Page 1
AGA
Industrial & Commercial Thermal
Burner control units BCU 460, BCU 465
Technical Information · GB
6 Edition 03.16l
• Replaces the local control cabinet
• For burners in intermittent operation or in continuous operation
• Flame control by UV, ionization or a further option of using the
furnace chamber temperature
• Display of the program status, unit parameters and flame signal;
Manual mode for burner adjustment and for diagnostic purposes
• Visualization and adaptation to the specific application via the
PC programming and diagnostic software BCSoft to simplify
logistics management.
Page 2
Contents
Burner control units BCU 460, BCU 465.............1
Contents ............................................2
1 Application ........................................5
1.1 Examples of application ........................... 7
1.1.1 BCU 460: Modulating-controlled burner .............7
1.1.2 BCU 460..L: Two-stage-controlled burner ............8
1.1.3 BCU 465..L: Single-stage-controlled burner with
pneumatic
air/gas ratio control system .................................9
1.1.4 BCU 465..L : Single-stage-controlled burner .......10
1.1.5 BCU 460..B1 for PROFIBUS DP ......................11
1.1.6 BCU 460..D: High temperature equipment ..........11
2 Certification ......................................12
3 Function ..........................................13
3.1 Connection diagrams .............................13
3.1.1 BCU 460..E1.........................................13
3.1.2 BCU 460 ............................................. 14
3.1.3 BCU 465..E1......................................... 15
3.1.4 BCU 465 ............................................16
3.1.5 BCU 465T..E1 ........................................17
3.1.6 BCU 465T ...........................................18
3.1.7 BCU 4 60..P..E1 with industrial plug connector .....19
3.1.8 BCU 460..P with industrial plug connector .........20
3.1.9 BCU 465..P..E1 with industrial plug connector ......21
3.1.10 BCU 465..P with industrial plug connector........22
3.1.11 BCU 460..B1..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.12 BCU 460..B1 .......................................24
3.1.13 BCU 465..B1..E1 ...................................25
3.1.14 BCU 465..B1 .......................................26
3.1.15 BCU 465T..B1..E1 ...................................27
3.1.16 BCU 465T..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 BCU..P with 16-pin industrial plug connector ....29
3.3 PROFIBUS DP ................................... 30
3.3.1 Safet y-related control signals.......................30
3.3.2 BCSoft................................................31
3.3.3 Configuration, MasterSlave procedure .............31
3.3.4 Addressing............................................31
3.3.5 Network technology................................. 32
3.3.6 Configuration........................................ 32
3.3.7 Bus communication .................................32
3.4 BCU 460 program sequence .....................34
3.5 BCU 465 program sequence .....................36
3.6 Program status and fault messages..............39
4 Parameters .......................................41
4.1 Scanning the parameters .........................42
4.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.2.1 Burner flame signal..................................43
