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BCU 580
Technical Information
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Elster BCU 580 Technical Information

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Page 1

Burner control units BCU 580

Technical Information · GB
6 Edition 11.15
• 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
• Flexible range of applications due to parameterization possibilities
• Assume safety functions pursuant to EN746-2
• EC type-tested and certified
• Safety functions up to SIL3 (DINEN62061)
corresponding to PLe (ISOEN13849)
Page 2

Contents

Burner control units BCU 580 ....................... 1
Contents........................................2
1 Application.....................................5
1.1 Examples of application..........................8
1.1.1 Stage-controlled main burner with alternating pilot burner 8
1.1.2 Stage-controlled main burner with permanent pilot burner 9
1.1.3 Two-stage-controlled main burner with permanent pilot
burner ..............................................10
1.1.4 Modulating-controlled burner .......................11
1.1.5 Flame control using the temperature .................12
1.1.6 PROFINET connection using bus module BCM ..........13
1.1.7 ON/OFF rotary impulse control.......................14
1.1.8 Modulating burner control . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Certification ................................... 16
3 Function...................................... 17
3.1 Connection diagram ........................... 17
3.1.1 BCU580..F1 with ionization control in single-electrode
operation ............................................17
3.1.2 BCU580..F2 .....................................18
3.1.3 BCU580..F3 .....................................19
3.1.4 Flame control ................................... 20
3.2 BCU 580 program sequence ....................21
4 Air control ....................................23
4.1 Capacity control ...............................24
4.1.1 BCU..F1/F2 ...................................... 24
4.1.2 BCU..F3 ........................................ 25
5 Valve proving system ...........................26
5.1 Tightness test .................................26
5.1.1 Test instant.......................................27
5.1.2 Program sequence............................... 28
5.1.3 Test period t
5.1.4 Opening time t
5.1.5 Measurement time t
5.2 Proof of closure function........................33
5.2.1 Program sequence............................... 33
................................... 30
P
................................. 30
L
............................30
M
6 BCSoft .......................................34
7 Profinet ......................................35
7.1 BCU and bus module BCM ......................36
7.2 GSD file for PLC configuration ....................37
7.2.1 Modules for cyclic data exchange................... 38
7.2.2 Indexes for acyclic communication.................. 44
8 Program step/status............................45
9 Fault signalling ................................47
10 Parameters ..................................50
10.1 Scanning the parameters ......................55
10.2 Flame control ................................55
10.2.1 Switch-off threshold of the flame amplifier ........... 55
10.2.2 Flame control .................................. 56
10.2.3 High temperature operation . . . . . . . . . . . . . . . . . . . . . . .57
10.3 Behaviour during start-up......................60
10.3.1 Burner 1 start-up attempts ........................ 60
10.3.2 Burner 2 start-up attempts ........................61
10.3.3 Burner application .............................. 62
10.3.4 Safety time 1 t
10.3.5 Flame proving period 1 t
10.3.6 Safety time 2 t
10.3.7 Flame proving period 2 t
SA1 ...........................................65
SA2 ..........................................66
....................... 65
FS1
...................... 66
FS2
10.4 Behaviour during operation ....................67
10.4.1 Restart .........................................67
10.4.2 Minimum operating time t
10.4.3 Pilot burner .................................... 69
...................... 69
B
10.5 Safety limits .................................70
10.5.1 Safety time during operation ...................... 70
10.6 Air control ................................... 71
10.6.1 Capacity control..................................71
10.6.2 Running time selection............................78
10.6.3 Running time....................................78
10.6.4 Low fire over-run ................................79
10.6.5 Controller enable signal delay time t
10.6.6 Air actuator control.............................. 80
..............79
RF
BCU 580 · Edition 11.15 2
= To be continued
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Page 3
Contents
10.6.7 Air actuator can be activated externally on start-up ... 83
10.6.8 Air actuator in the event of fault ................... 83
10.6.9 Capacity control (bus)............................ 84
10.7 Valve check .................................89
10.7.1 Valve proving system ............................ 89
10.7.2 Relief valve (VPS) ................................90
10.7.3 Measurement time V
10.7.4 Valve opening time 1 t
.......................... 90
p1
...........................91
L1
10.8 Behaviour during start-up......................92
10.8.1 Minimum pause time tBP ......................... 92
10.9 Manual mode ...............................93
10.9.1 Operating time in Manual mode ................... 93
10.10 Functions of terminals 50, 51, 65, 66, 67 and 68...94
10.10.1 Function of terminal 50 .......................... 94
10.10.2 Function of terminal 51 .......................... 94
10.10.3 Function of terminal 65.......................... 94
10.10.4 Function of terminal 66.......................... 95
10.10.5 Function of terminal 67 .......................... 95
10.10.6 Function of terminal 68.......................... 95
10.11 Password...................................96
10.12 Fieldbus communication . . . . . . . . . . . . . . . . . . . . . . 96
11 Selection .....................................97
11.1 Type code ...................................97
12 Project planning information.....................98
12.1 Installation...................................98
12.2 Commissioning ..............................98
12.3 Electrical connection ..........................99
12.3.1 OCU .......................................... 99
12.3.2 Safety current inputs.............................100
12.3.3 UVD control....................................101
12.4 Actuators ..................................102
12.4.1 IC20..........................................102
12.5 Parameter chip card .........................103
12.6 Protecting the pilot burner from overload ........103
12.7 Calculating the safety time t
SA........................104
12.8 Fifth or switchable gas valve on BCU..F3 .........105
13 Accessories ................................. 106
13.1 BCSoft .....................................106
13.1.1 Opto-adapter PCO 200 ...........................106
13.1.2 Bluetooth adapter PCO 300 .......................106
13.2 OCU ......................................106
13.3 Connection plug set..........................106
13.4 Stickers for labelling.......................... 107
13.5 “Changed parameters” stickers ................ 107
14 OCU .......................................108
14.1 Application .................................108
14.2 Function ...................................109
14.2.1 Manual mode ..................................109
14.3 Electrical connection ......................... 110
14.4 Installation ................................. 110
14.5 Selection ................................... 110
14.6 Technical data for OCU ........................111
15 BCM 500 ....................................112
15.1 Application ..................................112
15.2 Function ....................................112
15.3 Electrical connection ..........................112
15.4 Installation ..................................112
15.5 Selection ................................... 113
15.6 Technical data .............................. 113
16 Technical data ................................114
16.1 Electrical data ............................... 114
16.2 Mechanical data ............................ 115
16.3 Environment ................................ 115
16.4 Dimensions ................................ 115
16.5 Safety-specific characteristic values..............116
16.6 Converting units..............................117
17 Maintenance .................................118
18 Legend ......................................119
19 Glossary....................................120
BCU 580 · Edition 11.15 3
= To be continued
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Page 4
Contents
19.1 Waiting time tW .............................120
19.2 Ignition time t
19.3 Safety interlocks .............................120
19.4 Safety time on start-up t
19.5 Safety time during operation t
19.6 Safety shut-down............................ 121
19.7 Fault lock-out ............................... 121
19.8 Warning signal.............................. 121
19.9 Timeout.................................... 121
19.10 Lifting ..................................... 121
19.11 Air valve ................................... 121
19.12 Diagnostic coverage DC .....................122
19.13 Operating mode............................122
19.14 Safe failure fraction SFF ......................122
19.15 Probability of dangerous failure PFH
19.16 Mean time to dangerous failure MTTF
Feedback .....................................123
Contact.......................................123
..............................120
Z
....................120
SA1
SB......................120
..........122
D
.........122
d
BCU 580 · Edition 11.15 4
= To be continued
▼
Page 5

1 Application

▼
Burner control unit with plug-in spring force connection terminals
Burner control unit BCU 580 controls, ignites and monitors gas burners in intermittent or continuous operation. It can be used for gas burners of unlimited capacity which are ignited by pilot burners. The burners may be modulating-controlled or stage­controlled. Its fast reaction to various process requirements makes the BCU suitable for frequent cycling operation.
On industrial furnaces, it reduces the load on the central furnace control by taking over tasks that relate to the burner, for example it ensures that the burner ignites in a safe condition when it is restarted.
The air control on the BCU..F1, F2 or F3 assists the furnace control for cooling, purging and capacity control tasks.
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. The burners
or a connected control element can be activated manually
using the integrated Manual mode for setting and diagnostic
purposes. Thanks to the optionally integrated valve proving system, the
valves can be checked for leaks by querying an external gas
pressure switch or it can be checked whether the gas valve
on the inlet side is closed.
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.
BCU 580 · Edition 11.15 5
Page 6
The monitored outputs for the actuator and valves are ac­commodated in a plug-in power module. This can simply be replaced if necessary.
Once the plug-in power module has been removed, the param­eter chip card and fuses are accessible.
The BCU can be installed on a DIN rail in the control cabinet. Plug-in connection terminal strips on the BCU make it easier to install and remove.
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.
The address for the fieldbus communication is set using three
code switches.
The optional bus module BCM500 makes it possible to con-
nect the BCU to a PROFINET network via a fieldbus interface.
Networking via the fieldbus enables multiple BCUs to be con-
trolled and monitored by an automation system (e.g.PLC). The
bus module is prepared for DIN rail installation. It is pushed
on to the BCU from the side.
Thanks to the operator-control unitOCU, display functions and op­eration of the BCU can be relocated to the control cabinet door.
BCU 580 · Edition 11.15 6
Page 7
Application
Bogie hearth forging furnace in the metal­lurgical industry
Intermittent shuttle kiln in the ceramics industry
Walking beam furnace with overhead firing
BCU 580 · Edition 11.15 7
Page 8
Application
FCU 500
46
HT
49
50
P
V1 V2
VAS
Process control (PCC)
PLC
ϑ1
A
1 2 3
38371817
BCU 580..C0F3
µC
10
4
41
42
43
13 14
57
9 5
ϑ2

1.1 Examples of application

1.1.1 Stage-controlled main burner with alternating pilot burner

Control:
VAG
1
2
VR..L
VAS 1
V4
TZI/TGI
UVS
Main burner ON/OFF or High/Low
The main burner can be started with re-
duced capacity after the operating signal from the pilot burner has been detected.
The pilot burner is switched off automati-
cally after the main burner has started up. When the main burner is switched off, the pilot burner automatically switches on again. This reduces the main burner start-up time.
The UV sensor monitors the flame signal
from pilot and main burners.
The BCU provides the cooling and purg-
ing processes.
02–0402–04 06–08 06–08
ϑ1 1
ϑ2
2
t
BCU 580 · Edition 11.15 8
Page 9
Application > Examples of application
V1 V2
VAS
Process control (PCC)
FCU 500
PLC
VAG

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 operating signal from the pilot burner has been detected. Pilot and main burners can be
V4
operated simultaneously. This reduces the time required by the main burner for starting up.
The BCU provides the cooling and purg-
ing processes.
HT
P
04 0402–04 06–08 06–08
ϑ1
38371817
BCU 580..C0F3
46
µC
49
50
10
1 2 3
ϑ2
A
4
41
1
42
2
43 13 14 57
9 8 5
VR..L
ϑ1
1
ϑ2
2
TZI/TGI
t
BCU 580 · Edition 11.15 9
Page 10
Application > Examples of application
TZI/TGI
VAS
VAS 1
VAG
IC 40 + BVA
V1
V2
V3
V4
VAS 1
4
10
12 7
16
12
M
µC
BCU 580..C0F2
µC
38371817
1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
ϑ1
9
13 14 15
57
85
53 55 51 52
4
41
42
43
1
2
ϑ2
t
1
2
04 0402–04 06–08 06–08
ϑ1
ϑ2
PLC

1.1.3 Two-stage-controlled main burner with permanent pilot burner

Control: Main burner ON/OFF with ignition via bypass
The main burner can be started with
minimum capacity after the operating signal from the pilot burner has been detected. When the operating state is reached, the BCU issues the Enable sig­nal for the maximum burner capacity. Pilot and main burners can be operated simultaneously. This reduces the time re­quired by the main burner for starting up.
The BCU provides the cooling and purg-
ing processes.
BCU 580 · Edition 11.15 10
Page 11
Application > Examples of application
FCU 500
HT
P
V1
VAS
Process control (PCC)
ϑ1
A
1 2 3
38371817
BCU 580..C0F1
46
µC
49
50
52 53 54 55 56
V2
Control: Main burner continuous

1.1.4 Modulating-controlled burner

VAG
VAS 1
The butterfly valve for air is moved to the
position for minimum capacity in order to
V4
start the main burner. The main burner is started with minimum capacity after the operating signal from the pilot burner
PLC
has been detected. The control system controls the burner capacity via the but­terfly valve for air after the operating state has been signalled. Pilot and main
ϑ2
TZI/TGI
burners can be operated simultaneously.
This reduces the time required by the
main burner for starting up.
4
41
1
42
2
43
13 14
57
9 8 5
M
IC 20 + BVA
04 0402–04 06–08 06–08
ϑ1
1
ϑ2
2
t
BCU 580 · Edition 11.15 11
Page 12
Application > Examples of application

1.1.5 Flame control using the temperature

FCU 500..H1
5-8
STM
HT
18
HT
49
HT
49
BCU 580..D
µC
5
BCU 580..D
µC
5
8
8
M
In high temperature systems (temperature >750°C), the flame may be controlled indirectly via the temperature.
As long as the temperature in the furnace chamber is below
750°C, the flame must be controlled by conventional methods.
If the temperature in the furnace chamber rises above the spontaneous ignition temperature of the gas/air mixture (>750°C), the FCU signals to the downstream burner control units via the fail-safe HToutput that the furnace system is in High temperature mode(HT). When the HTinput is activated, the burner control units switch to High temperature mode. They operate without evaluating the flame signal and their internal flame control is non-functional.
If the furnace temperature falls below the spontaneous igni­tion temperature (<750°C), the FCU disconnects the HToutput from the electrical power supply. As soon as the signal to the HTinputs of the burner control units is no longer present, the
flame signals are once again monitored by a UVsensor or ionization electrode.
In the event of a fault in a temperature monitoring component (e.g. sensor discontinuity, sensor short-circuit) or in the event of a mains failure, the flame control task is transferred to the burner control units.
BCU 580 · Edition 11.15 12
Page 13
BCU 580
BCM
BCU 580
BCM
BCU 580
BCM
PROFINET
2
1
2
1
2
1
BUS
FCU
P
HT
PLC
Application > Examples of application

1.1.6 PROFINET connection using bus module BCM

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 opposite direction, it sends operating status, the level of the flame signal and the current program status.
Control signals that are relevant for safety, such as the safety interlocks, purge and HTinput, are transferred independently of the bus communication by separate cables.
BCU 580 · Edition 11.15 13
Page 14
Application > Examples of application
PZL PZH PZ
DG DG DG
min
49 15 131450
DG
max
µC
DG
46
1
ϑ
2
3
FCU 500..F0
STM
DL
M
VAS
45
pu/2
P
>750°
47 4858
minDLPurge
PZL PDZ
DG DG
VAS
VAS
BCU 580..F3
BCU 580..F3
VR..L
VR..L

