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Elster BCU 480 Manual

Elster BCU 480 Manual

Burner control units
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Burner control units BCU 480

Technical Information · GB
6.1.2.8 Edition 06.07
•
For pilot and main burners of unlimited capacity in intermittent or continuous
operation pursuant to EN 746-2
•
Automatic burner control unit, ignition transformer, indicators and operating
controls in a space-saving metal housing which replaces the local burner
control cabinet
•
Flame control 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 diagnostic purposes
•
Visualisation and adaptation to the specific application via the PC
programming and diagnostic software BCSoft to simplify logistics
management
•
Spacious connection chamber with plug-in terminal blocks and plug-in cable
glands for quick installation and servicing
•
Air valve control relieves the furnace control
•
Optional PROFIBUS-DP interface
•
EC type-tested and certified
www.kromschroeder.com

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  • Page 1: Burner Control Units Bcu 480

    Burner control units BCU 480 Technical Information · GB 6.1.2.8 Edition 06.07 • For pilot and main burners of unlimited capacity in intermittent or continuous operation pursuant to EN 746-2 • Automatic burner control unit, ignition transformer, indicators and operating...

  • Page 2: Table Of Contents

    4.1.1 BCU 480 ........
  • Page 3 8.2 With UV sensor ....... 57 BCU 480 · Edition 06.07...

  • Page 4: Application

    The air valve control assists the furnace control for cooling, purging and capacity control tasks. The burner control units BCU 480 control, ignite and monitor The program status, the unit parameters and the level of the gas burners for intermittent or continuous operation. As a re- flame signal can be read directly from the unit.
  • Page 5 Application To reduce the installation and wiring costs, Elster Kromschröder offers an optional PROFIBUS-DP interface to transfer the ac- tivation signals and feedbacks so as to expand the remote servicing and diagnostics facilities. Bogie hearth forg- ing furnace in the...

  • Page 6: Examples Of Application

    UV sensor UVD 1 is used for continuous operation, UV sensor UVS for intermittent opera- tion. The BCU provides the cooling and purg- ing processes. 02–04 06–08 02–04 06–08 ϑ1 VR..L ϑ2 BCU 480 · Edition 06.07...

  • Page 7: Stage-Controlled Main Burner With Permanent

    Pilot and main burners can be operated simultaneously. This reduces ϑ1 ϑ2 the time required by the main burner for starting up. BCU 480 The BCU provides the cooling and purg- ing processes. µC 02–04 06–08 06–08 ϑ1 VR..R ϑ2 BCU 480 · Edition 06.07...

  • Page 8: Two-Stage-Controlled Main Burner With Permanent

    This reduces the time required by the 50 51 main burner for starting up. The BCU provides the cooling and purg- ing processes. 02–04 06–08 06–08 ϑ1 ϑ2 IC 40 BCU 480 · Edition 06.07...

  • Page 9: Modulating-Controlled Burner

    BCU 480 nalled. Pilot and main burners can be operated simultaneously. This reduces µC the time required by the main burner for starting up. BV+IC BCU 480 · Edition 06.07...

  • Page 10: Bcu 480

    L1, N, PE controlling the air valve from the control system to the BCU 480..B1. In the oppo- site direction it sends operating status, the level of the flame signals and the current program status.

  • Page 11: Certification

    Certification The burner control unit BCU 480 is designed for applications pursuant to the Machinery Directive (98/37/EC). 3 .1 EC type-tested and certified pursuant to – Gas Appliances Directive (90/396/EC) in conjunction with EN 298 – Low Voltage Directive (73/23/EEC) in conjunction with EN 60730 –...

  • Page 12: Function

    7 8 9 7 8 9 10 24 25 Function 4 .1 .1 BCU 480 For the explanation of symbols, see Legend. 4 .1 Connection diagrams For cable selection and wiring, see Project planning informa- tion. BCU 480 · Edition 06.07...

  • Page 13: Bcu 480

    BCU 480..B1/1 2B 2A 1B 1A PROFIBUS-DP 4 .1 .2 BCU 480 . .B1 with Profibus For the explanation of symbols, see Legend. For further information on BCUs with Profibus, see Technical Information Bulletin “Burner control unit for Profibus-DP BCU 400..B1”.

  • Page 14: Bcu 480

    4 .1 .3 BCU 480 . .P with 16-pin industrial plug connector The burner control unit BCU 480..P can be supplied with an industrial chassis plug (pursuant to VDE 0627). This 16-pin plug connector ensures fast connecting or disconnecting of units without any additional wiring required.
  • Page 15 16 15 14 8 11 10 ϑ ϑ 7 8 9 7 8 9 10 24 25 L1 (L1) N (L2) BCU 480 . .P with industrial plug connector For the explanation of symbols, see Legend. BCU 480 · Edition 06.07...