4.2.2 Switch-off threshold of the flame amplifier.........43
4.2.3 High temperature operation in the case of BCU..
D2 or BCU..D3 .............................................44
4.2.4 UVS check ...........................................46
4.3 Behaviour in start-up position/standby ..........47
4.3.1 Flame-simulation check in start-up position/
standby .....................................................47
4.3.2 Position indicator input on BCU 465T..O (POC) ....48
4.3.3 Minimum burner pause time t
....................49
BP
4.4 Behaviour during start-up ....................... 50
4.4.1 Safety time on start-up tSA .........................50
4.4.2 Minimum burner on time t
4.4.3 Flame proving period t
4.4.4 Burner start-up at tempts ...........................50
.........................50
B
............................50
FS
4.5 Behaviour during operation.......................52
4.5.1 Safety time during operation tSB for V1 and V2 ..... 52
4.5.2 Fault lock-out or restart .............................52
4.5.3 Immediate fault lock-out after installation fault ....53
4.5.4 Program status on last fault ........................54
4.6 Air valve control on BCU..L ........................55
4.6.1 Purge ................................................55
4.6.2 Cooling in start-up position/standby ...............56
4.6.3 Air valve opens in the case of external activation
(not during start-up).......................................56
BCU 460, BCU 465 · Edition 03.16l 2
= To be continued
▼
Page 3
Contents
4.6.4 Air valve opens in the case of external activation
(even during start-up) ......................................57
4.6.5 Air valve opens with valve V1 .........................57
4.6.6 Air valve opens with valve V2 .........................57
4.6.7 Low fire over run-time t
down .......................................................58
4.6.8 Behaviour of the air valve after a fault lock-out .....59
after a controlled shut-
KN
4.7 Extended air control with BCU 465..L ........... 60
4.7.1 Air flow monitoring during purging (BCU 465..L) ...60
4.7.2 Pre-ventilation time t
465..L) ......................................................61
4.7.3 Air flow monitoring during operation (BCU 465..L) . 62
4.7.4 Delayed air flow monitoring (BCU 465) .............63
4.7.5 Post-ventilation time t
down (BCU 465..L) ........................................63
4.7.6 Pre-ventilation time after safety shut-down (BCU
465..L) .....................................................64
4.7.7 Pre-ventilation for restart/start-up attempts (BCU
465..L) .....................................................64
4.7.8 Pre-ventilation after reset (BCU 465..L) ............64
before start-up (BCU
VL
after a controlled shut-
NL
4.8 Manual mode .....................................65
4.8.1 Manual mode limited to 5 minutes..................65
5 Selection ........................................ 66
5.1 Type code ........................................ 66
6 Project planning information .....................67
6.1 Cable selection ...................................67
6.1.1 Ionization cable.......................................67
6.1.2 Ignition cable .........................................67
6.1.3 UV cable ..............................................67
6.2 Ignition electrode .................................67
6.2.1 Electrode distance ...................................67
6.2.2 Star electrodes .......................................67
6.3 Calculating the safety time tSA .................. 68
6.4 Minimum burner on time .........................69
6.5 Safety interlock (Limits) ..........................69
6.6 Protection of safety-relevant outputs ............69
6.7 Emergency stop ..................................69
6.7.1 In the event of fire or electric shock .................69
6.7.2 Triggered by the safety interlock (limits) ............69
6.8 Reset ..............................................70
6.8.1 Parallel reset.........................................70
6.8.2 Permanent remote reset ............................70
6.8.3 Automatic remote reset (PLC) ......................70
6.9 Burner start .......................................70
6.10 Restart and start-up attempts ..................70
6.11 Fault signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.12 Overload protection .............................71
6.13 Installation ......................................71
6.14 Wiring............................................72
6.15 BCU and BCU..E1 (with and without adapted
power management)..................................72
6.16 Signal distributor board .........................72
6.17 PROFIBUS DP ...................................73
6.17.1 Safety-related control signals .....................73
6.17.2 Wiring the PROFIBUS plug connector .............73
6 . 17. 3 E MC ................................................73
6.17.4 Unit replacement...................................73
6.17.5 Status and fault messages for PROFIBUS DP ..... 74
6.18 Third gas valve (can be shut down) on
BCU 460..L and BCU 465 ............................76
6.19 BCU switched off................................77
6.20 Note on EC-type examination...................77
6.21 Mains switch ....................................77
6.22 SIL/PL level for thermoprocessing equipment 77
6.23 Changing parameters ...........................78
7 Flame control .................................... 79
7.1 With ionization sensor .............................79