1.1.7 ON/OFF rotary impulse control

For processes which require a turndown of more than 10:1 and/or those which require heavy circulation of the furnace atmosphere to ensure a uniform tem­perature, e.g. heat treatment furnaces
M
operating at low and medium tempera­tures in the metallurgical industry.
With ON/OFF cyclic control, the capacity supplied to the process is controlled by
VAS
means of a variable ratio of the operat­ing time to the pause time. In this type of
VAGVAS
control, the burner output pulse frequen­cy always maintains full momentum and results in maximum convection in the furnace chamber, even with regulated heating.
The pneumatic ratio control system con-
trols the gas pressure on the burner pro­portionally to the air pressure and thus
VAS
VAGVAS
maintains a constant air/gas ratio. At the same time, it acts as a low air pressure protection device.
The ignition and monitoring of the pilot/
main burners is ensured by burner con­trol units BCU580.
The centrally checked safety functions
TE
such as pre-purge, tightness test, flow detector and pressure switch check (gas-
min.
, gas
max.
, air
) are provided by the
min.
FCU500.
BCU 580 · Edition 11.15 14
Page 15
Application > Examples of application
PZL PZH PZ
DG DG DG
min
49 15 131450
DG
max
µC
DG
46
1
ϑ
2
3
FCU 500..F1
STM
DL
minDLPurge
M
PZL PDZ
VAS
45
pu/2
P
>750°
TC
0°➔90°
53
90°➔0°
54 55
47 4858
VAS
M
VAS
BCU 580..F3
BCU 580..F3
VR..L

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 processes in
M
which infiltrated air may flow into the furnace through switched off burners.
The capacity can be adjusted continu-
ously by activating the air control valve (analogue or 3-point step signal).
VAS
The pneumatic ratio control system con-
trols the gas pressure on the burner pro-
VAGVAS
portionally to the air pressure and thus maintains a constant air/gas ratio. At the same time, it acts as a low air pressure protection device.
The ignition and monitoring of the pilot/
main burners is ensured by burner con­trol units BCU580.
VAS
VAGVAS
The centrally checked safety functions
such as pre-purge, tightness test, flow detector and pressure switch check (gas-
min.
, gas
max.
, air
) are provided by the
min.
FCU500.
DG DG
BCU 580 · Edition 11.15 15
VR..L
TE
Page 16
2 Certification
Certified to SIL and PL
For systems up to SIL 3 pursuant to EN 61508 and PL e pursu­ant to ISO 13849
EU certified pursuant to
– Gas Appliances Directive (2009/142/EC)
Meets the requirements of the
– Low Voltage Directive (2006/95/EC), – EMC Directive (2004/108/EC)
FM approved
Factory Mutual Research Class: 7400 Process Control Valves. Designed for applications pursuant to NFPA 85 and NFPA 86. www.approvalguide.com
Eurasian Customs Union
The product BCU580 meets the technical specifications of the
Eurasian Customs Union.
ANSI/CSA approved
American National Standards Institute/Canadian Stand­ards Association – ANSI Z21.20/CSA C22.2 No. 199 www.csagroup.org – Class number: 3335-01 and 3335-81.
BCU 580 · Edition 11.15 16
Page 17

3 Function

3.1 Connection diagram

3.1.1 BCU580..F1 with ionization control in single-electrode operation
Alternative flame control, see page20 (Flame control).
Detailed connection diagrams for actuators and frequency converters, see from page71 (Capacity control)
Electrical connection, see page98 (Project planning infor­mation)
Explanation of symbols, see page119 (Legend)
I
ϑ1
A
p
u
PZL
GZL
2
Air
HT
P
Air
P70P69
P70ϑ2P70
P71
min
P72P72
P73
1 2 3 4
230V
9 11
c
121062
61
5 6 7 8
c
4645 65 66 67 6849 50 51
24V
DC
3,15AT
4241 43
17 18 37 38
2
1
max. 1 A; 24 V DC, 250 V AC
V4
V3
88
µC
13 14 15 57
53 54 55 56
V2
V1
mA
52
0.6 × I
N
L1
BCU 580..F1
(P40 = 2/3) => 51
0 V+24 V
N
BCU 580 · Edition 11.15 17
Page 18
Function > Connection diagram
3.1.2 BCU580..F2
Alternative flame control, see page20 (Flame control). Detailed connection diagrams for actuators and frequency
converters, see from page71 (Capacity control) Electrical connection, see page98 (Project planning infor-
mation) Explanation of symbols, see page119 (Legend)
I
ϑ1
A
Luft
P71
ϑ2
P72P72
Luft
min
(P69 = 13)
P73
p
HT
PP
0,6 × I
u
PZL
GZL
2
P70
P70
N
L1
1 2 3 4
4645 65 66 67 6849 50 51
52
61
5 6 7 8
c
230V
24V
DC
88
µC

BCU 580..F2

9 11
c
121062
3,15AT
3,15AT
AUTO
COM
2
1
4241 43
4241 43
max. 1 A;
max. 1 A; 24 V DC,
24 V DC, 250 V AC
250 V AC
17 18 37 38
17 18 37 38
V4
V4
V3
V3
V2
13 14 15 57
13 14 15 57
LO
HI
53 54 55 56
V2
V1
V1
mA
0 V+24 V
N
BCU 580 · Edition 11.15 18
Page 19
Function > Connection diagram
3.1.3 BCU580..F3
Alternative flame control, see page20 (Flame control). Detailed connection diagrams for actuators, see from
page71 (Capacity control) Electrical connection, see page98 (Project planning infor-
mation) Explanation of symbols, see page119 (Legend)
I
ϑ1
A
p
u
PZL
GZL
2
Air
HT
P
Air
P70P69
P70ϑ2P70
P71
min
P72P72
P73
1 2 3 4
230V
9 11
c
121062
61
5 6 7 8
c
4645 65 66 67 6849 50 51
24V
DC
3,15AT
4241 43
17 18 37 38
2
1
max. 1 A; 24 V DC, 250 V AC
V4
V3
88
µC
13 14 15 57
53 54
V2
V1
52
0.6 × I
N
L1

BCU 580..F3

0 V+24 V
N
BCU 580 · Edition 11.15 19
Page 20
9 11
121062
61
1 2 3 4
ϑ1
5 6 7 8
4241 43
2
1
NL1
I
I
Z
9 11
121062
61
1 2 3 4
ϑ1
5 6 7 8
4241 43
2
1
NL1
UVS
1 2 3
9 11
121062
61
1 2 3 4
ϑ1
5 6 7 8
A
2
1
NL1
0 V
24 V
+ –
0–20 mA
UVD1
1 2
4
3
5 6
9 11
121062
61
1 2 3 4
ϑ1
5 6 7 8
A
2
1
NL1
0 V
24 V
+ –
0–20 mA
UVD1
1 2
4
3
5 6
Function > Connection diagram

3.1.4 Flame control Ionization control in double-electrode operation

UVS control
UVD control
A voltage supply of 24 VDC is required to operate the UV
sensor for continuous operation UVD1.
The 0–20mA current output can be used to display the flame
signal. The cable to the control room must be screened. The 0–20mA current output is not required for normal operation.
Depending on Parameter79, the following connection dia­grams apply, see also page69 (Pilot burner).
Alternating pilot burner (Parameter 79=0):
Permanent pilot burner (Parameter 79=1):
BCU 580 · Edition 11.15 20
Page 21
Function
▼

3.2 BCU 580 program sequence

Parameters 48 and 49 = 0: High/Low control during operation, cooling in standby
Example of application, see page10 (Two-stage-controlled main burner with permanent pilot burner)
Switch on BCU 580
▼
In the event of fault signal: reset
▼
00
PO
A0
H1
02
External actuation of the air valve for purging
External actuation of the air valve for cooling
Pilot burner start-up with ϑ1signal
Wait until the running time has elapsed(P42)
Safety interlocks
Start-up position/standby
▼
Flame simulation check
▼
▼
▼
▼
▼
Safety time 1 t
running,
SA1
ignition in process,
valves V1 and V4 open
▼
If no flame detected:
max. 3 start-up attempts
or fault lock-out
▼
03
04
05
06
07
Flame proving period 1 t
FS1
▼
running(P95)
In the event of flame failure:
fault lock-out
▼
Pilot burner operation signalling contact closes
▼
In the event of flame failure:
restart or fault lock-out
▼
Main burner start-up with ϑ2signal
▼
Wait until the running time has elapsed(P42)
▼
Safety time 2 t
running,
SA2
valves for 1st gas stage (main burner) open.
▼
If no flame detected:
max. 3 start-up attempts
or fault lock-out
▼
Flame proving period 2 t
▼
running(P97)
FS2
In the event of flame failure: fault lock-out
BCU 580 · Edition 11.15 21
Page 22
Function > BCU 580 program sequence
08
Main burner operation signalling contact closes,
minimum operating time tB starts(P61)
▼
In the event of flame failure:
restart or fault lock-out
▼
A8
External actuation of the air valve for capacity control
Controlled shut-down via ϑsignals for pilot and main
08
00
If min. operating time tB has elapsed:
operation signalling contact opens,
burners
▼
gas valves close and
running time (P42) starts to elapse
BCU 580 · Edition 11.15 22
Page 23

4 Air control

VAS
M
PZL PZH PZ
PZL PDZ
TE
BCU 580..F3
FCU 500..F0
µC
P
DG DG DG
VAS
VAS
VAGVAS
VAS
VR..L
VR..L
DG DG
DG
minDGmax
49 15 131450
45
47 4858
>750°
pu/2
ϑ
1
46
2
3
DL
minDLPurge
BCU 580..F3
VAGVAS
VAS
M
PZL PDZ
BCU 580..F3
FCU 500..F0
µC
P
VR..L
VR..L
DG DG
49 15 131450
45
47 4858
>750°
ϑ
1
46
2
3
DL
minDLPurge
BCU 580..F3
M
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 actuators (BCU..F1= actuators IC20/40, BCU..F2= RBW actuators, BCU..F3= valve) are actu­ated for this purpose by the capacity control system of the BCU.
After being enabled by the protective system, the BCU can start the burners. The capacity is controlled during operation by an external temperature control system.
BCU 580 · Edition 11.15 23
Page 24
V1
IC 20 + BVA
BCU 580..C0F1
µC
38371817
1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
ϑ1
13 14 57
TZI/TGI
9 8 5
VAS
VAS 1
VAG
V2
V4
M
52 53 54 55 56
4
41
42
43
1
2
ϑ2
PLC
Air control

4.1 Capacity control

4.1.1 BCU..F1/F2

The BCU..F1/F2 activates a control element via the outputs for capacity control (terminals 53 to56) for purging, cooling or starting the burner. This control element moves to the required position for the relevant operating situation.
As soon as there is a purge signal at terminal50 of BCU..F1/ F2, the control element is activated by the outputs for capacity control to approach the position for pre-purge. The protec-
tive system (e.g. FCU500) starts the pre-purge time if there is adequate air flow. After the elapse of the pre-purge time, the control element moves to the ignition position. Once the protective system (terminal46, safety interlocks) has issued the enable signal, the pilot and main burners can be started by the start-up signals at terminals1 and4. The control element can be activated to control the burner’s capacity dependent on parameters 48 and49.
Modulating control
Parameter 48 = 3
After the operating signal has been received from the burner
and after expiry of the delay time for the controller 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). The temperature controller controls the burner capacity (air volume) on the basis of the required temperature. Depending on the wiring of the temperature controller, the actuator may be adjusted between maximum capacity and ignition capacity or minimum capacity.
Staged control
P48 = 0, 1 or 2 Depending on parameters 48 and 49, the control element may
be activated either by the program or externally via the input at terminal2, see also from page80 (Air actuator control).
BCU 580 · Edition 11.15 24
Page 25
BCU 580..C0F3
µC
VAS
VAS 1
VAG
TZI/TGI
VR..L
V1 V2
V4
10
UVS
38371817
1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
4
ϑ2
9
13 14
57
5
41
42
43
ϑ1
1
2
PLC
Air control > Capacity control

4.1.2 BCU..F3

The BCU..F3 activates an air valve for purging, cooling or start­ing the burner. The required air capacity is released by the air valve.
As soon as there is a purge signal at terminal 50 of BCU.. F3, the air valve is activated by the output at terminal 10. The protective system (FCU500) starts the pre-purge time if there is adequate air flow. After the elapse of the pre-purge time, the air valve closes for ignition. Once the protective system (terminal 46, safety interlocks) has issued the enable signal, the burner can be started by the start-up signal at terminal1. The gas valves for the 1ststage are opened and the burner is
ignited (on the BCU..C1 after a successful valve check). After the operating signal has been received from the burner, the gas valve for the 2
nd
stage opens.
Staged control
P48 = 0, 1 or 2 Depending on parameters 48 and 49, the control element may
be activated either by the program or externally via the input at terminal2, see also from page80 (Air actuator control).
BCU 580 · Edition 11.15 25
Page 26

5 Valve proving system

V2
p
u
V
p1
V1
PZ
p
u
2
The BCU500..C1 is fitted with an integrated valve proving system. This allows either the tightness of the gas solenoid valves and the pipework between them to be checked (tight­ness test) or the closed position of a solenoid valve (proof of closure function) to be checked.
Once the test has been carried out successfully, the burner enable signal is issued.
For details, see following chapterTightness test and page33 (Proof of closure function)

5.1 Tightness test

The aim of the tightness control is to identify an inadmissible
leak on one of the gas solenoid valves and to prevent burner start. Gas solenoid valves V1 and V2 are tested as is the pipe­work between the valves.
European standards EN 746-2 and EN 676 stipulate tightness controls for capacities over 1200kW (NFPA 86: from 117kW or
400,000 Btu/h). The tightness control function satisfies the requirements of
EN1643, EN746-2, ISO13577-2 and NFPA86 for valve prov­ing systems.
BCU 580 · Edition 11.15 26
Page 27
VAS
VAS 1
VAG
V1 V2
V4
13 14 57
PZH
pu/2
45
V
p1
VAS
VAS 1
VAG
V1
V2
V3
V4
VAS 1
13 14 15 57
pu/2
45
PZH
V
p1
Valve proving system > Tightness test

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 each shut-down of the burner, see page89 (Valve proving system).
The gas line is always safeguarded by a gas solenoid valve during this check.
Before burner start-up
The valve check is started when the start-up signalϑ1 is present at terminal1. The BCU checks the tightness of the gas solenoid valves and the pipework between the valves. The gas line is always safeguarded by a gas solenoid valve during this check. The pilot burner is ignited when pre-purge is ended and the tightness has been checked successfully.
After burner shut-down
After the burner has been shut down, the BCU checks the tight­ness of the gas solenoid valves and the pipework between them. Once the test has been carried out successfully, the next burner start is enabled.
The BCU always conducts a tightness test if mains voltage is available or if it is reset after a fault lock-out.
An additional bypass/relief valve must be installed in gas sections with an air/gas ratio control. This ensures that the test volume Vp1 can be vented during the tightness test with the air/gas ratio control closed.
BCU 580 · Edition 11.15 27
Page 28
Valve proving system > Tightness test
▼
START
V1
tL = P59
V1
tM = P56
p
u
pZ >
2
+
V2
V2
tL = P59
V2
tM = P56
+
Program A Program B
pZ >
V1 V2
–
OK
V2
PZ
pu/2
–
p
u
2
p
z
V1
+
V2
tL = P59
V2
tM = P56
p
u
pZ >
2
–
V1
OK
V1
tL = P59
V1
tM = P56