  • Page 16: Bcu 480 Program Sequence

    (display A1 ). signal V1” (terminal 4). Once the start-up Wait until signal ϑ1 has been applied, the BCU 480 min. burner pause time t has elapsed opens valve V1 and ignites the burner.
  • Page 17 In the event of flame failure: signal ϑ2 has been applied (terminal 21), fault lock-out the BCU 480 opens valve V2. The main burner is ignited by the pilot burner. If a The air valve can be set to open...
  • Page 18 4 start-up attempts or fault lock-out Function > BCU 480 program sequence Behaviour of the pilot burner in the event of flame failure during operation The air valve can be set to open Flame proving period If the flame fails during operation, either...

  • Page 19: Program Status And Fault Messages

    Purge Air valve No air flow in position X High temperature operation** X. X. * In Manual mode, two dots will blink on the display in program status 01 – 08 . ** Optionally available. BCU 480 · Edition 06.07...

  • Page 20: Parameters

    0 – 25 s  Air valve control 0; 1; 2; 3  Air valve can be activated externally on start-up 0; 1  Air valve closed/can be activated in the event of malfunction 0; 1  BCU 480 · Edition 06.07...

  • Page 21: Scanning The Parameters

    BCU can be scanned one after the other by repeatedly pressing the Reset/Information button (for 2 second). In the event of a fault, the BCU halts the program run, the display blinks and it then displays the cause of the fault in coded form. BCU 480 · Edition 06.07...

  • Page 22: Flame Control

    In parameter 03, it is now shown which program 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. BCU 480 · Edition 06.07...

  • Page 23: High Temperature Operation In The Case Of Bcu

    For this purpose, we recommend a safety temperature monitor with twin thermocouple (DIN 3440). Sensor discontinuity, sensor short-circuit, failure of a component or mains failure must set the installation to a safe state. BCU 480 · Edition 06.07...
  • Page 24 UV control with UVD). The BCU switches off the burner once the DI input has been disconnected from the electrical power supply and restarts with flame simulation check (recommended in the case of UV control with UVS). BCU 480 · Edition 06.07...
  • Page 25 If no flame signal is present when High temperature operation is deactivated, the burner control unit performs a fault lock-out, regardless of parameter 33. Fault, pilot burner ϑ1 16-17 ϑ2 28-29 18-19 Fault, main burner ϑ1 16-17 ϑ2 28-29 18-19 BCU 480 · Edition 06.07...

  • Page 26: Uvs Check

    It must be ensured in this case that the program sequence started matches the application. This parameter may be set in this way only if the burner can restart as intended in all operating phases. BCU 480 · Edition 06.07...

  • Page 27: Pilot And Main Burner Monitoring

    ϑ1 separately. ϑ2 The BCU 480 can also be used on indirectly ignited surface burners with end point monitoring. The pilot burner is switched off during the main burner safety Three different operating modes are possible: time t .

  • Page 28: Permanent 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 is applied synchronously and that immediately after the flame proving period t , the main burner is started. BCU 480 · Edition 06.07...

  • Page 29: Behaviour In Start-Up Position/Standby

    ϑ2 The burner must have been switched off for at least 4 s be- fore start-up in order for the flame simulation check to be conducted correctly. BCU 480 · Edition 06.07...

  • Page 30: Minimum Burner Pause Time T

    After the pause time, the burner is started if the start-up signal (ϑ) is applied. The minimum burner pause time t serves to adapt the pro- gram sequence to the requirements of the application. BCU 480 · Edition 06.07...

  • Page 31: Behaviour During Start-Up

    Pilot burner Parameter 22 ϑ1 16-17 ϑ1 ϑ2 28-29 18-19 16-17 18-19 This indicates the safety time on start-up t for the main burner. This indicates the safety time on start-up t for the pilot burner. BCU 480 · Edition 06.07...

  • Page 32: Flame Proving Period T

    Parameter 25 28-29 18-19 ϑ1 16-17 ϑ2 28-29 18-19 Programmable time between 0 and 25 s. This time elapses before the BCU starts the next program step so as to give the flame time to stabilise. BCU 480 · Edition 06.07...

  • Page 33: Burner Start-Up Attempts

    The display blinks and shows the cause of the fault. ϑ1 16-17 18-19 If no flame forms during start-up, a fault lock-out is performed after expiry of time t . The display blinks and shows the cause of the fault. BCU 480 · Edition 06.07...
  • Page 34 ϑ2 28-29 18-19 If no flame forms during the start-up of the main burner, a fault lock-out is performed after expiry of time t . The display blinks and shows the cause of the fault. BCU 480 · Edition 06.07...

