Page 1: Table Of Contents
Draft Transmitter Adjustments Attachments: Applicable Hauck Drawings These instructions are intended to serve as guidelines covering the installation, operation, and maintenance of Hauck equipment. While every attempt has been made to ensure completeness, unforeseen or unspecified applications, details, and variations may preclude covering every possible contingency.
Page 2: General Information
For optimum use of the BCS panel, it is suggested that the drawings provided by Hauck be referred to for limit switch and valve installation and wiring. In the event that a recommended switch or valve is not used, it may be necessary to connect jumper wire(s) between appropriate terminals in the control panel or burner junction box.
Page 3: Installation
Install the stack temperature thermocouple in the dryer exhaust duct to sense exhaust gas temperature. See Appendix G. for installation instructions. Install a Hauck Rapid Response material temperature thermocouple in the material discharge chute to sense the temperature of the material leaving the dryer. See Appendix H.
Page 4 Page 4 BCS6000B-9 IMPORTANT Thermocouple cables must be separated from AC power and control wiring to avoid interference and nuisance shutdowns. Observe polarity when making thermocouple connections. Regardless of thermocouple type, the red wire is always negative. A pressure tap for the dryer draft transmitter should be located in the 10 o’clock or 2 o’clock position on the dryer breech.
Page 5: Adjustments And Final Checkout
Page 5 BCS6000B-9 E. ADJUSTMENTS and FINAL CHECKOUT: Record all settings on the CONFIGURATION RECORD SHEET provided in Appendix B. IMPORTANT The burner control motors incorporate a position feedback slidewire. A 5 Vdc supply voltage from the panel is connected to the slidewires in order to generate 0 to 5 Vdc position feedback signals for the PLC.
Page 6 Page 6 BCS6000B-9 CONTROL LOOP TUNING Screen After setting and recording all parameters on the motor calibration & setup screen, press MAIN MENU key to return to the menu screen then select the CONTROL LOOP TUNING button to display the loop tuning screen. This screen is used to enter tuning constants for each of the three PID control loops.
Page 7 Page 7 BCS6000B-9 DRAFT CONTROL Enter a draft control PURGE SETPOINT for use during the burner purge sequence. Set this value higher than the normal draft setpoint to prevent dusting as the air damper drives open for purge. Enter LOW FIRE and HIGH FIRE SETPOINTS for draft control. The draft setpoint will automatically ramp from the low fire to the high fire setpoint as the burner firing rate increases.
Page 8: Electronic Valve Characterization
Page 8 BCS6000B-9 Time and Date Setting Simultaneously press the upper left and lower left corners of the touchscreen to enter the screen setup mode then select CLOCK to access the time and date settings. Use the keypad to enter the desired value then press Sec, Min, Hr, Day, Mon, or Yr as applicable. For example, to set the month to September, use the keypad to enter 9, then press Mon.
Page 9: Operation
Page 9 BCS6000B-9 Setup an analyzer to monitor stack or drum emissions. With the burner firing in manual at approximately 10% output, select the bias point setting screen. Allow the analyzer readings to stabilize, then increase or decrease the air input, if required. Make small adjustments and allow readings to settle after each change.
Page 10 Page 10 BCS6000B-9 6. Momentarily press the RESET button to initiate the system purge sequence. a. An "OPENING AIR VALVE” message will appear as the burner air control motor drives open. b. After the air control motor has opened more than 50%, purge timer, 1TR, will be energized and begin timing and a “PURGING”.
Page 11 Page 11 BCS6000B-9 15. Note that the burner may be forced to low fire at any time by pressing the DRIVE TO LOW FIRE button. a. The button will be highlighted and “LOW FIRE SELECTED” will appear in the message box. b.
Page 12: Troubleshooting
Page 12 BCS6000B-9 H. TROUBLESHOOTING Use the HELP screens on the touch screen or refer to the following table. MESSAGE DIAGNOSTICS The difference between the Zero and Span feedback values of each CONTROL MOTOR CALIBRATION motor must be greater than 3300. Verify that the motors travel full REQUIRED stroke during the motor calibration procedure.
Page 13 Indicates low PLC battery voltage. The battery compartment is REPLACE PLC BATTERY located in the CPU. A replacement battery is available from Hauck (part no. 62311) or Automation Direct (part no. D2-BAT-1). *The control motor and excess fuel faults all indicate possible problems with the burner control motors or the position feedback circuits.
Page 14 Page 14 BCS6000B-9 ALARM HISTORY Screen An alarm history screen is also provided for use as a troubleshooting guide. From the MAIN MENU screen press ALARM HISTORY to view a list of the last 99 logged events and the order in which they occurred.
Page 15: Appendix A Operator Interface Screens
Page 15 BCS6000B-9 APPENDIX A: OPERATOR INTERFACE SCREENS MAIN SCREEN This screen displays overall system status and is the default screen on system power-up. It provides AUTO/MANUAL control selection and setpoint (SP) inputs for the temperature control loops. Note that the message box in the lower left corner of the screen appears on all screens to provide the operator with system status messages.
Page 16 Page 16 BCS6000B-9 MOTOR CALIBRATION & SETUP Reference Section E. Used to ZERO and SPAN the burner control motors and to enter motor deadband settings. Provides numeric inputs for burner firing rate limits, gas pressure correction and temperature bias settings. CONTROL LOOP TUNING Reference Section E.