5.1.2 Program sequence

The tightness test starts by checking the external pressure
switch. If pressure pZ> pu/2, programA starts. If pressure pZ < pu/2, programB starts, see page29 (Pro-
gram B).
Program A
Valve V1 opens for the opening timet
set in parameter59. V1
L
closes again. During the measurement time tM, the tightness control checks the pressurepZ between the valves.
If pressurepZ is less than half the inlet pressurepu/2, valveV2 is leaking.
If pressure pZ is greater than half the inlet pressurepu/2, valveV2 is tight. ValveV2 is opened for the set opening timetL. V2 closes again.
During the measurement time tM, the tightness control checks the pressurepZ between the valves.
If pressurepZ is greater than half the inlet pressurepu/2, valveV1 is leaking.
If pressurepZ is less than half the inlet pressurepu/2, valveV1 is tight.
The tightness test can only be performed if pressurepd down-
stream of V2 is around atmospheric pressure and the volume downstream of V2 is at least 5× higher than the volume between the valves.
+
p
u
pZ >
2
–
V1
OK
BCU 580 · Edition 11.15 28
V1
V2
–
p
u
pZ >
2
+
V2
OK
Page 29
Valve proving system > Tightness test
START
V1
tL = P59
V1
tM = P56
p
u
pZ >
2
+
V2
+
Program A Program B
pZ >
V1 V2
–
OK
V2
PZ
pu/2
–
p
u
2
p
z
V1
+
V2
tL = P59
V2
tM = P56
p
u
pZ >
2
–
V1
OK
Program B
Valve V2 opens for the set opening timetL. V2 closes again. During the measurement time tM, the tightness control checks the pressurepZ between the valves.
If pressurep If pressure p
>pu/2, valveV1 is leaking.
Z
< pu/2, valve V1 is tight. ValveV1 is opened for
Z
the set opening timetL. V1 closes again. During the measurement time tM, the tightness control checks
the pressurepZ between the valves. If pressurep If pressurep
<pu/2, valveV2 is leaking.
Z
>pu/2, valveV2 is tight.
Z
The tightness test can only be performed if pressurepd down-
stream of V2 is around atmospheric pressure and the volume downstream of V2 is at least 5× higher than the volume between the valves.
V2
tL = P59
V2
tM = P56
+
p
u
pZ >
2
–
V1
OK
BCU 580 · Edition 11.15 29
V1
V2
tL = P59
tM = P56
–
pZ >
V1
V1
p
u
2
+
V2
OK
Page 30
P
13
144
5
p
u
/2
PZ
ϑ
1
pu/2
PZ
V
p1
V1 V2
p
u
p
z
p
d
Valve proving system > Tightness test
▼

5.1.3 Test period tP

Depending on the burner capacity, the tightness of the gas solenoid valves must be checked in accordance with the rel­evant application standard, e.g. EN676, EN746, NFPA85 and NFPA86.
The test period tP is calculated from:
– Opening times t – Measurement times t
for V1 and V2,
L
for V1 and V2.
M
tP [s] = 2 x tL + 2 x t
M

5.1.4 Opening time tL

Standard EN1643:2000 allows a maximum opening time of 3s for the tightness test if the main gas valves are actuated directly. If gas can flow into the combustion chamber when a valve is opened, the gas volume must not exceed 0.083% of the maximum flow rate.
is set using parameter56 to a value between 3 and 3600s– see page90 (Measurement time Vp1).
The required measurement time tM is calculated from:
Inlet pressure pu [mbar]
Leakage rate QL [l/h] Test volume Vp1 [l] Calculation of the test volume – see page30 (Test vol-
ume Vp1)
For one test volume V
between 2gas solenoid valves
p1
Adjustable using parameter56
t
M
[s] =
(
2 x pu x V
p1
Q
L
)
For a large test volume Vp1 with reduced testing time
Adjustable using parameter56
t
M
[s] =
0.9 x pu x V
(
p1
Q
L
)
Conversion into US units– see page117 (Converting units)
Leakage rate
The BCU tightness test ensures that the leakage rate QL is <0.1% of the maximum flow rate Q
(N)max.
.
5.1.5 Measurement time t
The sensitivity of the tightness control in the BCU can be ad­justed for each individual system by adapting the measure­ment timetM. The longer the measurement timetM, the greater
M
Leakage rate QL [l/h]
Q
=
[m3/h] x 1000 [l/h]
(N)max.
1000 x 1 [m3/h]
the sensitivity of the tightness control. The measurement time
BCU 580 · Edition 11.15 30
Test volume V
p1
Page 31
Valve proving system > Tightness test > Measurement time tM
▼
Test volume Vp1 is calculated from the valve volumeVV, add­ed to the volume of the pipeVR for each additional metre in lengthL.
V
L
= VV + L x V
p1
R
Valves Pipework
Type Volume VV [l] DN
VAS 1 0.25 10 0.1 VAS 2 0.82 15 0.2 VAS 3 1.8 20 0.3 VAS 6 1.1 25 0.5 VAS 7 1.4 40 1.3 VAS 8 2.3 50 2 VAS 9 4.3 65 3.3 VG 10 0.01 80 5 VG 15 0.07 100 7.9 VG 20 0.12 125 12.3 VG 25 0.2 150 17.7 VG 40/VK 40 0.7 200 31.4 VG 50/VK 50 1.2 250 49 VG 65/VK 65 2 VG 80/VK 80 4 VK 100 8.3 VK 125 13.6 VK 150 20 VK 200 42 VK 250 66
Volume per metre
V
[l/m]
R
The measurement time required for the test volumeVp1 must
be set on the basis of the calculation using parameter56. For the calculation, see page32 (Calculation examples).
BCU 580 · Edition 11.15 31
Page 32
BCU 570..C1
µC
131415
4758 48
TC
M
>750°
1
2
3
V
p1
VAS 665 VAS 665
p
u
= 50 mbar
Q
(N) max.
=
200 m
3
/h
DN65
9.5 m
Valve proving system > Tightness test > Measurement time tM
Calculation examples
2 valves VAS 665, distance L = 9.5 m, inlet pressure pu = 50 mbar, max. flow rate Q
Leakage rate Q
=
L
Test volume V
see page30 (Test volume Vp1)
= 200 m3/h.
(N)max.
3
200 m
/h x 1000 l/h
1000 x 1 m
= 1.1 l + 9.5 m x 3.3 l/m = 32.45 l
p1
Measurement time for one test volume V
p1
Parameter 70 = 0
t
M
[ s ] =
2 x 50 mbar x 32.45 l
200 l/h
= 16.23 s
Set the next highest value (20s) using parameter56, see page90 (Measurement time Vp1).
/h
= 200 l/h
3
BCU 580 · Edition 11.15 32
Page 33
13
14
ϑ
1
V1 V2
45
GZL
Valve proving system

5.2 Proof of closure function

The proof of closure function monitors the function of the gas solenoid valveV1. The proof of closure function can be activated using parameter51=4, see page89 (Valve proving system).
A limit switch on gas solenoid valveV1 signals the closed position of the valve to the BCU (terminal45) for this purpose.
By checking the closed position using the proof of closure function, the BCU complies with the requirements of NFPA85 (Boiler and Combustion Systems Hazards Code) and NFPA86 (Standard for Ovens and Furnaces).

5.2.1 Program sequence

When the start-up signalϑ1 is received at terminal1, the BCU checks that valve V1 is in its closed position using the POC switch. After a timeout time of 10s, a signal from the POC switch (valve V1 is closed) must be received at terminal45. Otherwise, the BCU performs a fault lock-out with fault messagec1.
As soon as the BCU has opened valve V1, it queries the open position of the valve via the POC switch. If a signal is still re­ceived at terminal45 from the POC switch after a timeout time of 10s, the BCU performs a fault lock-out with fault messagec8.
BCU 580 · Edition 11.15 33
Page 34

6 BCSoft

The BCSoft engineering tool provides extended access to theBCU. BCSoft makes it possible to set device parameters on Windows-based PCs in order to adjust the BCU to the specific application. In addition, BCSoft provides extended access to the individual statistics and protocol functions.
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106 (BCSoft).
BCU 580 · Edition 11.15 34
Page 35
7 Profinet
BCU 580
BCM
BCU 580
BCM
BCU 580
BCM

PROFINET

2
1
2
1
2
1
BUS
FCU
P
HT
PLC
Profinet is a manufacturer-independent, open standard for industrial Ethernet. It covers the requirements for automation technology (manufacturing automation, process automation, drive applications with or without functional safety).
Profinet is a bus variant for fieldbus communication, optimized for speed and low connection costs.
The basic function of Profinet is the exchange of process and required data between an IOcontroller (e.g.PLC) and several distributed IOdevices (e.g.BCU/FCU).
The signals from the IOdevices are read into the IOcontroller cyclically. There, they are processed and are then output to the IOdevices again.
In addition to cyclic data exchange, Profinet also provides acyclic data exchange for events which are not constantly repeated such as sending parameter settings and configu­ration data when the IOdevices start up or sending a diag­nostic message from the IOdevice to the IOcontroller during operation. The data read or written acyclically by read/write
services are specified by an index, see page44 (Indexes for acyclic communication).
The technical properties of an IOdevice are described by the
manufacturer in a device master data file (GSDfile). The GSD file contains the device image, the communications properties and all fault messages from the IO device in text form which are important for the configuration of the Profinet network and the data exchange. The configuration is completed using an engineering tool which is supplied by the manufacturer of the IO controller. Modules defined in the GSD file may be selected for configuration to include them in the system, see also page37 (GSD file for PLC configuration).
BCU 580 · Edition 11.15 35
Page 36
BUS
FCU
P
HT
56
BCUBCM
L1,
M
ϑ
PROFINET
53 55 5254
90° ➔ 0
0 ➔ 90°
3PS
Temperature controller
PLC
Profinet

7.1 BCU and bus module BCM

The optional bus module BCM 500 is required to integrate 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 the BCU (IOdevice) and PLC (IOcontroller).
Bus module BCM500 has two RJ45 connection sockets for connection to the fieldbus on its front. The connection sockets are combined with an internal 2-port switch. This allows the BCM500 together with the BCU to be integrated in various network topologies (star, tree or line topology). Requirements such as Auto Negotiation and Auto Crossover are satisfied.
Safety-related signals and interlocks (e.g. safety interlock) must be wired independently of the fieldbus communication direct to the BCU and the protective system (e.g.FCU).
All network components which connect the automation system
and the field devices must be certified for Profinet 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.
BCU 580 · Edition 11.15 36
Page 37
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 communications properties of the BCU. Modules defined in the GSD file may be selected for configuration to integrate the BCU, see page38 (Modules for cyclic data exchange).
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 instructions for the engineering tool for your automation system.
For parameter settings on the BCU and code switch settings on the BCM, see page96 (Fieldbus communication).
BCU 580 · Edition 11.15 37
Page 38
Profinet > GSD file for PLC configuration
▼