  • Page 35: Behaviour During Operation

    The BCU cannot be reset by mains failure. The fault signalling contact does, however, open as soon as the mains voltage fails. See also parameter 32, Behaviour of the air valve in the event of a fault lock-out. BCU 480 · Edition 06.07...
  • Page 36 The precondition for a restart is that activation of the restart al- lows the burner to restart as intended (in all operating phases). In this case, it must be ensured that the program sequence started by the BCU matches the application. BCU 480 · Edition 06.07...

  • Page 37: Fault Lock-Out Or Restart, Main Burner

    After a fault lock-out, the burner control unit can be reset, either with the button on the front panel or using an external button. Several burner control units can be reset in parallel using the external button. BCU 480 · Edition 06.07...
  • Page 38 The precondition for a restart is that activation of the restart al- lows the burner to restart as intended (in all operating phases). In this case, it must be ensured that the program sequence started by the BCU matches the application. BCU 480 · Edition 06.07...

  • Page 39: Air Valve Control On Bcu

    – opens with valve V1 – opens with valve V2 – opens once the main burner has reached its operating position – Low fire over run time t after a normal shut-down BCU 480 · Edition 06.07...

  • Page 40: Air Valve Opens In The Case Of External Activation (Not During Start-Up)

    In this case, activation of the air valve during burner start via ϑ2 input 23 must be prevented. 28-29 External control allows switchover between low fire and high fire during operation. 18-19 ϑ BCU 480..L VAS 1 VR..R BCU 480 · Edition 06.07...

  • Page 41: Air Valve Opens In The Case Of External Activation (Even During Start-Up)

    Parameter 31 = 1: The air valve can be activated even dur- 00 A0 00 A0 ing start-up. ϑ1 These settings may be selected only if the burner can start with full air capacity. 16-17 ϑ2 28-29 18-19 ϑ BCU 480..L VAS 1 VAS..L BCU 480 · Edition 06.07...

  • Page 42: Air Valve Opens With Valve V2

    ON/OFF via the ϑ input. ϑ1 The air valve can be activated externally via input 23 for cool- ing the burner in the start-up position/standby. 16-17 ϑ2 28-29 18-19 ϑ BCU 480..L VAS 1 VR..R BCU 480 · Edition 06.07...

  • Page 43: Air Valve Opens With Operating Signal

    ON/OFF via the ϑ input. ϑ1 The air valve can be activated externally via input 23 for cool- ing the burner in the start-up position/standby. 16-17 ϑ2 28-29 18-19 ϑ BCU 480..L VAS 1 VR..R BCU 480 · Edition 06.07...

  • Page 44: Low Fire Over Run Time T Kn After A Normal Shut-Down

    On/Off control. Its must be ensured that GIK..B no excess gas occurs. VG..N The low fire over run time has an effect on the behaviour of the main burner only. VR..R Background: The pilot burner is only used in single-stage operation. BCU 480 · Edition 06.07...

  • Page 45: Behaviour Of The Air Valve In The Event 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 23. Parameter 32 = 1: The air valve can be activated externally via input 23 even during a fault, e.g. for cooling. BCU 480 · Edition 06.07...

  • Page 46: Manual Mode

    On units with air valve control, the air valve can be opened and closed repeatedly by pressing the button during operation. Manual mode can be terminated by switching off the BCU (On/Off button). BCU 480 · Edition 06.07...

  • Page 47: Selection

    = 3 s, 5 s or 10 s = Rated heat output = Ignition capacity The safety time of the automatic burner control unit depends on the burner type, the burner capacity and the respective application. BCU 480 · Edition 06.07...

  • Page 48: Selection Table

    9-pin D-Sub bus plug connector, IP 54 = /1* * If “none”, this specification is omitted. * If 1 start-up attempt, this specification is omitted. 1) Not in conjunction with PROFIBUS-DP = B1.  = standard,  = available. BCU 480-5/-3/1LW3GBC Order example BCU 480 · Edition 06.07...

  • Page 49: Project Planning Information

    50 m. Avoid external electrical interference. Install as far as possible from mains and ignition cables and interference from electro-magnetic sources. If possible, do not lay in a metal conduit. Several ionisation cables can be routed together. BCU 480 · Edition 06.07...

  • Page 50: Minimum Combustion Time

    The minimum combustion time for the pilot burner is limited to the safety time on start-up (t Background: The pilot burner is only used in single-stage operation. BCU 480 · Edition 06.07...

