krom schroeder BCU 46 Series Operating Instructions Manual

Burner control unit

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Burner control unit BCU 46x, 480
CONTENTS
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Checking the usage . . . . . . . . . . . . . . . . . . . . . 2
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
parameter chip card . . . . . . . . . . . . . . . . . . . . . . 4
5 Cable selection and installation . . . . . . . . . . . . 5
6 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7 Connection diagram . . . . . . . . . . . . . . . . . . . . . 7
8 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Commissioning . . . . . . . . . . . . . . . . . . . . . . . 14
10 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . 15
and the parameters. . . . . . . . . . . . . . . . . . . . . . 26
13 Parameters and values . . . . . . . . . . . . . . . . . 27
14 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
15 Technical data . . . . . . . . . . . . . . . . . . . . . . . 31
16 Safety instructions . . . . . . . . . . . . . . . . . . . . 32
17 Logistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
18 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 32
19 Certification . . . . . . . . . . . . . . . . . . . . . . . . . 33
20 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATING INSTRUCTIONS
Cert. Version 03.19 · Edition 02.22 · EN · 03251582

1 SAFETY

1.1 Please read and keep in a safe place
Please read through these instructions care-
fully before installing or operating. Following the installa-
tion, pass the instructions on to the operator. This unit
must be installed and commissioned in accordance
with the regulations and standards in force. These
instructions can also be found at www.docuthek.com.
1.2 Explanation of symbols
1 , 2 , 3 , a , b , c = Action
➔ = Instruction
1.3 Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
1.4 Safety instructions
Information that is relevant for safety is indicated in the
instructions as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.
1.5 Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.

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Summary of Contents for krom schroeder BCU 46 Series

  • Page 1: Table Of Contents

    Burner control unit BCU 46x, 480 OPERATING INSTRUCTIONS Cert. Version 03.19 · Edition 02.22 · EN · 03251582 1 SAFETY 1.1 Please read and keep in a safe place Please read through these instructions care- fully before installing or operating. Following the installa- tion, pass the instructions on to the operator.
  • Page 2: Checking The Usage

    Input function: auxiliary gas and LDS 2 CHECKING THE USAGE No pressure switches Burner control units BCU 460, 465 and 480 are de- Air pressure switch signed to control, ignite and monitor gas burners in Gas pressure switch intermittent or continuous operation. They replace Pressure switches for gas and air the local control cabinet.
  • Page 3: Installation

    2.2 Part designations 3 INSTALLATION CAUTION Please observe the following to ensure that the BCU is not damaged: – The device must not be installed in a public place. It must be accessible to authorized personnel only. Unauthorized personnel could make changes which could cause the system to become unsafe or dangerous.
  • Page 4: Replacing The Power Module/Bus Module

    3.1 Screwing on the BCU 4 REPLACING THE POWER MODULE/ From inside: BUS MODULE/PARAMETER CHIP 1 Open the cover of the BCU. CARD CAUTION Please observe the following to ensure that the BCU is not damaged: – Different power supply for the gas valves. The following combinations of BCU and LM are allowed: 2 Screw on the BCU with four screws, Ø...
  • Page 5: Cable Selection And Installation

    5 CABLE SELECTION AND INSTAL- 6 WIRING LATION CAUTION ➔ Signal and control line for screw terminals max. Please observe the following to ensure that the 2.5 mm (min. AWG 24, max. AWG 12), for spring BCU is not damaged: force terminals max.
  • Page 6 ➔ A short-circuit on the outputs causes one of the 4 After wiring, close the housing cover again and replaceable fuses to trip. tighten the cover screws to 2.4 Nm. ➔ Do not set the remote reset so that it operates (automatically) in cycles.
  • Page 7: Connection Diagram

