to a safe status using a second shut-down method (isolation of the valve outputs from the mains).
Legend 18 Legend TC Tightness test /2 Half of the inlet pressure Ready for operation Inlet pressure Safety interlocks (limits) Outlet pressure Control element position check Test volume LDS Safety limits (limits during start-up) Valve with proof of closure switch Gas valve Air valve Three-point step switch...
Glossary 19 Glossary 10 s) is the minimum operating time of the burner and burner control unit. 19 .1 Waiting time t 19 .5 Safety time during operation t In standby, the waiting time t starts to elapse in the background.
Glossary 19 .6 Safety shut-down In order to restart, the BCU can only be reset manually using the button on the front panel, the OCU or the re- The burner control unit performs a safety shut-down mote reset input (terminal 3). immediately after receiving a signal from a safety de- vice or after a fault is detected (e.g.
Glossary 19 .10 Lifting 19 .13 Operating mode After positioning the actuator IC 20, the BCU checks by IEC 61508 describes two modes of operation for safety means of brief lifting whether its feedback input (termi- functions. These are low demand mode and high de- nal 52) has been activated by the correct output signal mand or continuous mode.
Glossary 19 .14 Safe failure fraction SFF Fraction of safe failures related to all failures, which are assumed to appear from EN 13611/A2:2011 19 .15 Probability of dangerous failure PFH Value describing the likelihood of dangerous failure per hour of a component for high demand mode or con- tinuous mode.
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