7.2 With UV sensor ....................................79
7.3 Via the temperature in high temperature
equipment ........................................... 80
8 Accessories.......................................81
8.1 High-voltage cable ...............................81
8.2 Industrial plug connector, 16-pin.................81
BCU 460, BCU 465 · Edition 03.16l 3
= To be continued
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Page 4
Contents
8.3 PROFIBUS plug connector .......................81
8.4 BCSoft ............................................82
8.4.1 Opto-adapter........................................ 82
8.5 “Changed parameters” stickers ..................82
8.6 External securing bar .............................83
8.7 Fastening set .....................................83
8.8 Radio interference suppressed electrode plugs..83
9 Technical data ................................... 84
9.1 BCU..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
9.2 PROFIBUS DP ....................................85
9.3 Safety-specific characteristic values .............86
9.4 Control elements .................................87
9.5 Installation ........................................87
10 Legend ......................................... 88
11 Glossary ........................................ 89
11.1 Waiting time t
11.2 Safety time on start-up t
11.3 Ignition time t
..................................89
W
......................89
SA
..................................89
Z
11.4 Flame simulation/Flame simulation delay time
.....................................................89
t
LV
11.5 Safety time during operation t
............... 90
SB
11.6 Flame signal .................................... 90
11.7 Fault lock-out ...................................90
11.8 Safety interlocks (Limits) ....................... 90
11.9 Pilot gas valve V1 ............................... 90
11.10 Main gas valve V2 ............................. 90
11.11 Continuous operation ..........................91
11.12 Air valve.........................................91
11.13 Diagnostic coverage DC........................91
11.14 Mode of operation..............................91
11.15 Safe failure fraction SFF .......................91
11.16 Probability of dangerous failure PFH
11.17 Mean time to dangerous failure MTTF
........91
D
.......91
d
Feedback ...........................................92
Contact.............................................92
BCU 460, BCU 465 · Edition 03.16l 4
= To be continued
▼
Page 5
Application
▼
The BCU unites
the functionally
interrelated components of automatic burner control unit, ignition
transformer, Manual/Automatic
mode and display
of operating and
fault statuses in
a compact metal
housing.
1 Application
The burner control units BCU 460 and BCU 465 control,
ignite and monitor gas burners for intermittent or continuous operation. As a result of their fully electronic design, they react quickly to various process requirements
and are therefore suitable for frequent cycling operation.
They can be used for directly ignited industrial burners
of unlimited capacity. The burners may be modulating or
stage-controlled. The BCU is installed near the burner
to be monitored.
On industrial furnaces, the BCU reduces the load on the
central furnace control by taking over tasks that only relate to the burner, for example it ensures that the burner
The optional air valve control on the BCU..L assists the
furnace control for cooling, purging and capacity control tasks.
The BCU 465..L is fitted with air flow monitoring and pre-
and post-ventilation for use on recuperative burners.
The program status, the unit parameters and the level of
the flame signal can be read directly from the unit. The
burner can be controlled manually for commissioning
and diagnostic purposes.
If the local requirements on the burner control unit
change, the PC software BCSoft can be adjusted to the
unit parameters of the application by using the optical
interface.
always ignites in a safe condition after it has been restarted.
BCU 460, BCU 465 · Edition 03.16l 5
Page 6
Application
Roller hearth kiln
in the ceramics
industry
BCU on radiant
tube burner
Hardening fur-
nace with lots of
industrial burners
located side-by-
side
The service personnel is supported by a convenient vis-
ualization system of the input and output signals and
the error history.
The new power management scheme reduces installa-
tion and wiring costs. The power for the valves and ignition transformer is supplied via the power supply of the
BCU, protected by a replaceable fine-wire fuse.
The conventional wide-spread systems used in indus-
trial furnace and kiln construction require bridging of
large distances for signal processing. The optionally
available BCU..B1 for connection to the PROFIBUS DP
fieldbus is equipped for this purpose.
As a standardized fieldbus system, the PROFIBUS DP
considerably reduces development, installation and
commissioning costs compared to conventional wiring.
The use of a standard bus system offers massive ben-
efits compared to manufacturer-specific bespoke solutions. Time-tested hardware components, standardized
connection methods and a series of tools of bus diagnostics and optimization are available on the market
from a whole range of manufacturers. The widespread
use of the system ensures that the planning and service personnel are very familiar with how the system operates and how to handle it and can therefore operate
the system efficiently.