Page 17 Page 17 BCS6000B-9 RUN MENU Reference Section E Used to set the burner startup percentage and ramp rate for automatic temperature control. Also provides for low fire drive alarms and draft setpoint inputs, selection of control mode and parameters for automatic draft increase control. BIAS POINT SETTINGS Reference Section F Two separate screens (GAS and OIL/LP) are provided setup the electronic valve characterization for the air valve.
Page 18 Page 18 BCS6000B-9 TREND Three separate trend screens provide 15 minute, 4 hour and 8 hour trends of Material temperature; Stack temperature, Setpoint and burner firing rate.
Page 19: Appendix B Configuration Record
Page 19 BCS6000B-9 APPENDIX B: CONFIGURATION RECORD MAIN MENU SCREEN PLC PROGRAM: __________ SCREEN PROGRAM: __________ MOTOR CALIBRATION & SETUP SCREEN MOTOR ZERO SPAN DEADBAND FUEL BURNER OUTPUT LIMIT: __________ GAS PRESSURE: __________ oz. MATERIAL TEMPERATURE BIAS: __________ STACK TEMPERATURE BIAS: __________ CONTROL LOOP TUNING SCREEN MATERIAL STACK...
Page 20: Appendix C Recommended Spare Parts
Module, 8-point AC input, Automation Direct D2-08NA-1 58479 Module, 8-point relay output, Automation Direct D2-08TR 63319 Module, 8-point voltage input, Automation Direct F2-08AD-2 300181 Operator interface touch screen, Automation Direct EZ-S8C-F 43508 Material thermocouple, Hauck TC100A-J 43868 Stack thermocouple, Hauck TC200A-J...
Page 21: Appendix Ddl250 Programmable Controller
APPENDIX D: DL250 PROGRAMMABLE CONTROLLER VENDOR: Automation Direct (800) 633-0405 BASE: 9-Slot base Hauck part number 58484 / Automation Direct model number D2-09B CPU: Central processing unit Hauck part number 400429 / Automation Direct model number D2-250 BATTERY Hauck part number 62311 / Automation Direct model number D2-BAT-1...
Page 22 Page 22 BCS6000B-9 SLOT 3: 8-Point AC input module Hauck part number 58481 / Automation Direct model number D2-08NA-1 Input Wire Function High gas pressure limit Secondary air motor starter interlock Primary air motor starter interlock Primary air pressure switch...
Page 23 Page 23 BCS6000B-9 APPENDIX E: UDC1000 SERIES LIMIT INSTRUMENTS Hauck part number 300003 Honeywell model DC100L-1-1-7-0-1-0-0-0 Two Honeywell UDC1000 series instruments are provided for temperature indication and over- temperature protection. Each instrument receives a thermocouple input and provides a 0 to 5Vdc temperature signal to the PLC.
Page 24 Page 24 BCS6000B-9 changed and the RESET key must be pressed to accept the change. Momentarily press the SET UP and keys again to exit the configuration mode. Fahrenheit Centigrade Type J Type K Type J Type K Lower Upper Upper Upper Upper...
Page 25: Appendix F Exhaust Fan Flow Limit Installation
Page 25 BCS6000B-9 APPENDIX F: EXHAUST FAN FLOW LIMIT SWITCH INSTALLATION Mount the exhaust fan flow switch in the dryer exhaust duct as shown below. CY6909 Drawing showing the installation of the exhaust fan flow switch. Wire the exhaust flow switch to the appropriate terminals. The exhaust flow switch is an interlock which requires the exhauster to be operating prior to ignition of the burner.
Page 26: Appendix G Stack Thermocouple Installation
Page 26 BCS6000B-9 APPENDIX G: STACK THERMOCOUPLE INSTALLATION Install a Hauck stack temperature thermocouple in the dryer exhaust duct to sense exhaust gas temperatures. Drawing showing placement of thermocouple in exhaust duct. NOTE Thermocouple cables must be separated from AC power and control wiring to avoid interference and nuisance shutdowns.
Page 27: Appendix H Material Thermocouple Installation
Page 27 BCS6000B-9 APPENDIX H: MATERIAL THERMOCOUPLE INSTALLATION Install a Hauck Rapid Response Material Temperature Thermocouple in the material discharge chute to sense the temperature of the material leaving the dryer. Wire the thermocouple to the proper terminals in the panel.
Page 28 Page 28 BCS6000B-9 NOTE During normal operation, the thermocouple should be rotated once a month to expose a different area of its surface to the abrasive forces of the material. This procedure will increase the effective life of the thermocouple. If excessive wear occurs, a protective tube may be added to shield the shaft in the region of the high velocity flow.
Page 29: Appendix I Draft Transmitter Adjustments
Page 29 BCS6000B-9 APPENDIX I: DRAFT TRANSMITTER ADJUSTMENTS The NEXT and ENTER buttons located below the Lcd display may be used to adjust or reconfigure the draft transmitter if required. Wait 1 or 2 seconds between each button press to allow the display to update.
Page 30 Page 30 BCS6000B-9 4 MA ADJUSTMENT Verify that when the transmitter reads 0.00, the BCS 6000 touchscreen display also reads 0.00. If necessary, adjust the transmitter 4 mA value using the following procedure. • Press the NEXT button one time to change the lower display to CALIB. •...

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