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 required for cyclic data exchange between the controller and the burner control units BCU580 are shown in the following table. The modules are assigned to the slots.
Module Slot
Input ad-
dress
Output
address
Inputs/outputs 1 n...n+2 n Burner 1 flame signal 2 n Burner 2 flame signal 3 n Status signal 4 n Fault and warning signals 5 n...n+1 Remaining times 6 n...n+1
TC remaining times
1)
7 n...n+1 PLC output information 8 n BCU input terminal information 9 n...n+2 BCU output terminal information 10 n...n+1
1)
Only for BCU..C1. Slot 7 is not transferred with other
device versions.
BCU 580 · Edition 11.15 38
Page 39
Profinet > GSD file for PLC configuration > Modules for cyclic data exchange
▼
“Inputs/outputs” module – slot1
The digital input and output signals from the burner control units BCU560, BCU565 and BCU580 are included in this module.
Input bytes (device ➔ controller)
The input bytes describe the digital signals which are trans­ferred from the BCU (IOdevice) to the digital inputs of the PLC (IOcontroller). The digital signals take up 2bytes (16bits).
Bit Byte n Byte n+1 Byte n+2
Burner 1 oper-
0
ating signal
Burner 2 oper-
1
ating signal
BCU system
2
fault
Max. capacity reached1) Min. capacity reached
1)
menox ON BOOL
Free BOOL
Air ON Free BOOL
For­mat
3 Fault lock-out Pre-purge ON Free BOOL
Safety shut-
4
down
5 Warning
6 ON
Manual mode
7
1)
Only with three-point step control via bus.
DI ON Free BOOL
Ready for op­eration Burner 2 flame signal Burner 1 flame signal
Free BOOL
Free BOOL
Free BOOL
Output byte (controller ➔ device)
The output byte describes the digital signals which are output
by the PLC (IOcontroller) to the BCU (IOdevice). The digital sig­nals to control the burner control unit BCU occupy 1byte (8bits).
Parallel to the bus communication, terminals 1 to4, 44 and 50 of the BCU can be wired. This allows the BCU to be con­trolled using the digital signals of the bus communication or the inputs at the terminals.
In the event that the bus communication is faulty or interrupted and during the initialization of the bus communication after switching on, the digital signals are interpreted as“0”. If the BCU is controlled using the inputs at the terminals during this time, the normal program runs even if the bus communication is faulty or interrupted.
Bit Byte n Format
0 Reset
1 Burner 1 start
2 External air ON
1)
1)
1)
BOOL BOOL BOOL
3 Pre-purge ON BOOL
4 Burner 2 start
1)
BOOL
5 menox ON BOOL
2)
2)
BOOL BOOL
6 Open control element, three-point step Open 7 Close control element, three-point step Close
1)
Parallel to the bus communication, terminals 1 to 4 can be
wired.
2)
Only with three-point step control via bus.
BCU 580 · Edition 11.15 39
Page 40
Profinet > GSD file for PLC configuration > Modules for cyclic data exchange
▼
“Burner 1 flame signal” module (device ➔ controller)– slot2
The flame signal for burner1 is transferred from the BCU to the PLC as an analogue value using this module. The flame signal occupies one byte with values from 0 to255 (=flame signal from 0 to 25.5µA).
Bit Byte n Data type Format Value
0
1 2 3
Burner 1 flame signal
4
Byte DEC
0 – 255
(0 – 25.5 μA) 5 6 7
“Burner 2 flame signal” module (device ➔ controller)– slot3
The flame signal for burner2 is transferred from the BCU to the PLC as an analogue value using this module. The flame signal occupies one byte with values from 0 to255 (=flame signal from 0 to 25.5µA).
Bit Byte n Data type Format Value
0
1 2 3
Burner 2 flame signal
4
Byte DEC
0 – 255
(0 – 25.5 μA) 5 6 7
“Status signal” module (device ➔ controller)– slot4
This module transfers the status signals from the BCU to
thePLC. The status signals occupy one byte (0to255). Every status signal is allocated a code. The allocation is described in the code table “GSD Codes BCU580”.
Bit Byte n
Data
type
Format Value
0
1 2 3
Status signals Byte DEC
4
5
0 – 255
(see
Code table “GSD_
Codes_BCU580.xlsx”
at
www.docuthek.com)
6 7
BCU 580 · Edition 11.15 40
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Profinet > GSD file for PLC configuration > Modules for cyclic data exchange
▼
“Fault and warning signals” module (device ➔
controller)– slot5
The fault and warning signals are transferred from the BCUto the PLC using this module. The fault and warning signals oc­cupy one byte each (0to255).
The allocation of the output codes to the fault and warning signals is described in the code table “GSD Codes BCU580”. The same allocation table applies to the fault signals and the warning signals.
Bit Byte n
Data
type
Format Value
0
1 2 3
Fault signals Byte DEC
4 5
0 – 255
(see
Code table
“GSD_Codes_
BCU580.xlsx” at
www.docuthek.com)
6 7
Bit Byte n+1
Data
type
Format Value
0
1 2 3
Warning signals Byte DEC
4 5
0 – 255
(see
Code table
“GSD_Codes_
BCU580.xlsx” at
www.docuthek.com)
6 7
“Remaining times” module (device➔ controller)– slot6
This module transfers the remaining times of various processes
from the BCU to thePLC. The remaining time occupies 2bytes.
Bit Byte n Byte n+1
Data
type
Format Value
0
1 2 3
Remaining times Word DEC
4
0 – 6554
(0 – 6554 s) 5 6 7
BCU 580 · Edition 11.15 41
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Profinet > GSD file for PLC configuration > Modules for cyclic data exchange
▼
“Remaining times of the valve proving system” module
(device➔controller)– slot7
Only for BCU..C1. The module in BCU..C0 contains no information. This module transfers the remaining time of the valve prov-
ing system from the BCU..C1 to thePLC. The remaining time occupies 2bytes.
The valve check runs parallel to other time-related processes, e.g. pre-purge. To display the remaining time of the valve proving system separately, it is transferred separately.
Bit Byte n Byte n+1
Data
type
Format Value
0
1
2
Remaining times
3
of the valve prov-
4
ing system
5
Word DEC
0 – 6554
(0 – 6554 s)
6 7
“PLC output information” module (device ➔ controller)–
slot8
This module transfers information on signals which the PLC
uses to control the BCU back to the PLC. This allows the signal transfer from the PLC to the BCUto be checked.
Bit Byte n Format
0 Reset BOOL
1 Burner 1 start BOOL 2 External air ON BOOL 3 Pre-purge ON BOOL
4 Free BOOL
5 menox ON BOOL
1)
1)
BOOL BOOL
6 Open control element, three-point step Open 7 Close control element, three-point step Close
1)
Only with three-point step control via bus.
BCU 580 · Edition 11.15 42
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Profinet > GSD file for PLC configuration > Modules for cyclic data exchange
“BCU input terminal information” module (device ➔
controller)– slot9
This module transfers the signal states of the digital inputs on the BCU (inputterminals) to thePLC.
Bit Byte n Byte n+1 Byte n+2 Format
0 Terminal 1 Terminal 48
1 Terminal 2 Terminal 49 2 Terminal 3 3 Free 4 Terminal 44 5 Terminal 45 6 Terminal 46 7 Terminal 47
Terminal 50 Free Terminal 51 Free Terminal 52 Free Terminal 65 Free Terminal 66 Free Terminal 67 Free
“BCU output terminal information” module (device➔
controller)– slot10
This module transfers the signal states of the digital outputs on the BCU (outputterminals) to thePLC.
Bit Byte n Byte n+1 Format
0 Terminal 9
1 Terminal 10 2 Terminal 13 Terminal 53 3 Terminal 14 Terminal 54 BOOL 4 Terminal 15 5 Terminal 17/18 6 Terminal 37/38 7 Terminal 41
1)
Only for BCU..F2: terminal53 is used as an input.
Bit 6 has no function.
Terminal 68
Free
Terminal 42 Terminal 43
Terminal 55 Terminal 56 Terminal 57
Free
BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL
BOOL BOOL
1)
BOOL
BOOL BOOL BOOL BOOL
BCU 580 · Edition 11.15 43
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Profinet > GSD file for PLC configuration

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 possible to read information on parameters, statistics and fault history on an event basis (e.g. using system function block Siemens FSB52RDREC).
The available data records differ in terms of their indexes.
Index Description 1001 Parameter 1002 Device statistics, counter 1003 Device statistics, faults/warnings 1004 Operator statistics, counter 1005 Operator statistics, faults/warnings 1006 Fault history 1007 Power module statistics
The contents and description of the indexes are described in the code table “GSD Codes BCU580” (download from www. docuthek.com).
BCU 580 · Edition 11.15 44
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8 Program step/status

▼
1)
DISPLAY
00
A0
P0
H0
01
A1
H1
A
A
A
02
A2
H2
03
A3
04
A4
H4
H5
06
A6
07
A7
Program step/status Initializing
Cooling
2)
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 Delay Delay Safety time 2 Safety time 2 Flame proving period 2 Flame proving period 2
BP
2)
2)
2)
2)
FS1
FS1
BCU 580 · Edition 11.15 45
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Program step/status
1)
DISPLAY
08
A8
H8
U I
– –
1)
In Manual mode, two dots blink on the display.
2)
Air actuator (control element/valve) is open.
Program step/status Burner 2 operation Burner 2 operation Delay Remote control with OCU Data transfer (programming mode) Device Off
BCU 580 · Edition 11.15 46
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9 Fault signalling

▼
Fault message (blinking)
Burner 1 flame simulation
No flame after safety time 1
Flame failure during flame proving period1t
Flame failure during burner 1 operation
Burner 2 flame simulation
Flame failure during safety time 2
Flame failure during flame proving period 2
Flame failure during burner 2 operation
Too many remote resets
Too many restarts
Too many restarts for burner 2
Controller enable output (terminal 56)
Simultaneous activation (terminals 51 and 52)
Actuator wiring (terminals 52 – 55)
Actuator feedback (terminal 52)
Simultaneous Min./Max. bus command
Non-fail-safe parameters (NFS) inconsistent
Fail-safe parameters (FS) inconsistent
Mains voltage
Faulty parameterization
Incompatible bus module
Power module defective
FS1
DISPLAY
01
02
03
04
05
06
07
08
10
11
12
20
21
22
23
24
30
31
32
33
35
36
Description
Flame simulation/flame signal before ignition No flame formation to end of 1st safety time
Flame failure during operation Flame simulation/flame signal before burner2 start No flame formation to end of 2nd safety time
Flame failure during operation
Remote reset activated >5× in 15min. > 5 restarts in 15 minutes > 5 restarts in 15 minutes
Controller enable output incorrectly connected/supplied with power from an external source
“Maximum capacity” and “Ignition capacity” position feedback
from butterfly valve set simultaneously Faulty wiring of terminals 52 to 55 Maximum or ignition capacity is not constantly signalled back to
terminal52
“Open actuator” and “Close actuator” bus signals set simultaneously
NFS parameter range is inconsistent FS parameter range is inconsistent Operating voltage too high/low Parameter set contains illegal settings
Relay contact error
BCU 580 · Edition 11.15 47
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Fault signalling
▼
Fault message (blinking)
Fuse defective
Inlet valve(s) leaking
Outlet valve(s) leaking
Pressure switch/gas valve wiring
Gas valve wiring
Safety interlock failure
Permanent remote reset
Timing cycle too short
Waiting for ignition position (LDS)
Wiring for multi-flame control
Internal error Internal error Internal error Internal error Internal error Internal error Internal error
emBoss
Minimum capacity not reached
Maximum capacity not reached
Ignition capacity not reached
Communication with bus module
Parameter chip card (PCC)
POC valve open
DISPLAY
39
40
41
44
45
51
52
53
54
56
80
89
94
95
96
97
98
99
A
A
A
E
1
Description
Device fuse F1 is defective Leak found on inlet valve Leak found on outlet valve
Reversed valve connection
Remote reset input activated >25s Minimum timing cycle not observed
Faulty feedback signal of the control element position for ignition capacity
Faulty wiring for multi-flame control Flame amplifier error/device error Error in processing internal data Error at digital inputs Error at digital outputs Error when checking the SFR Error when reading the EEProm Error when writing to the EEProm Shut-down without application error Position for minimum capacity has not been reached after 255s Position for maximum capacity has not been reached after 255s Position for ignition capacity has not been reached after 255s Bus module fault Incorrect or defective PCC Valve not closed
BCU 580 · Edition 11.15 48
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Fault signalling
Fault message (blinking)
POC valve closed
Air monitor “no flow” state
Low air pressure
Low air pressure
Air flow during pre-purge
Waiting for connection
Invalid address
Invalid configuration
Invalid network name
Controller in STOP position
Burner 1 flame simulation
No flame after safety time 1
Flame failure during flame proving period 1
Flame failure during burner 1 operation
Burner 2 flame simulation
Flame failure during safety time 2
Flame failure during flame proving period 2
DISPLAY
8
0
1
2
,
4
,
6
,
8
P
0
1
2
3
4
A 1
A 2
A 3
A4
A 5
A 6
A 7
Description
Valve not open Fault Air monitor “no flow” state check Fault Air monitor operating check
3
,
5
,
Low air pressure during program step 2, 3, 4, 5, 6, 7 or8
7
,
Air flow failure during pre-purge BCU waiting for connection to controller Invalid or incorrect address set on bus module
The bus module has received an incorrect configuration from the controller Invalid network name or no address allocated in the network name
Controller in STOP position Burner 1 flame simulation while air valve open No flame during safety time 1 while Flame failure during flame proving period1 while Flame failure during burner 1 operation while Burner 2 flame simulation while No flame during safety time 2 while Flame failure during flame proving period2 while
air valve open
air valve open
air valve open
air valve open
air valve open
air valve open
Flame failure during burner 2 operation
BCU 580 · Edition 11.15 49
A8
Flame failure during burner 2 operation while
air valve open
Page 50

10 Parameters

▼
Any changes to parameters will be saved to the parameter chip card.
Name Parameter Value range Description
Burner 1 FS1 flame signal switch-off threshold Burner 2 flame signal switch-off thresholdFS2
Flame control 04
High temperature operation 06
Burner 1 start-up attempts 07
Burner 2 start-up attempts 08
01 0 – 20
02 0 – 20
0
1 2 3 4 5 6 7 8 0 2 3
1 2 3
1 2 3
Burner 1 FS1 flame signal switch-off thresh­old in µA Burner 2 FS2 flame signal switch-off thresh­old in µA Ionization UVS UVD Ionization1 and UVS 2 Ionization1 and UVD 2 UVS 1 and ionization 2 UVD 1 and UVD 2 UVD 1 and ionization 2 UVD 1 and UVS 2 Off Intermittent operation with UVS
Continuous operation with ionization/UVD 1 start-up attempt 2 start-up attempts 3 start-up attempts 1 start-up attempt 2 start-up attempts 3 start-up attempts
Factory default
settings
2
(5 when P04 = 1)
2
(5 when P04 = 1)
0
0
1
1
BCU 580 · Edition 11.15 50
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Parameters
▼
Name Parameter Value range Description
0
1
2
Restart 09
Safety time during operation 19 0; 1; 2 Time in seconds 1
Capacity control 40
Running time selection 41
Running time 42 0 – 250
3 4 5 6
0
1 2 3 5 0
1
2
3
Off Burner 1 Burner 2 Burner 1 and burner 2 Max. 5× in 15min. for burner1 Max. 5× in 15min. for burner2 Max. 5×
Off With IC 20 With IC 40 With RBW With air valve Off; checking the positions for minimum/ maximum capacity On; for approaching the positions for mini­mum/maximum capacity On; for approaching the position for maxi­mum capacity On; for approaching the position for mini­mum capacity Running time in seconds if parameter 41 = 1, 2 or 3
in 15 min. for burner1 and burner2
Factory default
settings
BCU..F0 = 0
BCU..F1 = 1 BCU..F2 = 3 BCU..F3 = 5
0
0
30
BCU 580 · Edition 11.15 51
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Parameters
▼
Name Parameter Value range Description
Low fire over-run 43
Controller enable signal delay time tRF
Air actuator control 48
Air actuator can be activated ex-
ternally on start-up
Air actuator in the event of fault 50
Valve proving system 51
Relief valve (VPS) 52
44 0 – 250 Time in seconds 0
49
0
1 2 3 4 5 6 7 8 9
10
0
1 2 3
4 0
1 0
1 0
1 2 3
4 2 3 4
Off
Up to minimum capacity 1 s 2 s 3 s 4 s 5 s 10 s 20 s 30 s 40 s
Opens on external activation
Opens with gas stage 1
Opens with operating signal
Controller enable following operating sig-
nal or in standby
Opens with V4 pilot burner
Cannot be activated
Can be activated externally
Cannot be activated
Can be activated externally
Off Tightness test before start-up Tightness test after shut-down Tightness test before start-up and after
shut-down
Proof of closure function V2 V3 V4
Factory default
settings
1
0
0
1
0
2
BCU 580 · Edition 11.15 52
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Parameters
▼
Name Parameter Value range Description
3
Measurement time Vp1 56
Valve opening time 1 tL1 59 2 – 25 Time in seconds 2
Minimum operating time tB 61 0 – 250 Time in seconds 0 Minimum pause time tBP 62 0 – 3600 Time in seconds 0
Operating time in Manual mode 67
Function of terminal 50 68
Function of terminal 51 69
Function of terminal 65 70
Function of terminal 66 71
Function of terminal 67 72
Function of terminal 68 73
5 – 25
30 – 3600
0
1 23 24
0
8 13
0
8
0
8 20
0
8
21
0
8 22
Time in seconds
in 5s steps in 10s steps
Unlimited
5 minutes
Purge with Low signal
Purge with High signal Off AND with emergency stop (trm.46)
Max. capacity position feedback (IC40/
RBW) Off AND with emergency stop (trm.46)
Off AND with emergency stop (trm.46)
LDS ignition position check
Off AND with emergency stop (trm.46)
Multi-flame control (MFC) start-up condi-
tions
Off AND with emergency stop (trm.46)
Multi-flame control (MFC) operating condi-
tions
Factory default
settings
10
1
24
0
0
0
0
0
BCU 580 · Edition 11.15 53
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Parameters
Name Parameter Value range Description
Capacity control (bus) 75
0
1
2
3
4
5
Off
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 position
MIN. to MAX. capacity; standby in position
for MIN. capacity; burner quick start
IGNITION to MAX. capacity; standby in
Factory default
settings
0
CLOSED position; burner quick start
Password 77 0000 – 9999 Four-digit number code 1234
Burner application 78
Pilot burner 79
Fieldbus communication 80
0
1 2 3 4 5 0
1 0
1 2
Burner 1 Burner 1 with pilot gas Burner 1 and burner 2 Burner 1 and burner 2 with pilot gas
Two-stage burner 1
Burner 1 and two-stage burner 2 With shut-down In continuous operation Off With address check No address check
2
0
1
Safety time 1 tSA1 94 2, 3, 5, 10 Time in seconds 5 Flame proving period 1 tFS1 95 0 – 20 Time in seconds 2 Safety time 2 tSA2 96 2, 3, 5, 10 Time in seconds 5 Flame proving period 2 tFS2 97 0 – 20 Time in seconds 2
BCU 580 · Edition 11.15 54
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Parameters

10.1 Scanning the parameters

During operation, the 7-segment display shows the program step/status.
All the parameters of the BCU can be scanned in numerical order by repeatedly pressing the Reset/Information button (for 1s).
The parameter display is ended 60seconds after the last time the button is pressed or by switching off theBCU.
The BCU indicates when the mains switch has been switched off. The parameters cannot be scanned when the BCU is switched off or when a fault message is displayed.