BCU 460, BCU 465 · Edition 03.16l 6
Page 7
Application
BCU 460
1.1 Examples of application
1.1.1
BCU 460: Modulati n g-controlled
burner
Control: continuous.
The external control system moves
L1, N, PE
DI
P
PLC
mA
DI
5
6
3
12
4
µC
9
19
18
17
16
the butterfly valve for air to ignition
position. The burner starts at lowfire rate, and a controller controls
the burner
capacity via the butterfly valve for
air after the operating state has
been signalled.
VG..L
DK+GT
M
BCU 460, BCU 465 · Edition 03.16l 7
GIK
BIO
BIC
Page 8
Application
BCU 460..L
1.1.2 BCU 460..L: Two-stagecontrolled burner
Control: ON/OFF or ON/HIGH/
LOW/OFF intermittent operation.
The BCU supports the cooling and
purging processes. The burner
L1, N, PE
DI
PLC
P
starts at low-fire rate. When the
operating state is reached, the BCU
advises the control unit. The PLC
can now pulse the air valve in order
DI
5
6
3
12
26
A
P
23 4
22
19
µC
9
18
17
16
to control the burner capacity.
VG..N
VR..R
BCU 460, BCU 465 · Edition 03.16l 8
GIK..B
BIO
BIC
Page 9
Application
BCU 465..L
VG..L
1.1.3 BCU 465..L: Single-stagecontrolled burner with pneumatic
air/gas ratio control system
Control: ON/OFF.
The BCU supports the cooling and
purging processes. The variable
L1, N, PE
DI
PLC
P
air/gas ratio control compensates
for gas/air pressure fluctuations.
Optional: the pressure switch monitors the air flow during pre-purge
DI
5
6
3
12
26
A
P
22
23 4
19
µC
21
18
17
16
and operation. The gas/air mixture
is adjusted to the requirements of
the applications using the differing parameters of pre- and postventilation.
BICR
VR..R
BCU 460, BCU 465 · Edition 03.16l 9
Page 10
22
DI
L1, N, PE
µC
P
23 4
19
18
17
16
A
P
5
3
DI
6
SPS
Application
▼
BCU 465..L
1.1.4 BCU 465..L: Single-stage-
L1, N, PE
DI
PLC
P
controlled burner
Control: ON/OFF.
The gas/air mixture is adjusted to
the requirements of the applica-
DI
5
6
3
12
26
A
P
22
23 4
19
µC
21
18
17
16
tions using the differing parameters
of pre- and post-ventilation. The
pressure switch monitors the air
flow in the air supply line or in the
flue gas exhaust.
VG..L
GEH
EKO
BICR
VR..R
BCU 465..L
12
LEH
26
21
EKO
VG..L
BICR
VR..R
BCU 460, BCU 465 · Edition 03.16l 10
Page 11
Application
BCU 4xx..D
6
DI
L1, N, PE
DI
PLC
P
BUS
PROFIBUS DP
BCU 460..B
1…51 1…51 1…51
BUS BUS BUS
1
BCU 460..B
STM
C
9
2
> 750°C
BCU 460..B
L1
3
BCU 4xx..D
6
DI
C
1.1.5
BCU 4 60.. B1 for PROFIBU S DP
The bus system transfers the con-
trol signals for starting, resetting
and for controlling the air valve from
the control system (PLC) to the
BCU..B1. 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
and digital input, are transferred
independently of the bus communication by separate cables.
1.1.6
BCU 4 60..D : High temperature
equipment
Indirect flame control using the
temperature. During the start-up
process, as long as the wall temperature is below auto ignition temperature, the flame must be controlled
by conventional methods. When the
9
working temperature has exceeded
750°C, the safety temperature
monitor (STM) takes over the indirect flame control.
BCU 460, BCU 465 · Edition 03.16l 11
Page 12
Certification
2 Certification
Certificates – see Docuthek.
Certified pursuant to SIL
For systems up to SIL 3 pursuant to EN 61508.
Pursuant to EN ISO 138491:2006, Table 4, the BCU
can be used up to PL e.