  • Page 51: Reset

    Reset/Information button on the unit. Note the requirements of the Standards. For exceptions, see Standards. The burner malfunction must be remedied. The malfunction can not be remedied by changing the method of activation. BCU 480 · Edition 06.07...

  • Page 52: Fault Signalling

    ). The max. number of start-ups per minute depends on the safety time t and the ignition transformer used: Ignition transformer TZI Max. start-ups/min. 5-15/100 5-15/100 5-15/100 7-25/20 7-25/20 7-25/20 7,5-12/100 7,5-12/100 7,5-12/100 7,5-20/33 7,5-20/33 7,5-20/33 BCU 480 · Edition 06.07...

  • Page 53: Installation

    Open BCU and screw on with four screws (Ø 4 mm, min. length 15 mm). From outside Screw on the closed unit to the rear with 4 self-tapping screws (enclosed). Otherwise, mount with external securing bars or fastening set (see Accessories). BCU 480 · Edition 06.07...
  • Page 54 The third gas valve (V3) and the air valve are activated simultaneously. During 02–04 06–08 06–08 purging/cooling, the gas valve (V3) is ϑ1 not activated. ϑ2 IC 40 BCU 480 · Edition 06.07...

  • Page 55: Bcu Switched Off

    ON signal), then disconnect the safety interlocks and finally Since EN 298 (1993) does not describe all functions of the BCU, switch off the system. the operator is responsible for ensuring that all parameters and functions are matched to the respective application. BCU 480 · Edition 06.07...

  • Page 56: Changing Parameters

    Document changed parameters in BCSoft using the protocol function and enclose the protocol with the plant documenta- tion. If a replacement is ordered for a BCU with changed param- eters, refer to the protocol for details. BCU 480 · Edition 06.07...

  • Page 57: Flame Control

    This can be programmed using parameter 35. For further information, see brochure UVS. The burner control unit BCU..U is prepared for UV sensor UVD 1. This enables continuous operation. For further information, see Technical Information Bulletin UVD. BCU 480 · Edition 06.07...

  • Page 58: Accessories

    Read the current parameters direct from the unit. Attention, paramètres modifiés ! Les informations figurant sur la plaque signalétique ne sont plus valables dans leur intégralité. Veuillez vous référer directement aux paramètres actualisés. BCU 480 · Edition 06.07...

  • Page 59: External Securing Bar

    Order No.: 74960414 Order No.: 74960422 9 .7 Radio interference suppressed electrode adapters Plug cap, 4 mm, interference-suppressed, Order No. 04115308. Straight adapter, 4 mm, interference-suppressed, Order No. 04115307. Straight adapter, 6 mm, interference-suppressed, Order No. 04115306. BCU 480 · Edition 06.07...

  • Page 60: Technical Data

    Output current: max. 2 A per output, but total current for valves and ignition transformer max. 2.5 A. Inherent current: Operation and fault signalling contacts: Signal “1” typ. 2 mA dry contact, max. 2 A, 264 V, not fused internally. BCU 480 · Edition 06.07...
  • Page 61 Input/Output safety circuit: All inputs/outputs marked with “ ” (see connection dia- gram) may be used for safety tasks. Weight: approx. 5 kg (11 lb) depending on version. BCU . .B1 External fuse: 12 A per zone. BCU 480 · Edition 06.07...

  • Page 62: Housing Dimensions

    C: 2-digit 7-segment display. D: Mains switch to isolate the BCU on two poles from the mains. E: Reset/Information button to reset the system after a fault or to scan parameters on the display. � 4,5 mm 0.177" BCU 480 · Edition 06.07...

  • Page 63: Legend

    Safety time on start-up 3 s, 5 s or 10 s Safety time during operation < 1 s or < 2 s Ignition time 2 s, 3 s or 6 s Flame simulation delay time 25 s Flame proving period 0 – 25 s BCU 480 · Edition 06.07...

  • Page 64: Glossary

    The duration of the ignition time is either 2, 3 or 7 seconds depending on safety time t selected. If the flame fails during operation, the valve outputs are dis- connected within the safety time t BCU 480 · Edition 06.07...

  • Page 65: Flame Signal

    It remains open until the burner is switched – to control the burner capacity in ON/OFF mode and in off again by a normal shut-down or fault lock-out. High/Low mode when using a pneumatic air/gas ratio control system. BCU 480 · Edition 06.07...

  • Page 66: Feedback

    Strotheweg 1 · 49504 Lotte (Büren) We reserve the right to make technical Germany modifications in the interests of progress. T +49 541 1214-0 Copyright © 2007 Elster Group F +49 541 1214-370 All rights reserved. info@kromschroeder.com www.elster.com www.kromschroeder.de BCU 480 · Edition 06.07...

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