10.2 Flame control

The BCU is fitted with a flame amplifier which evaluates whether an adequate flame signal is supplied by the burner using an ionization electrode or UV sensor.
10.2.1 Switch-off threshold of the flame amplifier Burner 1 FS1 flame signal switch-off threshold
Parameter 01 The sensitivity at which the burner control unit detects a flame
at burner1 can be set using parameter01. In the case of UV control, this value can be increased, should
the burner to be monitored be influenced by other burners for example.
During start-up
If the measured flame signal falls below the set value (2 to 20µA) during the start-up after elapse of safety time1, the BCU performs a safety shut-down with subsequent fault lock-out or up to two further start-up attempts. The number of start-up attempts can be defined using parameter07, see page60 (Burner 1 start-up attempts).
During operation
If the measured flame signal falls below the set value (2 to 20µA) during operation after elapse of the safety time during operation (parameter19), the BCU performs a safety shut-down with subsequent fault lock-out or a restart. The restart function can be defined using parameter09, see page67 (Restart).
Burner 2 flame signal switch-off thresholdFS2
Parameter 02 The sensitivity at which the burner control unit detects a flame
at burner2 can be set using parameter02. In the case of UV control, this value can be increased, should
the burner to be monitored be influenced by other burners for example.
BCU 580 · Edition 11.15 55
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Parameters > Flame control

10.2.2 Flame control

Parameter 04 Parameter 04 = 0: flame control is performed with an ioniza-
tion electrode. Parameter 04 = 1: flame control is performed with a UV sensor
for intermittent operation (UVS). Parameter 04 = 2: flame control is performed with a UV sensor
for continuous operation (UVD). Parameter 04 = 3: burner 1 flame control is performed with
an ionization electrode. Burner2 flame control is performed with a UV sensor for intermittent operation(UVS).
Parameter 04 = 4: burner 1 flame control is performed with an ionization electrode. Burner2 flame control is performed with a UV sensor for continuous operation(UVD).
Parameter 04 = 5: burner 1 flame control is performed with a UV sensor for intermittent operation(UVS). Burner2 flame control is performed with an ionization electrode.
Parameter 04 = 6: burner1 and burner2 flame control is performed with a UV sensor for intermittent operation(UVS) on each burner.
Parameter 04 = 7: burner 1 flame control is performed with a UV sensor for continuous operation(UVD). Burner2 flame control is performed with an ionization electrode.
Parameter 04 = 8: burner 1 flame control is performed with a UV sensor for continuous operation(UVD). Burner2 flame control is performed with a UV sensor for intermittent opera­tion(UVS).
and restarted automatically after an operating time of 24hours.
The restart does not meet the requirements of EN298 for UV
sensor continuous operation because the required self-test (at least once per hour) is not performed while the burner is operating.
This shut-down and subsequent restart are performed in the
same way as a normal controlled shut-down. This process is controlled independently by the BCU and therefore it must be checked whether the industrial process permits the pause in heat supply it creates.
UV sensor for continuous operation
The reaction times of the BCU and UV sensor for continuous
operation are coordinated so that the set safety time during operation (parameter 19) is not extended.
UV sensor for intermittent operation
For intermittent operation, the operating state of the complete system is limited to 24h pursuant to EN298. To meet the re­quirement for intermittent operation, the burner is shut down
BCU 580 · Edition 11.15 56
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t
SA1
t
Z
04 0602 0300
t
t
FS1
t
SA2
07 08
t
FS2
5
13
V1 1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
1
43
2
49
HT
Parameters > Flame control
▼

10.2.3 High temperature operation

Parameter 06
Operation of firing systems at temperatures above 750°C
The BCU..D1 and BCU..D2 have a fail-safe input with the func­tion “High temperature operation”. If firing systems are oper­ated above 750°C, the system is considered to be an item of high temperature equipment (see EN746-2). Here, flame control must be in operation until the furnace wall temperature has exceeded 750°C.
Below 750°C, the flame is monitored by conventional means (UV sensor or ionization electrode). In High temperature mode (>750°C), the flame may be controlled via the temperature using a safety temperature monitor(STM) in order to increase the system’s availability. This means that no incorrect flame signals, e.g. signals from a UV sensor which interprets reflected UV radiation as extraneous signals, may lead to faults.
FCU 500..H1
5-8
STW
HT
18
BCU 580 · Edition 11.15 57
BCU 580..D
µC
HT
49
BCU 580..D
HT
49
8
5
µC
8
5
M
When the HT input is activated (terminal49), the burner control unit reverts to High temperature mode, i.e.: the BCU operates
without evaluation of the flame signal. The safety function of the device-internal flame control system is deactivated.
In High temperature mode, the gas valves are opened and the burners are started as usual without monitoring the pres­ence of a flame.
The precondition for this operating mode is that an external
flame supervision device ensures the presence of the flame in a fail-safe manner indirectly via the temperature. For this purpose, we recommend a safety temperature monitor with double thermocouple (DIN 3440). The flame must be moni­tored again by conventional means (UV sensor or ionization electrode) in the event of sensor discontinuity or short-circuit, failure of the safety temperature monitor or power failure.
Only if the temperature at the furnace wall has exceeded
750°C may voltage be applied to the HT input (terminal 49)
so as to activate High temperature mode.
Page 58
06 07 0808
t
t
SA2tFS2
5
13
V1 1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41
42
49
t
SA1
t
Z
0402 0301
t
FS1
t
W
L1
HT
08
08
t
5
13
V1
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
49
L1
HT
Parameters > Flame control > High temperature operation
▼
If the temperature in the furnace chamber drops below 750°C,
Parameter 06 = 3 (BCU..D1) the HTinput must be disconnected from the electrical power supply and the furnace must then be operated with flame control.
The BCU then responds, depending on setting: Parameter 06 = 0
The High temperature mode function is switched off. Flame control takes place dependent on the setting in parameter 04 (by ionization electrode, UVS sensor or UVD sensor).
Parameter 06 = 2 (BCU..D1)
Despite the HT input having been disconnected from the elec-
trical power supply, the burner remains in operation. The BCU
performs flame control again (recommended in the case of
ionization control or UV control withUVD).
The BCU switches off the burner once the HT 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 580 · Edition 11.15 58
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t
04 04
5
13
V1 1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
49
L1
HT
t
08 08
5
13
V1
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
49
L1
HT
Parameters > Flame control > High temperature operation
If no flame signal is present when High temperature mode is deactivated, the burner control unit performs a fault lock-out, regardless of parameter06.
Fault, pilot burner
Fault, main burner
BCU 580 · Edition 11.15 59
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t
SA1
t
Z
04
t
00 02
5
13
V1
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
t
SA1
t
Z
t
SA1
t
Z
t
00 02
5
13
V1
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
Parameters

10.3 Behaviour during start-up

10.3.1 Burner 1 start-up attempts

Parameter 07
Up to three start-up attempts are possible in certain condi­tions. In accordance with EN746-2, a restart may be con­ducted only if the safety of the installation is not impaired. Note the requirements of the standards!
For FM and CSA approved units, it is only possible to select one start-up attempt (P07=1).
This parameter defines the maximum number of possible start-up attempts of burner1.
If no flame is detected during start-up, an immediate fault lock-out (P07=1) or up to two additional start-up attempts (P07=2,3) are performed depending on parameter07.
Parameter 07 = 1: 1 start-up attempt.
Parameter 07 = 2, 3: two or three start-up attempts.
If no flame is formed during the start-up so that at the end of
the safety timet
no flame signal is detected, the BCU closes
SA1
the gas valves and repeats the start-up. Each start-up attempt
begins with the parameterized start-up behaviour.
If the safety timet
elapses without a flame signal having
SA1
been detected, even after the last parameterized start-up
attempt, this will result in a BCU safety shut-down with sub-
sequent fault lock-out. The fault message 04 will flash in the
BCU display depending on the burner operating mode.
If no flame is formed during the start-up so that at the end of the safety timet
no flame signal is detected, this will result
SA1
in a BCU safety shut-down with subsequent fault lock-out. The fault message 04 will flash in the BCU display depending on the burner operating mode.
BCU 580 · Edition 11.15 60
Page 61
t
SA1
t
Z
04 06 02 03 00
t
t
FS1
t
SA2
06
5
13
V1 1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
1
43
2
t
SA2
t
SA2
t
SA2
t
SA1
t
Z
04 0602 0300
t
t
FS1
06
t
W
06
06
05
05
t
W
5
13
V1 1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
1
43
2
Parameters > Behaviour during start-up

10.3.2 Burner 2 start-up attempts

Parameter 08
Up to three start-up attempts are possible in certain condi­tions. In accordance with EN746-2, a restart may be con­ducted only if the safety of the installation is not impaired. Note the requirements of the standards!
For FM and CSA approved units, it is only possible to select one start-up attempt (P08=1).
This parameter defines the maximum number of possible start-up attempts of burner2.
If no flame is detected during start-up, an immediate fault lock-out (P08=1) or up to two additional start-up attempts (P08=2,3) are performed depending on parameter08.
Parameter 08 = 1: 1 start-up attempt.
Parameter 08 = 2, 3: two or three start-up attempts.
If no flame is formed during the start-up so that at the end
of the safety timet
no flame signal is detected, the BCU
SA2
closes the gas valves and repeats the start-up. Each start-up
attempt begins with the parameterized start-up behaviour.
If the safety timet
elapses without a flame signal having
SA2
been detected, even after the last parameterized start-up
attempt, this will result in a BCU safety shut-down with sub-
sequent fault lock-out. The fault message 06 will flash in the
BCU display depending on the burner operating mode.
If no flame is formed during the start-up so that at the end of the safety timet
no flame signal is detected, this will result
SA1
in a BCU safety shut-down with subsequent fault lock-out. The fault message 06 will flash in the BCU display depending on the burner operating mode.
BCU 580 · Edition 11.15 61
Page 62
BCU 570
µC
V1
V2
14 1513
BCU 570
µC
V1
V2
V3
14 1513
Parameters > Behaviour during start-up
▼

10.3.3 Burner application

Parameter 78 This parameter enables the BCU to be adjusted to various
burner applications. In addition, an optional pilot gas valve (V3) can be parameterized via which the burner is started with a defined ignition capacity.
Parameter 78 = 0: burner 1. Two valves (V1,V2) are included for the burner. These are connected to the valve outputs (terminals
13 and14). Valves V1 and V2 are opened in parallel to start
the burner in order to release the gas supply to the burner.
030201 04
9 13
1
14
2
15
3
5
17-18
t
BP
SA1
FS1
t
t
t
Parameter 78 = 1: burner 1 with pilot gas. Three valves (V1, V2
andV3) are included for a burner with a pilot gas valve. These
are connected to the valve outputs (terminals 13, 14 and15).
Valves V1 and V3 open to start the burner. The burner is started
with a limited ignition capacity using gas valveV3. After the
elapse of the safety time t
(program step02), valve V2 opens.
SA1
Valve V3 limits the ignition capacity. After the elapse of the
flame proving period t
(program step04), it is closed again.
FS1
For this application, it must be ensured that the flame proving
period (P95) is set to a value ≥2s.
030201 04
9 13
1
14
2
15
3
5
17-18
t
BP
BCU 580 · Edition 11.15 62
SA1
FS1
t
t
t
Page 63
V1
V2
V4
14 5713
0302H1 06 07
2
1
3
9
14 15
13
5
17-18
t
t
FS1
t
SA1
t
SA2
H8
t
FS2
08
t
RF
8
4
57
1 2
V1
V2
V3
V4
14 15 5713
0302H1 06 07
2
1
3
9
14 15
13
17-18
t
t
FS1
t
SA1
t
SA2
H8
t
FS2
08
t
RF
4
57 5
8
1 2
Parameters > Behaviour during start-up > Burner application
▼
Parameter 78 = 2: burner 1 and burner 2. Three valves (V1, V2 andV4) are included for a modulating burner with a pilot burner. These are connected to the valve outputs (terminals
13, 14 and57). Valves V1 and V4 open to start the pilot burner.
Gas valveV2 releases the gas supply to the main burner.
For this application, it must be ensured that the flame proving
period(P97) is set to a value ≥2s.
Parameter 78 = 3: burner 1 and burner 2 with pilot gas. In this application, the burner has an additional pilot gas valveV3. The valves are connected to the valve outputs (terminals 13,
14, 15 and57). Valves V1 and V4 open to start the pilot burner.
The burner is started with a limited ignition capacity using gas valveV3. After the elapse of the safety time t step06), valve V2 opens (terminal14). Pilot gas valveV3 is closed again after the elapse of the flame proving period t (program step07).
BCU 580 · Edition 11.15 63
(program
SA2
FS2
Page 64
BCU 570
µC
V1
V2
V3
14 1513
BCU 570..C1F1
µC
V1
V2
V3
V4
14 15 5713
040302 H5 06
2
1
3
9
14 15
13
5
17-18
t
t
FS1
t
SA1
07
t
SA2
08
t
FS2
4
57
8
2
1
Parameters > Behaviour during start-up > Burner application
Parameter 78 = 4: two-stage burner 1. Three valves (V1, V2 andV3) are included for a two-stage-controlled burner. These are connected to the valve outputs (terminals 13, 14 and15). The burner can be started with minimum capacity. When the operating state (program step04) is reached, the BCU issues the Enable signal for the maximum burner capacity to gas valveV2.
030201 04
9 13
1
14
2
15
3
1
5
17-18
Parameter 78 = 5: burner 1 and two-stage burner2. In this
application, the burner has an additional pilot gas valveV3.
The valves are connected to the valve outputs (terminals 13, 14, 15 and57). Valves V1 and V4 open to start the pilot burner. The burner is started with a limited ignition capacity using
gas valveV3. ValveV2 (terminal14) can be opened with the
operating signal (program step08) in order to operate burner2
at maximum capacity.
t
t
SA1
BP
t
FS1
t
BCU 580 · Edition 11.15 64
Page 65
t
SA1
t
Z
04 06 07 08 02 03 00
t
t
FS1
t
SA2
t
FS2
5
13
V1
57
V4
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
1
43
2
17-18
Parameters > Behaviour during start-up
10.3.4 Safety time 1 t
SA1
Parameter 94 During the safety time 1 t
SA1
It can be set to 2, 3, 5 or 10s.
, the flame (pilot flame) is ignited.
10.3.5 Flame proving period 1 t
FS1
Parameter 95
Flame proving period 1 (t
) can be parameterized to enable
FS1
the flame on burner1 to stabilize after the elapse of safety
time1. Only when the flame proving period has elapsed will
the next program steps be initiated by the BCU. The flame
proving period can be set between 0 and 20s.
88
11 46 1 9 13 57
5 4 14 8 41 42 43
17-18
L1
ϑ1
V1 V4 1
ϑ2
V2
2
1 2
t
Safety time1 starts with the application of the ϑ1signal (ter­minal1). The valves open at the start of safety time1. The fuel supply to burner1 is released so that a flame can form. If no
04 06 07 08 02 03 00
t
Z
t
SA1
t
FS1
t
SA2
t
FS2
flame is detected at the end of safety time1, the valves are closed again. Depending on parameter07 (Burner1 start-up attempts), the BCU reacts either with an immediate safety shut-down with fault lock-out (P07=1) or with one or two ad­ditional start-up attempts (P07= 2 or3). The BCU will complete a maximum of three start-up attempts.
Safety time1 must be determined on the basis of current na­tional standards and regulations. The burner application and the burner capacity are the main criteria for this.
If the ϑ1signal (terminal1) drops out during safety time1, the valves will not be switched off until the end of safety time1.
BCU 580 · Edition 11.15 65
Page 66
t
SA1
t
Z
04 06 07 08 02 03 00
t
t
FS1
t
SA2
t
FS2
5
13
V1
57
V4
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
1
43
2
17-18
t
SA1
t
Z
04 06 07 08 02 03 00
t
t
FS1
t
SA2
t
FS2
5
13
V1
57
V4
1
14
V2
2
ϑ1
ϑ2
8
4
88
1
46
11
9
41 42
L1
1
43
2
17-18
Parameters > Behaviour during start-up
10.3.6 Safety time 2 t
SA2
Parameter 96 During the safety time 2 t
, the flame on burner2 (main
SA2
flame) is ignited. It can be set to 2, 3, 5 or 10s.
10.3.7 Flame proving period 2 t
FS2
Parameter 97 Flame proving period 2 t
can be parameterized to enable
FS2
the flame on burner2 to stabilize after the elapse of safety time2. Only when the flame proving period has elapsed will the next program steps be initiated by the BCU. The flame proving period can be set between 0 and 20s.
Safety time2 starts with the application of the ϑ2signal (ter­minal4). Valve V2 opens at the start of safety time2. The fuel supply to burner2 is released so that a flame can form. If no flame is detected at the end of safety time2, the valves are closed again. Depending on parameter08 (Burner2 start-up attempts), the BCU reacts either with an immediate safety shut-down with fault lock-out (P08=1) or with one or two ad­ditional start-up attempts (P08= 2 or3). The BCU will complete a maximum of three start-up attempts.
Safety time2 must be determined on the basis of current national standards and regulations. The burner application and the burner capacity are the main criteria for this.
If the ϑ1signal (terminal1) drops out during safety time2, the valves will not be switched off until the end of safety time2.
BCU 580 · Edition 11.15 66
Page 67
04
t
t
SB
04
88
ϑ
1
46
11
9 5 13
V1
57 V4
L1
42
41
t
SA
t
Z
04 04 02 03 01
t
t
FS
t
W
t
SB
1x
>2 s
88
ϑ
1
46
9 5 13
V1
57 V4
11
L1
42
41
Parameters
▼