EU certified pursuant to
– Gas Appliances Directive (2009/142/EC) in conjunc-
tion with EN 298:2012
Meets the requirements of the
– Low Voltage Directive (2006/95/EC),
– EMC Directive (2004/108/EC).
ANSI/CSA approved
FM approved
Factory Mutual Research Class: 7610 “Combustion
Safeguards and Flame Sensing Systems”.
Suitable for applications pursuant to NFPA 86.
www.approvalguide.com
AGA approved
AGA
Australian Gas Association, Approval No.: 6478
http://ww w.aga.asn.au/product _directory
Eurasian Customs Union
The products BCU 460 and BCU 465 meet the techni-
cal specifications of the Eurasian Customs Union.
American National Standards Institute/Canadian
Standards Association –ANSI Z21.20/CSA C22.2, No.
199/UL 372
www.csagroup.org – Class number: 333501 and
333581.
BCU 460, BCU 465 · Edition 03.16l 12
Page 13
Function
F1
V1 V2 C N SµCL
N1
O
I
1 2 5 6 119 10 12 13 14 15 18 19 20 26 2722
3 4
ϑ
DI
s1
88
N1
c1
PE
7
Z I
8
230V~
v1c2v2
V1
Test
n
N1N1 N1
16 17
max. 2 A,
253 V
V2
s
max. 2 A,
253 V
(BCU 460..L)
7 8 9 7 8 9 1110
1
2
UVS
3
(BCU 460..C)
BCU 460..E1
40 41 42 43 44 45 46 47
F3
l
23
30 31 32 33 34 35 36 37
l
38
50 51
A
P
L1 (L1)
N (L2)
PE
3 Function
3.1 Connection diagrams
3.1.1 BCU 460..E1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
BCU 460, BCU 465 · Edition 03.16l 13
Page 14
Function
F1
V1 V2 C N SµCL
O
I
1 2 5 6 119 10 12 13 14 15 18 19 20 26 2722
3 4
ϑ
DI
s1
88
N1
c1
PE
7
Z I
8
230V~
v1c2v2
V1
7 8 9 7 8 9 1110
3.1.2 BCU 460
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
s
max. 2 A,
253 V
(BCU 460..L)
23
A
P
Test
n
N1N1 N1
16 17
max. 2 A,
253 V
V2
1
2
UVS
3
(BCU 460..C)
BCU 460
40 41 42 43 44 45 46 47
F3
l
30 31 32 33 34 35 36 37
38
L1 (L1)
N (L2)
l
50 51
PE
BCU 460, BCU 465 · Edition 03.16l 14
Page 15
Function
F1
V1 V2 C M LN S
N1
O
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
3 4
ϑ
DI
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
7 8 9 7 8 9 1110
3.1.3 BCU 465..E1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
n
N1N1 N1
V2
s m
16 17
max. 2 A,
253 V
UVS
1
2
3
21 28 29
max. 2 A,
253 V
23
25
A
P
(BCU 465..C)
BCU 465..L..E1
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
BCU 460, BCU 465 · Edition 03.16l 15
Page 16
Function
F1
V1 V2 C M LN S
O
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
3 4
ϑ
DI
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
7 8 9 7 8 9 1110
3.1.4 BCU 465
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
n
N1N1 N1
V2
s m
16 17
max. 2 A,
253 V
UVS
1
2
3
21 28 29
max. 2 A,
253 V
23
25
A
P
(BCU 465..C)
BCU 465..LBCU 465..L
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
BCU 460, BCU 465 · Edition 03.16l 16
Page 17
Function
F1
V1 V2 C M LN S
N1
O
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
3 4
Digital input*