    ➔ The connection diagram shows BCU..E1 with LM.. 7 CONNECTION DIAGRAM ➔ Legend – see page 30 (14 Legend). BCU 460/LM..F0 LM 400..F0 UA-Sk BCU 460 (BCU..E0) F 3,15 A F3 3,15 A 230 V Start 1 N PE EN-7...
  • Page 8 ➔ Legend – see page 30 (14 Legend). BCU 460/LM..F3 ➔ The connection diagram shows BCU..E1 with LM.. LM 400..F3 UA-Sk BCU 460 (BCU..E0) F 3,15 A F3 3,15 A 230 V Start 1 N PE EN-8...
  • Page 9 ➔ Legend – see page 30 (14 Legend). BCU 465/LM..F3 ➔ The connection diagram shows BCU..E1 with LM.. LM 400..F3 UA-Sk BCU 465 DW 2 DW 1 (BCU..E0) F 3,15 A menox F3 3,15 A 230 V Start 1 N PE EN-9...
  • Page 10 ➔ Legend – see page 30 (14 Legend). BCU 480/LM..F3 ➔ The connection diagram shows BCU..E1 with LM.. LM 400..F3 UA-Sk BCU 480 (BCU..E0) F 3,15 A Start 2 F3 3,15 A 230 V Start 1 N PE EN-10...
  • Page 11 BCU..P3 with industrial plug connector Terminal assignment Termi- Function Burner 2 operating signal External air control Purge Burner 2 start High temperature Safety interlocks (limits) Burner 1 start NO fault signalling contact NO fault signalling contact Supply voltage for operating signals Burner 1 operating signal Remote reset...
  • Page 12 Flame control BCU 480 ➔ BCU 460, 465 = 1 flame amplifier Pilot burner = double-electrode operation/ ➔ BCU 480 = 2 flame amplifiers main burner = ionization: ➔ In the case of UV control, use Elster UV sensors ➔ Pilot burner in double-electrode operation ➔...
  • Page 13: Adjustment

    Pilot burner = single-electrode operation/main Pilot burner = UVC/main burner = ionization: ➔ Parameter I004 = 7. burner = UVC 1: ➔ Parameter I004 = 4. 51 21 BM PE 51 21 BM PE 54 24 PE 54 24 PE UVC 1 Pilot burner = UVS/main burner = ionization: ➔...
  • Page 14: Commissioning

    –– Device Off Data transfer (programming mode) 0.0. (blinking dots) Manual mode l XX Low NOx operation in program step XX High temperature operation in program h XX ➔ The first parameter value that was changed is step XX displayed. ➔...
  • Page 15: Manual Mode

    ➔ The display indicates 02or A2 if the air actuator has ➔ After 3 seconds in this position, the A value for the flame signal “ XXX” is displayed instead of the been opened. The gas valves open, the pilot burner (burner 1) ignites and safety time 1 starts to elapse.
  • Page 16: Assistance In The Event Of Malfunction

    ➔ The display runs to “ . .0.4.” (an “ A” rather than a “ 0” ➔ The BCU cannot be reset by mains failure (non-vol- appears if the air actuator is activated). atile fault lock-out). The fault signalling contact does, ➔...
  • Page 17 ? Start-up without flame – no gas supply – the • Remedy fault. display blinks and indicates E 02 or E A2. ! A gas valve does not open. • Check the gas pressure. • Check voltage supply to the gas valve. ? Operation –...
  • Page 18 ? The display blinks and indicates E 11. ? Operation – flame burning – burner 2 inter- rupted – the display blinks and indicates ! Too many restarts for burner 1. More than 5 re- E 08 or E A8. starts initiated within the last 15 minutes.
  • Page 19 • Reset the parameters to their original values • Check the bus system and PLC for compati- using the BCSoft software. bility. • Establish the cause of the fault to avoid repeat ! Bus module does not support the selected faults.
  • Page 20 • Comply with max. number of start-ups (n) per minute: Max. ? The display blinks and indicates E 41. Device type number ! The downstream gas solenoid valve (V2, V3 or [n/min] V4) is leaking. BCU..Q1 BCU..W1 • Check the downstream solenoid valve. BCU..Q1 BCU..W1 ! The gas pressure switch DGp...
  • Page 21 ? The display blinks and indicates E 85. ? The display blinks and indicates E 92. ! Error in flame amplifier, burner 2. ! Error in communication with flame amplifier • Press the Reset/Information button on module. the BCU. • Press the Reset/Information button on the BCU.
  • Page 22 • Check the butterfly valve and the function of the limit switches in the actuator. • Check the wiring. • Check the actuator. ? The display blinks and indicates E b 0. • If the fault cannot be remedied by doing this, ! Faulty connection to master.
  • Page 23 ? The display blinks and indicates E b 8. ? The display blinks and indicates E c 8. ! The unit is accessed by two or more devices ! The BCU is receiving no information as to wheth- with the same address. er the POC switch contact is still open.
  • Page 24 ! Poor equipotential bond. • Check whether the PROFIBUS DP shield is connected at all points to the same ground potential via the grounding system of the units. • If necessary, an equipotential bonding cable must be laid. ➔ If faults occur sporadically in the PROFIBUS DP ? The display blinks and indicates E d 2, E d 3, E d 4, E d 5, E d 6, E d 7 or E d 8? system, and are only indicated briefly in the bus...
  • Page 25 3 Remove the power module. ? The display blinks and indicates n 4. ! PLC in STOP position. • Check whether the PLC can be started. ? The display blinks and indicates OT. ! The ambient temperature is too high for the BCU (excessive temperature).
  • Page 26: Reading Off The Flame Signal, Fault Messages And The Parameters