10.4 Behaviour during operation

10.4.1 Restart

Parameter 09 This parameter determines whether the BCU initiates an im-
mediate safety shut-down with fault lock-out or an automatic restart after a flame failure during operation. Excessive restarts (max.5) can also be detected.
In accordance with EN746-2, a restart may be conducted only if the safety of the installation is not impaired. A restart is recommended for burners which occasionally display unstable behaviour during operation.
The precondition for an automatic restart is that the burner can 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.
Parameter 09 = 0: Off.
If a flame failure occurs during operation (minimum operating time of 2s), the valves are closed and the operation signalling contact is opened within the safety time during operationtSB.
The burner control unit then attempts to restart the burner
once. If the burner does not function, a safety shut-down with fault lock-out occurs. The display blinks and shows the fault message.
A safety shut-down with subsequent fault lock-out takes place in the event of flame failure during operation.
Parameter 09 = 1: burner 1. The restart function is active.
BCU 580 · Edition 11.15 67
Page 68
06
05
07
08
08
t
t
SA2
t
FS2
1x
t
W2
t
SB
>2 s
88
5
13
V1
57
V4
1
14
V2
2
ϑ1
ϑ2
8
4
1
46
11
9
41
42
L1
1
43
2
17-18
Parameters > Behaviour during operation > Restart
Parameter 09 = 2: burner 2.
Taking into account national standards and requirements,
it must be clarified whether the option may be used.
Parameter 09 = 5: max. 5× in 15 min. for burner2. Parameter 09 = 6: max. 5× in 15 min. for burner 1 and2.
If a flame failure occurs during operation (minimum operat­ing time of 2s), valve2 is closed and the operation signalling contact is opened within the safety time during operationtSB. The burner control unit then attempts to restart burner2 once. If burner2 does not function, a safety shut-down with fault lock­out occurs. The display blinks and shows the fault message.
Parameter 09 = 3: burner 1 and burner 2. Parameter 09 = 4: max. 5× in 15min. for burner1. The restart
function is active and is also monitored. In certain conditions, it is possible that the restart function is repeated continu­ously without a safety shut-down with subsequent fault lock­out being performed. The BCU has a safety shut-down with subsequent fault lock-out option if more than 5restarts are performed within a period of 15minutes.
BCU 580 · Edition 11.15 68
Page 69
Parameters > Behaviour during operation

10.4.2 Minimum operating time tB

Parameter 61 A minimum operating time (0 to 250s) may be defined to
ensure that the heating equipment operates stably. If the minimum operating time is active, burner operation
will be maintained until the set time has elapsed even if the start-up signal fails.
The minimum operating time starts as soon as the program step for operation/controller enable (display08) has been reached.
If the start-up signal drops out before the start of operation/ controller enable, e.g. during pre-purge, the burner control unit reverts directly to the start-up position (standby) and the burner is not ignited.
The minimum operating time can be cancelled by switching off the BCU or if a safety shut-down occurs.

10.4.3 Pilot burner

Parameter 79
04 06 07 0802 0300
P79 = 1
t
SA1
t
FS1
t
SA2
t
FS2
88
1
4
9
13
14
15
57
ϑ1 ϑ2
V1 V2 V3 V4
t
If a burner with a pilot burner is used, this parameter can be used to define whether the pilot burner is shut down 1second before the end of the second safety timet
or operates
SA2
continuously. Parameter 79 = 0: with shut-down. Parameter 79 = 1: in continuous operation.
BCU 580 · Edition 11.15 69
Page 70
Parameters

10.5 Safety limits

Parameter19 can be used to adjust the safety limits (safety time during operation) to the system requirements.

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 inputs (terminals 45 to51 and 65 to68). The safety time can be set to 1 or 2s. Prolong­ing the safety time during operation increases the installation availability in the case of brief-duration signal fades (e.g. fades of the flame signal).
In accordance with EN298, the maximum reaction time to a flame failure must not exceed 1s. In accordance with EN746-2, the safety time of the installation during operation (total closing time) may not exceed 3s.
The requirements of national standards and regulations must be satisfied.
BCU 580 · Edition 11.15 70
Page 71
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
PE
L1 N
3PS
3 2 116 67 4812 1115 13
S3 S4
S11
S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
S1
Min Max
Parameters
▼

10.6 Air control

10.6.1 Capacity control

Parameter 40 The BCU is fitted with an interface for connecting air actuators. The BCU..F1/F2 activates a control element via the outputs for
capacity control (terminals 53 to56) for purging, cooling or starting the burner. This control element moves to the required position for the relevant operating situation.
The BCU..F3 activates an air valve for purging, cooling or start­ing the burner via the output at terminal10. The required air capacity is released by the air valve.
Using parameter40, you can set which actuator is used for capacity control (actuators IC20, IC40, RBW or air valve).
Parameter 40 = 0: Off; no capacity control (no air actuator). Parameter 40 = 1: with IC20. The interface is configured to the requirements of actuators
IC20, IC20..E, IC50 or IC50..E. Alternatively, comparable three-point step actuators may be
used.
IC20
The positions for maximum capacity, ignition capacity and
minimum capacity can be set using the actuator. It is checked whether the relevant position has been reached using ter­minal52. If the position is not reached within the timeout time of 255s, the BCU will display fault message A , A or
A (maximum, ignition or minimum capacity not reached), see
page47 (Fault signalling).
BCU 580 · Edition 11.15 71
Page 72
0° 90°
S4
S1 S3
Burner control range
Butterfly valve setting range
Control range
Move to ignition position
Ignition pos.
Min.
pos.
Closed
pos.
Max. pos.
MIN
MIN
MIN
MAX
MAX
MAX
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
3PS
0° 90°
S4
S2
S1 S3
Burner control range
CLOSED
Butterfly valve setting range
Control range
Move to ignition position
Ignition pos.
Max. pos.
OPEN
S4
S2
Min.
pos.
Closed
pos.
MIN
MIN
MAX
MAX
Parameters > Air control > Capacity control
▼
In the event of a fault, the actuator is moved to the position set via camS4 for minimum capacity via the output at terminal54.
The control system is enabled for operation via the control­ler enable output (terminal56). During the controller enable procedure, the actuator can be adjusted infinitely between the positions for maximum and minimum capacity by an external three-point step controller or using bus signals. There is no timeout active in this case.
If bus control is active (parameter75), the controller enable out­put (terminal56) has a different function. The wiring between the BCU and the 3-point step controller can be adjusted so that the control range of the actuator is between the positions for maximum and ignition capacity.
The minimum position which can be reached is the closed
position.
Manual mode
In Manual mode, the actuator can be moved between the positions for maximum and minimum capacity in 3-point step operation. No timeout is active when approaching these posi­tions. The controller enable output (terminal56) is not active and not checked.
BCU 580 · Edition 11.15 72
Page 73
20 19 18 3 2 167 4812 11
S3
S4
S1 0
OUT
0°
➔
90°
0°
90°
90°
➔
0°
IC 20..E
S1
S2
517
+ +
IN
OK
R
R
PE
A
D
A
D
R
1 2 3 4 5 6
ON
µC
131516
M
PE
L1 N
S1
Min Max
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
3PS
Parameters > Air control > Capacity control
▼
IC20..E
procedure, the actuator can be adjusted infinitely between the positions for maximum and minimum capacity by a controller (0(4)–20mA, 0–10V) using the setpoint device on terminals 17 and18 or the bus signal. There is no timeout active in this case.
If bus control is active (parameter75), the controller enable out­put (terminal56) has a different function. The wiring between the BCU and the 3-point step controller can be adjusted so that the control range of the actuator is between the positions for maximum and ignition capacity.
Manual mode
In Manual mode, the actuator can be moved between the positions for maximum and minimum capacity in 3-point step
The positions for minimum capacity, maximum capacity and ignition capacity can be set using the actuator. When the appropriate position has been reached, this information is signalled back via terminal52. If no signal is received that the position has been reached within the timeout time of 255s, a safety shut-down of the BCU will be performed and a fault message (A , A or A ) will be displayed, see page47 (Fault signalling). In addition, the actuator will be moved to the set position for minimum capacity using the output at terminal54.
The control system is enabled during operation via the control­ler enable output (terminal56). During the controller enable
BCU 580 · Edition 11.15 73
operation. No timeout is active when approaching these posi­tions. The controller enable output (terminal56) is not active and not checked.
Page 74
N
19 18 16 15 14 12 11 10 8 7 5 4 2 1
A
AC
D
DC
mA
L N
22 21 20
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V DC
5 6 9 11
1210762
61
t [s]
t [s]
t
1
t
2
t
3
t
4
t
5
t
6
DI 1
DI 2
Purge
Closed
Ignition
High
fire
Parameters > Air control > Capacity control
▼
IC 40
Parameter 40 = 2: with IC40. To ensure that the actuator IC40 can be operated on the BCU..
F1, P40=2 (capacity control) must be set. The operating mode of actuator IC40 may be parameterized to11 or27.
of the BCU will be performed. A fault message (A
, A or A )
will be displayed, see page47 (Fault signalling). If a controller enable is active, the control system is enabled
for operation via the outputs at terminals 53 and55.
Operating mode 11
Operating mode 11 allows cyclic operation (ON/OFF and OFF/ Low/High/OFF).
The actuator IC moves to the “High fire” position during the
controller enable procedure. There is no timeout active in
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 ignition capacity. If the position is not reached within the timeout time of 255s, a safety shut-down
BCU 580 · Edition 11.15 74
this case.
BCU IC40 (operating mode 11)
Signal at
terminal
Position Butterfly valve position
55 53
OFF OFF Closed Closed
ON OFF Ignition
ON ON
High-fire
rate
Minimum/Ignition capacity
High-fire rate
OFF ON Purge Maximum capacity
Page 75
t [s]
t [s]
t
1
t
2
t
3
t
4
t
5
t
6
0–20
mA
DI 1
DI 2
Purge
Closed
Ignition
Parameters > Air control > Capacity control
▼
Operating mode 27
During the controller enable procedure, the actuator IC40 can be adjusted infinitely between the positions for maximum and minimum capacity using its analogue input (terminals18 and19). There is no timeout active in this case.
BCU IC40 (operating mode 27)
Signal at
terminal
Position Butterfly valve position
55 53
OFF OFF Closed Closed
ON OFF Ignition
ON ON 0 – 20 mA
Minimum/Ignition capacity
Any position between mini-
mum and maximum capacity
OFF ON Purge Maximum capacity
Fault
In the event of a fault, there will be no signal at terminals 53 and55 so that the actuator moves to the closed position. When approaching the closed position, no timeout of 255s is active since no feedback input is checked. This may result in a situation where the program is continued in the case of a request for the closed position, without the butterfly valve being closed. The outputs at terminals56 (controller enable) and54 (closed position) on the BCU are non-functional and are not activated.
Manual mode
In Manual mode, no external controller is enabled. The actua­tor can be moved to the positions for maximum capacity or ignition capacity by the user. 3-point step operation is not pos­sible. No timeout is active when approaching these positions.
BCU 580 · Edition 11.15 75
Page 76
N
M
R B W
90°➔0°
0°➔90°
L1
RBW
COM
HI
LO
AUTO
53 54 55 56
52
1 2 3 4645
65
66
67
68
17 18 37 38
13 14 15
BCU 580..F2
3,15AT
µC
49 50 51
88
c
c
41 42
24V DC
5 6 9 11
1210762
61
N
M
+ F -
0°➔90°
L1
mA
A
D
OUT
+
-
RBW
COM
HI
LO
AUTO
53 54 55 56
52
1 2 3 4645
17 18 37 38
13 14 15
BCU 580..F2
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
65
66
67
68
49 50 51
PLC
Parameters > Air control > Capacity control
▼
RBW
Parameter 40 = 3: with RBW. The actuator can be moved to the positions for maximum ca-
pacity (contact COM to HI) and minimum capacity (contact COM to LO) using the interface and by closing the various contacts.
reports that it has reached the position for minimum capac­ity via a signal to terminal52. The simultaneous activation of terminals 51 and52 results in a fault lock-out of theBCU.
If parameter 41 = 0, the system monitors the movement to the positions for maximum and minimum capacity with a timeout time of 255s. Reaching the relevant position imme­diately triggers the program continue switch conditions. If reaching the position is not signalled within the timeout time of 255s, a safety shut-down of the BCU will be performed.
A fault message (A or A ) will be displayed, see page47
(Fault signalling). If parameter 41 = 1, the system does not monitor whether the
positions for minimum and maximum capacity are reached. In this case, a running time of up to 250s must be defined using parameter42, see page78 (Running time). The program continue switch conditions are then controlled dependent on this time.
If a fault occurs, the actuator is moved to the position for mini­mum capacity.
Manual mode
In Manual mode, no external controller is enabled during the
The RBW actuator reports that it has reached the position for
controller enable procedure. The actuator can be moved to the positions for maximum capacity or ignition capacity by the user. 3-point step operation is not possible. No timeout is active when approaching these positions.
maximum capacity via a signal to terminal51. The actuator
BCU 580 · Edition 11.15 76
Page 77
BCU 580..F3
µC
VAS
VAS 1
VAG
TZI/TGI
VR..L
V1 V2
V4
10
9
13 14
57
8 5
Parameters > Air control > Capacity control
Parameter 40 = 5: with air valve. The positions for maximum capacity and ignition capacity 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.
Parameter 42 (Running time) can be used to adjust the be­haviour of slow opening and closing air valves so that the system can be set to ignition position before a start-up is initiated. Parameter 41 (Running time selection) must be set to 1 to adjust this behaviour.
See page 78 (Running time) and (78 (Running time se­lection)).
BCU 580 · Edition 11.15 77
Page 78
Parameters > Air control