ϑ
DI
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
7 8 9 7 8 9 1110
* = BCU 465T..D2
= BCU 465T..D3
** = BCU 465T..O
3.1.5 BCU 465T..E1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
n
N1N1 N1
V2
s m
16 17
max. 2 A,
253 V
UVS
1
2
3
21 28 29
max. 2 A,
253 V
OCS**
23
A
P
(BCU 465..C)
BCU 465T..L..E1
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
BCU 460, BCU 465 · Edition 03.16l 17
Page 18
Function
F1
V1 V2 C M LN S
O
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
3 4
Digital input*
ϑ
DI
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
7 8 9 7 8 9 1110
* = BCU 465T..D2
= BCU 465T..D3
** = BCU 465T..O
3.1.6 BCU 465T
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
n
N1N1 N1
V2
s m
16 17
max. 2 A,
253 V
UVS
1
2
3
21 28 29
max. 2 A,
253 V
OCS**
23
A
P
(BCU 465..C)
BCU 465T..L
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
BCU 460, BCU 465 · Edition 03.16l 18
Page 19
PE
s
s1
88
c1
O
I
F1
230V~
v1c2v2
max. 2 A,
253 V
V1 V2 C N SµCL
l
30 31 32 33 34 35 36 37
38
(BCU 460..L)
50 51
l
F3
(BCU 460..C)
40 41 42 43 44 45 46 47
1 2 5 6 119 10 12 13 14 15 18 19 20 26 2722
8
7
3 4 23
16 17
n
max. 2 A,
253 V
Test
UVS
1
2
3
7 8 9 7 8 9 1110
V1
V2
12 11 10 4 3916 15 14 8 7 6
I
Z
L1
N
PE
DI
16 15 1 4 12 11 10
9
8 7 6 4 3
P A
BCU 460..P..E1
N1
N1
N1N1 N1
Function
3.1.7 BCU 460..P..E1 with industrial plug connector
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
BCU 460, BCU 465 · Edition 03.16l 19
Page 20
PE
s
s1
88
c1
O
I
F1
230V~
v1c2v2
max. 2 A,
253 V
V1 V2 C N SµCL
l
30 31 32 33 34 35 36 37
38
(BCU 460..L)
50 51
l
F3
(BCU 460..C)
40 41 42 43 44 45 46 47
1 2 5 6 119 10 12 13 14 15 18 19 20 26 2722
8
7
3 4 23
16 17
n
max. 2 A,
253 V
Test
UVS
1
2
3
7 8 9 7 8 9 1110
V1
V2
12 11 10 4 3916 15 14 8 7 6
I
Z
L1
N
PE
DI
16 15 1 4 12 11 10
9
8 7 6 4 3
P A
BCU 460..P
N1
N1N1 N1
Function
3.1.8 BCU 460..P with industrial plug connector
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
BCU 460, BCU 465 · Edition 03.16l 20
Page 21
Function
F1
V1 V2 C M LN S
N1
O
I
1 2 5 6 7 8 119 10 12 13 14 15 22 23 26 27
3 4
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z
I
DI
P A
V1
V2
8 7 6 4 3
16 15
14
12 11 10
3.1.9 BCU 465..P..E1 with industrial plug connector
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
max. 2 A,
max. 2 A,
253 V
253 V
n
N1N1 N1
s m
16 17
21 25 28 29
l
12 11 10 4 3916 14 8 7 615
p
9
PE
L1
N
(BCU 465..C)
BCU 465..P..E1
40 41 42 43 44 45 46 47
F3
30 31 32 33 34 35 36 37 38 50 51
7 8 9 7 8 9 1110
UVS
l
1
2
3
BCU 460, BCU 465 · Edition 03.16l 21
Page 22
Function
F1
V1 V2 C M LN S
O
I
1 2 5 6 7 8 119 10 12 13 14 15 22 23 26 27
3 4
s1
C
88
230V~
v1c2v2
N1 N1N1 N1
c1
PE 18 19 20
Z
I
DI
V1
P A
8 7 6 4 3
16 15
14
12 11 10
3.1.10 BCU 465..P with industrial plug connector