    12 READING OFF THE FLAME SIGNAL, FAULT MESSAGES AND THE PARAM- ETERS ➔ If the unit is switched on, information about the flame signal intensity, the last 10 event messages (e.g. Power ON, error E002) and the parameter values can be read off by repeatedly pressing the Reset/Information button.
  • Page 27: Parameters And Values

    13 PARAMETERS AND VALUES Parameter Name Application parameters Value Parameter Running time A042 0–250 = Time in seconds Name Value Over-run 0 = Off Switch-off threshold 1 A001 2–20 = A A043 1 = Post-ventilation 2 = Low fire; actuator feedback Switch-off threshold 2 A002 3 = Low fire;...
  • Page 28 Parameter Parameter Name Name Value Value Air actuator (bus) LDS (bus) 0 = Off 0 = Off 1 = MAX to MIN 1 = Via FS bus 2 = MAX to LOW FIRE A089 2 = Via terminal A075 3 = MAX to IGNITION 3 = Via NFS bus 4 = MAX to MIN;...
  • Page 29 Interface parameters Parameter ➔ Interface parameters I040 to I099 are set at the Name factory and normally do not need to be adjusted. Value Function of input 1 CAUTION 0 = Off Changing the default settings of the interface pa- 1 = Sensor 1 rameters will change the functions of the inputs at 2 = Sensor 2...
  • Page 30: Legend

    14 LEGEND Symbol Description Test volume Symbol Description Current consumption of sensor/ Ready for operation contactor Tightness control opening time Safety interlocks (limits) Measurement time during tightness test Control element position check Tightness control test period (= 2 x t 2 x t Controlled air flow Flame proving period...
  • Page 31: Technical Data

    Actuator outputs (terminals 65, 66 and 67): max. 1 A 15 TECHNICAL DATA each, cos φ = 1. Air valve output (terminal 65): max. 1 A, cos φ = 1. WARNING Ignition transformer (terminal 51): max. 2 A. Information pursuant to REACH Regulation No. Total current for the simultaneous activation of the 1907/2006, Article 33.
  • Page 32: Safety Instructions

    16 SAFETY INSTRUCTIONS 17 LOGISTICS Scope of application: as set out in “Industrial thermo- Transport processing equipment – Part 2: Safety requirements Protect the unit from external forces (blows, shocks, for combustion and fuel handling systems” (EN 746-2) vibration). when used with fuels and oxidants. The BCU 4 is suita- Transport temperature: see page 31 (15 Technical ble for continuous operation (pursuant to EN 298:2012- data).
  • Page 33: Certification

    Scan of the Declaration of conformity (D, GB) – see www.docuthek.com There is no need for any additional EMC measure- ment when installed. SIL, PL For systems up to SIL 3 pursuant to EN 61508. Pursuant to EN ISO 13849-1, Table 4, the BCU can 74960414 Ø...
  • Page 34: Disposal

    FM approved Factory Mutual (FM) Research Class: 7610 “Combustion Safeguards and Flame Sensing Systems”. Suitable for applications pursuant to NFPA 86. Eurasian Customs Union The products BCU 460, BCU 465, BCU 480 meet the technical specifications of the Eurasian Customs Union. 20 DISPOSAL Devices with electronic components: WEEE Directive 2012/19/EU –...

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Bcu 480

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