10.6.2 Running time selection

Parameter 41 Parameter 41 = 0: Off; checking the positions for minimum/
maximum capacity. A signal that the positions for minimum and maximum capacity have been reached is returned and monitored with a timeout time of max. 255s. When the position has been reached, the BCU will initiate the next program step.
Parameter 41 = 1: On; for approaching the positions for mini­mum/maximum capacity. The Running time set using param­eter42 is activated for approaching these positions. After this time has elapsed, the BCU will initiate the next program step.
Parameter 41 = 2: On; for approaching the position for maxi­mum capacity. The Running time set using parameter42 is activated for approaching the position for maximum capacity. After this time has elapsed, the BCU will initiate the next pro­gram step. Approaching the position for minimum capacity is signalled and monitored.
Parameter 41 = 3: On; for approaching the position for mini­mum capacity. No signal is returned that the position for mini­mum capacity has been reached. The Running time set using parameter42 is activated for approaching the position for minimum capacity. After this time has elapsed, the BCU will initiate the next program step. Approaching the position for maximum capacity is signalled and monitored.

10.6.3 Running time

Parameter 42
This parameter can be used to adjust the behaviour of slow
opening and closing air valves. The running time starts when the air actuator is switched off. A restart of the burner after a controlled shut-down, a start-up attempt, restart, cooling or purging is delayed until the end of the running time. After the running time has elapsed, the burner is started if the start-up signal(ϑ) is applied.
The time should be adjusted such that the system can be set
to ignition position, i.e. that the air actuator is closed before a start-up is initiated.
BCU 580 · Edition 11.15 78
Page 79
BCU 580..F3
µC
VAS
VAS 1
VAG
TZI/TGI
VR..L
V1 V2
V4
10
9
13 14
57
8 5
Parameters > Air control
10.6.4 Low fire over-run
Parameter 43 The low fire over-run (tKN) is applicable to systems with a pneu-
matic air/gas ratio control system and On/Off control. Using the low fire over-run function reduces the O2 content in the furnace atmosphere.
00 A8
t
KN
88
L1
11 46
ϑ
1 9 5 13 14 V2 57 V4 2 10
41
1
42
2
43
V1
A
t
Parameter 43 = 0: Off. No low fire over-run is performed. The gas circuit is closed immediately owing to a quick closing gas valve in the case of On/Off control. The air circuit is closed more slowly. The air flowing in during this time increases the O2 content in the combustion chamber.
Parameter 43 = 1 (only for BCU..F1/F2): up to minimum capacity. The burner is not immediately switched off after the start-up signalϑ (terminal1) has been removed. During low fire over­run, the control element is moved to the position for minimum capacity and the gas valves remain open until the flame fails or the position for minimum capacity is reached. If the flame is extinguished, this does not result in a fault.
Parameter 43 = 2, 3, 4, 5, 10, 20, 30 or 40 (only for BCU..F3): time in seconds. During this time, the gas valve remains open. The air valve is closed with deactivated start-up signal(ϑ).
This means that the burner is initially adjusted down to low
fire and then switched off completely. Flame control is still operational. It must be ensured that no excess gas occurs.
10.6.5 Controller enable signal delay time t
RF
Parameter 44 (only on BCU..F1/F2)
The controller enable signal is delayed by 0, 10, 20 or 30 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 external temperature controller is delayed. The BCU shows program statusH8. After the elapse of the delay timetRF, the burner operation signalling contact (terminals 17,18) is closed and the controller enable output (terminal56) activated. The display changes to08.
BCU 580 · Edition 11.15 79
Page 80
t
SA1
t
Z
0402 0300 A0
t
t
FS1
t
SA2
t
FS2
A806 07
2 10
∨
53
A
88
ϑ1
46 1
ϑ2
4
11
9 5
37-38
13
V1
1 2
14 V2 14 V3 57 V4
17-18
8
M
t
SA1
t
Z
0402 0300 A0
t
t
FS1
t
SA2
t
FS2
00A0 00 A8A6 A7
2 10
∨
53
A
88
ϑ1
46 1
ϑ2
4
11
9 5
37-38
13
V1
1 2
14 V2 14 V3 57 V4
17-18
8
M
Parameters > Air control
▼

10.6.6 Air actuator control

Parameter 48 = 1: opens with gas stage1.
Parameter 48 In cyclic operation, parameters 48 and 49 on BCU..F1, F2 and F3
determine the behaviour of the air actuator during burner start. Parameter 48 = 0: opens on external activation.
The air actuator opens at the same time as safety timet
SA2
begins and the main burner starts.
This setting together with parameter 49= 0, see page83 (Air actuator can be activated externally on start-up), is re­quired for burners on which the air/gas ratio is controlled by a pneumatic air/gas ratio control system and which need to be started at low-fire rate, e.g. on two-stage-controlled burners, see page10 (Two-stage-controlled main burner with permanent pilot burner). In this case, activation of the air actuator during burner start via the input at terminal2 must be prevented.
External control allows switchover between low fire and high fire during operation.
BCU 580 · Edition 11.15 80
Page 81
t
SA1
t
Z
0402 0300 A0
t
t
FS1
t
SA2
t
FS2
00A0 00 A806 07
2 10
∨
53
A
88
ϑ1
46 1
ϑ2
4
11
9 5
37-38
13
V1
1 2
14 V2 14 V3 57 V4
17-18
8
M
t
SA1
t
Z
0402 0300
t
t
FS1
t
SA2
t
FS2
0806 07
88
ϑ1
46 1
ϑ2
4
11
9 5
37-38
13
V1
1 2
14 V2 14 V3 57 V4
17-18
8
56
mA
t
SA1
t
Z
0402 0300 A0
t
t
FS1
t
SA2
t
FS2
00A0 00 0806 07
2
53
A
17-18
M
56
mA
88
Parameters > Air control > Air actuator control
▼
Parameter 48 = 2: opens with operating signal.
This setting is required in the case of two-stage main burners which are switched ON/OFF via the ϑ2input.
The air valve opens simultaneously with the operating signal for the main burner. The air valve can be activated externally via the input at terminal2 for cooling the burner in the start-up position/standby. This function is not available during burner start-up and during operation.
Parameter 48 = 3: controller enable following operating signal or in standby.
This parameter is used to activate modulating capacity control
on BCU..F1 and F2. The controller enable signal is issued via the output at terminal 56 in the start-up position (standby) and during operation.
The air actuator can be opened in standby via the input at
terminal2 for this purpose. Cooling is then only possible in the start-up position/standby. The controller enable signal is suspended during cooling.
BCU 580 · Edition 11.15 81
Page 82
t
SA1
t
Z
A4A2 A300 A0
t
t
FS1
t
SA2
t
FS2
00A0 00 A8A6 A7
2 10
∨
53
A
88
ϑ1
46 1
ϑ2
4
11
9 5
37-38
13
V1
1 2
14 V2 14 V3 57 V4
17-18
8
M
Parameters > Air control > Air actuator control
Parameter 48 = 4: opens with V4 pilot burner.
The air valve opens with the start-up fuel rate. The air valve can be activated externally via the input at terminal2 for cooling the burner in the start-up position/standby.
BCU 580 · Edition 11.15 82
Page 83
02
00 A0
00
t
SA2
A807
04
t
t
FS2
06 88
A
37-38
2 10
43
13 5
V1 1
14
V2
1
46
11
9
8
2
4
42
1
2
t
SA1
t
Z
t
FS1
A0
00
03
ϑ
1
ϑ
2
∨
53
M
A2
00 A0
00
t
SA2
A8A7
A4
t
t
FS2
A6 88
A
37-38
2 10
43
13 5
V1 1
14
V2
1
46
11
9
8
2
4
42
1
2
t
SA1
t
Z
t
FS1
A0
00
A3
ϑ
1
ϑ
2
∨
53
M
Parameters > Air control

10.6.7 Air actuator can be activated externally on start-up

Parameter 49 Parameter 49 = 0: cannot be activated.
During start-up, the air actuator remains closed. The air actua­tor cannot be activated externally.
Parameter 49 = 1: can be activated externally.
The air actuator can be activated externally via the input at
terminal2 during start-up. Parameter48 must be set to0 for this purpose, see also page80 (Air actuator control).

10.6.8 Air actuator in the event of fault

Parameter 50
This parameter decides whether the air actuator can be ac-
tivated externally via the input at terminal2 in the event of a fault lock-out.
Parameter 50 = 0: cannot be activated. The air actuator re­mains closed in the event of a fault lock-out. It cannot be activated externally via the input at terminal2.
Parameter 50 = 1: can be activated externally. The air actuator can be activated externally via the input at terminal2 during a fault, e.g. for cooling.
BCU 580 · Edition 11.15 83
Page 84
0° 90°
S4
S1 S3
Burner control range
Butterfly valve setting range
Control range
Move to ignition position
Ignition pos.
Min.
pos.
Closed
pos.
Max. pos.
MIN
MIN
MIN
MAX
MAX
MAX
PE
L1 N
3 2 116 67 4812 1115 13
S3 S4
S11
S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
S1
Min Max
Y­Y+
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
Parameters > Air control
▼

10.6.9 Capacity control (bus)

Parameter 75 Controlling the burner capacity using the fieldbus is only pos-
sible with bus module BCM500 connected and enabled (P80=
1 or2).
The output at terminal 56 has a different function. Parameter 75 = 0: Off. No capacity control possible using
the fieldbus. Parameter 75 = 1: MIN. to MAX. capacity; standby in position
for MIN. capacity. The control range while the burner is oper­ating is between the positions for minimum capacity(S4) and maximum capacity(S3). The burner is ignited in the position for ignition capacity(S1). When the burner is switched off, the actuator is moved to the position for minimum capacity(S4).
This operating mode can be achieved with an actuator IC20, RBW or alternatively with a comparable three-point step ac­tuator.
If the air supply is stopped on a heated furnace with the burner switched off, the controls may be damaged by the hot furnace atmosphere as a result of the lowest possible position of the butterfly valve, limited byS4.
IC 20
Switching cam setting for ignition capacity, minimum and maximum capacity as well as pre-purge and standby:
S1: for ignition capacity of the burner. S3: for maximum capacity of the burner and pre-purge. S4: for minimum capacity of the burner and standby.
BCU 580 · Edition 11.15 84
Page 85
0° 90°
S4
S2
S1 S3
Burner control range
CLOSED
Butterfly valve setting range
Control range
Move to ignition position
Ignition pos.
Max. pos.
OPEN
S4
S2
Min.
pos.
Closed
pos.
MIN
MIN
MAX
MAX
PE
L1 N
3 2 116 67 4812 1115 13
S3 S4
S11
S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
S1
Min Max
Y-
Y+
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
Parameters > Air control > Capacity control (bus)
▼
Parameter 75 = 2: MIN. to MAX. capacity; standby in CLOSED position. The control range while the burner is operating is be­tween the positions for minimum capacity(S2) and maximum capacity(S3). The burner is ignited in the position for ignition capacity(S1). When the burner is switched off, the actuator is moved to the closed position(S4).
This operating mode can be achieved with an actuator IC20 or alternatively with a comparable three-point step actuator.
If the air supply is stopped on a heated furnace with the burner switched off, the controls are protected from the hot furnace atmosphere as a result of the butterfly valve being in the closed position (limited byS4). Check whether the burner can cope without cooling in this situation.
IC 20
Switching cam setting for ignition capacity, minimum and maximum capacity as well as pre-purge and standby:
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.
BCU 580 · Edition 11.15 85
Page 86
0° 90°
S4
S1 S3
Move to ignition position
Burner control range
CLOSED
IGNITION
Butterfly valve setting range
Control range
Ignition pos. Max. pos.
OPEN
Min.
pos.
Closed
pos.
MIN MAX
MAX
PE
L1 N
3 2 116 67 4812 1115 13
S3 S4
S11
S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
S1
Min Max
Y­Y+
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
Parameters > Air control > Capacity control (bus)
▼
Parameter 75 = 3: IGNITION to MAX. capacity; standby in CLOSED position.
The control range while the burner is operating is between the positions for minimum capacity(S1) and maximum capacity(S3). The burner is ignited in the position for minimum capacity(S1). When the burner is switched off, the actuator is moved to the closed position(S4).
This operating mode can be achieved with an actuator IC20, RBW or alternatively with a comparable three-point step ac­tuator.
If the air supply is stopped on a heated furnace with the burner switched off, the controls are protected from the hot furnace atmosphere as a result of the butterfly valve being in the closed position (limited byS4). Check whether the burner can cope without cooling in this situation.
IC 20
Switching cam setting for ignition capacity, minimum and maximum capacity as well as pre-purge and standby:
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 stand-
by.
BCU 580 · Edition 11.15 86
Page 87
S4
S2
S3
S1
0° 90°
Move to ignition position
Burner control range
Butterfly valve setting range
Control range
Max. pos.
OPEN
Ignition
pos.
Reversing direction of rotation for quick start
Min.
pos.
Closed
pos.
MIN
MIN
MIN
MAX
MAX
PE
L1 N
3 2 116 67 4812 1115 13
S3 S4
S11
S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
S1
Min Max
S2
Y-
Y+
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
Parameters > Air control > Capacity control (bus)
▼
Parameter 75 = 4: MIN. to MAX. capacity; standby in position for MIN. capacity; burner quick start.
The control range while the burner is operating is between the positions for minimum capacity(S4) and maximum capac­ity(S3). The burner is ignited in the position for ignition capac­ity(S1). Switching cam S2 (reverse direction of rotation) ensures that the position for ignition capacity is approached without pre-purging first (quick start). When the burner is switched off, the actuator is moved to the position for minimum capacity(S4).
This operating mode can be achieved with an actuator IC20 or alternatively with a comparable three-point step actuator.
If the air supply is stopped on a heated furnace with the burner switched off, the controls may be damaged by the hot furnace atmosphere as a result of the lowest possible position of the butterfly valve, limited byS4. If pre-purge is active, considerably lower air capacity than the maximum air capacity will be used for purging.
IC 20
Switching cam setting for ignition capacity, minimum and maximum capacity and reverse direction of rotation to ap­proach the position for ignition capacity:
S1: for ignition capacity of the burner. S2: for reversing the direction of rotation to approach the posi-
tion for ignition capacity. S3: for maximum capacity of the burner and pre-purge. S4: for the closed position of the butterfly valve and standby.
BCU 580 · Edition 11.15 87
Page 88
S2
S3
S1
S4
0° 90°
Move to ignition position
Burner control range
CLOSED
IGNITION
Butterfly valve setting range
Control range
OPEN
Max. pos.Ignition
pos.
Reversing direction of rotation for quick start
Min.
pos.
Closed
pos.
MIN MAX
MAX
PE
L1 N
3 2 116 67 4812 1115 13
S3 S4
S11
S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
S1
Min Max
S2
Y-
Y+
53 54 55 56
52
1 2 3 4645 65 66 67 6849 50 51
17 18 37 38
13 14 15
BCU 580..F1
3,15AT
µC
88
c
c
41 42
24V
DC
5 6 9 11
1210762
61
Parameters > Air control > Capacity control (bus)
Parameter 75 = 5: IGNITION to MAX. capacity; standby in CLOSED position; burner quick start.
The control range while the burner is operating is between the positions for ignition capacity(S1) and maximum capacity(S3). The burner is ignited in the position for ignition capacity(S1). Switching cam S2 (reverse direction of rotation) ensures that the position for ignition capacity is approached without pre­purging first (quick start). When the burner is switched off, the actuator is moved to the closed position(S4).
This operating mode can be achieved with an actuator IC20 or alternatively with a comparable three-point step actuator.
If the air supply is stopped on a heated furnace with the burner switched off, the controls are protected from the hot furnace atmosphere as a result of the butterfly valve being in the closed position (limited byS4). Check whether the burner can cope without cooling. If pre-purge is active, considerably lower air capacity than the maximum air capacity will be used for purging.
IC 20
The position for maximum capacity is achieved by the controller enable output (terminal56).
Switching cam settings S1, S2, S3 and S4: S1: for minimum capacity and ignition capacity of the burner. S2: for reversing the direction of rotation to approach the po-
sition for ignition capacity. The actuator will move to the position for ignition capacity without reaching the position
for maximum burner capacity. S3: for maximum capacity of the burner and pre-purge. S4: for the closed position of the butterfly valve and standby.
BCU 580 · Edition 11.15 88
Page 89
PZL
PZH
4913
1
450
ϑ
1
V1 V2
45
GZL
Parameters

10.7 Valve check

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. This allows either the tightness of the gas solenoid valves and the pipework between them to be checked (tightness test) or the closed position of a solenoid valve (proof of closure function) to be checked. If the proof of closure function is activated, the closed position of the gas solenoid valve at the inlet side is checked using a POC switch.
Parameter 51 = 0: Off. No valve check is activated. Parameter 51 = 1: tightness test before start-up. Parameter 51 = 2: tightness test after shut-down. With this
setting, a tightness test is also performed after a fault is reset and after mains on.
Parameter 51 = 3: tightness test before start-up and after shut-down.
An additional bypass valve must be installed in gas sections with an air/gas ratio control. The valve allows the closed air/ gas ratio control to be bypassed during the tightness test.
Parameter 51 = 4: proof of closure function (POC).
A signal is sent to the BCU via the POC switch on the gas
solenoid valve on the inlet side before burner start-up stating that the valve is closed. After burner start-up, the signal must drop out to indicate to the BCU that the valve is open.
BCU 580 · Edition 11.15 89
Page 90
V
2
V3
V4PZVAS
p
u
/2
14151345
5
7
V
p
1
V2
V3
V4
14 15
57
P
13
1
4
4
5
p
u
/2
PZ
ϑ
1
pu/2
PZ
V
p1
V1 V2
Parameters > Valve check

10.7.2 Relief valve (VPS)

Parameter 52 One of the valves connected to terminal 14, 15 or57 can be
selected to discharge the test volume during a tightness test.
Parameter 52 = 2: V2. The test volume is discharged via the valve connected to terminal14.
Parameter 52 = 3: V3. The test volume is discharged via the valve connected to terminal15.
Parameter 52 = 4: V4. The test volume is discharged via the valve connected to terminal57.
10.7.3 Measurement time V
p1
Parameter 56
The required measurement time must be determined ac-
cording to the requirements of the appropriate application standards, e.g. EN1643.
The required measurement time for the tightness test of Vp1
can be set using parameter56. The possible settings are 3s, 5 to 25s (in 5s steps) or 30 to 3600s (in 10s steps).
See also page30 (Measurement time tM).
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Parameters > Valve check

10.7.4 Valve opening time 1 tL1

Parameter 59 This parameter is used to define the opening time for the
valves (2 to 25s) which are opened to fill or discharge the test volume between the gas valves. If the preset opening timetL
= 2s is inadequate (e.g. if slow opening valves are used) to
fill the test volume or reduce the pressure between the valves, bypass valves can be used instead of the main valves.
The opening time may be longer than the 3s permitted by the standard (EN1643:2000) if
– the gas volume which flows into the combustion chamber
is equal to, or less than, 0.083% of the maximum flow rate
and
– if bypass valves are used.
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Parameters

10.8 Behaviour during start-up

10.8.1 Minimum pause time tBP

Parameter 62 A minimum pause time tBP (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.
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Parameters

10.9 Manual mode

If the Reset/Information button is pressed for 2s during switch-on, the BCU reverts to Manual mode. Two dots blink on the display. The BCU is now operating in Manual mode independently of the status of the inputs of the burner1 start­up signal (terminal1), controlled air flow (terminal2), remote reset (terminal3) and the burner2 start-up signal (terminal4). The functions of the safety-relevant inputs such as control­ler enable/emergency stop (terminal46) are retained. The manual start-up of the BCU can be initiated in Manual mode by pressing the Reset/Information button. Each time the but­ton is pressed again, the BCU moves to the next step of the program sequence and stops there, for example for adjusting an actuator or the gas/air mixture.
Actuator IC20, IC 40 and RBW
08
Following controller enable (status display actuator can be opened and closed as required. By holding the button, the actuator is first opened further. The BCU indicates
A
with blinking dots. Once the button has been released, the actuator stops in the relevant position. Pressing it again will result in closing the actuator to the position for minimum capacity. The BCU indicates A with blinking dots. A change of direction takes place each time the button is released and pressed again. When the actuator has reached its final posi­tion, the dots disappear.
), a connected

10.9.1 Operating time in Manual mode

Parameter 67 Parameter 67 determines when Manual mode is terminated. Parameter 67 = 0: Manual mode is not limited in time. If this function has been selected, operation of the burner may
be continued manually in the event of failure of the control system or the bus activation.
Parameter 67 = 1: the BCU will terminate Manual mode 5min­utes after the last time the button is pressed. It then moves abruptly back to the start-up position (standby).
If the unit is switched off or a power failure occurs, Manual mode on the BCU will be terminated regardless of param­eter67.
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Parameters

10.10 Functions of terminals 50, 51, 65, 66, 67 and 68

The BCU is informed via terminal50 by a separate automation system that purging is currently being performed.
Terminals 51, 65, 66, 67 and 68 can each be assigned a logi­cal AND gating with one of the inputs for the safety functions (terminals 46–50) using an appropriate parameter. If AND gating is required, the input concerned can be enabled.
Terminal51 can also be used as a feedback input for the maximum capacity position when operated with IC40/RBW.

10.10.1 Function of terminal 50

Parameter 68 The BCU..F1, F2 or F3 supports centrally-controlled pre-purge
or post-purge. In the case of multiple burner applications, burners with mechanical combustion air supply are used. The air for combustion and pre-ventilation is supplied by a central fan controlled by a separate automation system. The automation system sends a signal to terminal 50 during purg­ing. At this point, the BCU opens the air actuator (actuator, air valve) regardless of the status of the other inputs. The display shows
Parameter 68 = 23: purge with Low signal. Parameter 68 = 24: purge with High signal.
P 0
.

10.10.2 Function of terminal 51

Parameter 69 Parameter 69 = 0: Off. Parameter 69 = 8: AND with input at terminal46 (emergency
stop). Parameter 69 = 13: Max. capacity position feedback (IC40/
RBW), see page76 (Parameter 40 = 3: with RBW.).

10.10.3 Function of terminal 65

Parameter 70 Parameter 70 = 0: Off. Parameter 70 = 8: AND with input at terminal46 (emergency
stop).
BCU 580 · Edition 11.15 94
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B
CUBCU
FCU
µC
5455
53
+24V
M
L1
L1
54 55
53
M
66 66
Parameters > Functions of terminals 50, 51, 65, 66, 67 and 68

10.10.4 Function of terminal 66

Parameter 71 Parameter 71 = 0: Off. Parameter 71 = 8: AND with input at terminal46 (emergency
stop). Parameter 71 = 20: LDS ignition position check.
The BCU does not perform a burner start-up, restart or start-up attempt until the butterfly valve is in ignition position. To ensure that the burners only start with the start-up fuel rate, the FCU issues an enable signal to start the burner via terminal 66 to the BCU with setting P71=20. In addition, the safety interlocks must have been enabled by theFCU.

10.10.5 Function of terminal 67

Parameter 72 Parameter 72 = 0: Off. Parameter 72 = 8: AND with input at terminal46 (emergency
stop).

10.10.6 Function of terminal 68

Parameter 73 Parameter 73 = 0: Off. Parameter 73 = 8: AND with input at terminal46 (emergency
stop).
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Parameters

10.11 Password

Parameter 77 The password is designed to protect the parameter settings.
To prevent unauthorized changes to parameter 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. Note the effect of parameter settings on the safe functioning of your system.

10.12 Fieldbus communication

Parameter 80 Fieldbus communication can be activated using parameter80
when bus module BCM500 is connected. A device name must be entered in the automation system for
the unique identification of the control unit (BCU/FCU) in the Profinet IOsystem.
Parameter 80 = 0: Off. Parameterization access using BCSoft via Ethernet is still possible.
Parameter 80 = 1: with address check. The device name on delivery for the BCU580 is “not-assigned-bcu-580-xxx”. The expression “not-assigned-” must be deleted or may be re­placed with an individual name. The sequence xxx must be identical to the address set on the BCM500 using the code switches (xxx= address in the range 001 toFEF).
Parameter 80 = 2: no address check. The device name can be selected as specified by the automation system.
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11 Selection

Q W CO C1 F1 F2 F3 U0 D0 D1 K0 K1 K2 E
BCU 580
= standard,  = available
Order example
BCU 580WC1F1D0K1E

11.1 Type code

Code Description BCU Burner control unit 5 Series 500 80 Version for pilot and main burners Q
W C0
C1
F1 F2 F3
U0 Ionization or UV control in case of operation with gas
D0 D1
K0 K1 K2
E Individual packaging
             
Mains voltage: 120 V AC, 50/60 Hz
230 V AC, 50/60 Hz
No valve proving system
With valve proving system
Capacity control:
interface for actuator IC
interface for RBW actuators
air valve control
Digital input:
none
for high temperature operation
No plug-in terminals
Plug-in terminals with screw connection
Plug-in terminals with spring force connection
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12 Project planning information

12.1 Installation

Installation position as required. The BCU mounting is designed for horizontally aligned
35× 7.5mm DINrails.
If the DINrail is aligned vertically, end clamps are required (e.g. Clipfix35 by Phoenix Contact) to prevent the BCU from slipping.

12.2 Commissioning

Do not start the BCU until the parameter settings and wiring are correct and the faultless processing of all input and output signals complies with the local standards.
Environment
Install in a clean environment (e.g. a control cabinet) with an enclosure ≥IP54, whereby no condensation is permitted.
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Project planning information

12.3 Electrical connection

The BCU is designed for connection to a 1-phase system. 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. If the BCU is operated in ungrounded/IT systems, an insu­lation monitoring device must be provided to isolate it from the mains in the event of a fault. The cabling of the safety circuits (e.g. pressure switches, gas valves) outside enclosed instal­lation spaces must be protected from mechanical damage and stress (e.g. vibration or bending) as well as short-circuits, short-circuits to ground and cross-circuits.
Signal and control line for screw terminals max. 2.5mm2 (AWG12), for spring force terminals max. 1.5mm2 (AWG16).
Do not route BCU cables in the same cable duct as frequency converter cables or cables emitting strong fields.
External electrical interference must be avoided.

12.3.1 OCU

Cables for signalling and telecommunications systems are recommended for wiring the supplied plug connectors:
Cable length max. 10 m, 4-pin, min. 0.25 mm max. 0.34mm
2
(AWG 24),
2
(AWG22).
BCU 580 · Edition 11.15 99
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17 18 37 38
N
max. 1 A; 24 V DC, 250 V AC
BCU 580
3,15AT
µC
88
c
c
0 V+24 V
41 42
24V
DC
9 11
121062
61
230V
1 2 3 4
L1
ϑ1
P70ϑ2P70
P70P69
P73
P72P72
HT
p
u
2
GZL
PZL
P71
0,6 × I
N
4645 65 66 67 6849 50 51
5 6 7 8
13 14 15 57
V1
V2
V3
V4
A
53 54 55 56
P
M
I
Project planning information > Electrical connection

12.3.2 Safety current inputs

Actuation of the safety current inputs only with switchgear fea­turing mechanical contacts. If switchgear with semi-conductor contacts is used, the safety current 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.
The cabling outside enclosed installation spaces must be protected from mechanical damage and stress (e.g. vibration or bending) as well as short-circuits, short-circuits to ground and cross-circuits.
Calculation
IN = current of the sensor/contactor with the lowest switching capacity
Suitable fuse = 0.6 × I
N
BCU 580 · Edition 11.15 100
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