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
(BCU 465..C)
BCU 465..P
40 41 42 43 44 45 46 47
max. 2 A,
max. 2 A,
253 V
253 V
n
s m
16 17
21 25 28 29
l
30 31 32 33 34 35 36 37 38 50 51
F3
l
12 11 10 4 3916 14 8 7 615
V2
p
7 8 9 7 8 9 1110
9
1
2
UVS
PE
L1
N
3
BCU 460, BCU 465 · Edition 03.16l 22
Page 23
Function
F1
V1 V2 C N SµCL
s1
88
O
N1
I
1 2 5 6 119 10 12 13 14 15 18 19 20 26 2722
PE
DI
3.1.11 BCU 460..B1..E1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
N1
7
Z I
c1
8
230V~
v1c2v2
V1
7 8 9 7 8 9 1110
s
max. 2 A,
253 V
(BCU 460..L)
P
Test
N1N1 N1
V2
BCU..B1/1
1B1A2B2A
1
2
UVS
3
PROFIBUS-DP
(BCU 460..C)
BCU 460..B1..E1
40 41 42 43 44 45 46 47
F3
l
30 31 32 33 34 35 36 37
38
L1 (L1)
N (L2)
l
50 51
PE
OFF
ON
ON
OFF
BCU 460, BCU 465 · Edition 03.16l 23
Page 24
Function
F1
V1 V2 C N SµCL
s1
88
O
N1
I
1 2 5 6 119 10 12 13 14 15 18 19 20 26 2722
PE
DI
3.1.12 BCU 460..B1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
N1
7
Z I
c1
8
230V~
v1c2v2
V1
7 8 9 7 8 9 1110
s
max. 2 A,
253 V
(BCU 460..L)
P
Test
N1N1 N1
V2
BCU..B1/1
1B1A2B2A
1
2
UVS
3
PROFIBUS-DP
(BCU 460..C)
BCU 460..B1
40 41 42 43 44 45 46 47
F3
l
30 31 32 33 34 35 36 37
38
L1 (L1)
N (L2)
l
50 51
PE
OFF
ON
ON
OFF
BCU 460, BCU 465 · Edition 03.16l 24
Page 25
Function
F1
V1 V2 C M LN S
O
N1
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
DI
7 8 9 7 8 9 1110
3.1.13 BCU 465..B1..E1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
N1N1 N1
s m
21 28 29
max. 2 A,
253 V
V2
P
BCU..B1/1
1
2
UVS
3
PROFIBUS-DP
(BCU 465..C)
BCU 465..L..B1..E1
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
1B1A2B2A
OFF
ON
ON
OFF
BCU 460, BCU 465 · Edition 03.16l 25
Page 26
Function
F1
V1 V2 C M LN S
O
N1
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
DI
7 8 9 7 8 9 1110
3.1.14 BCU 465..B1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
N1N1 N1
s m
21 28 29
max. 2 A,
253 V
V2
P
BCU..B1/1
1
2
UVS
3
PROFIBUS-DP
(BCU 465..C)
BCU 465..L..B1
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
1B1A2B2A
OFF
ON
ON
OFF
BCU 460, BCU 465 · Edition 03.16l 26
Page 27
Function
F1
V1 V2 C M LN S
O
N1
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
Digital input*
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
DI
7 8 9 7 8 9 1110
* = BCU 465T..D2
= BCU 465T..D3
** = BCU 465T..O
3.1.15 BCU 465T..B1..E1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
N1N1 N1
s m
21 28 29
max. 2 A,
253 V
OCS**
V2
P
BCU..B1/1
1
2
UVS
3
PROFIBUS-DP
(BCU 465..C)
BCU 465T..L..B1..E1
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
1B1A2B2A
OFF
ON
ON
OFF
BCU 460, BCU 465 · Edition 03.16l 27
Page 28
Function
F1
V1 V2 C M LN S
O
N1
I
1 2 5 6 7 8 119 10 12 13 14 15 22 26 27
Digital input*
s1
C
88
230V~
v1c2v2
N1
c1
PE 18 19 20
Z I
V1
DI
7 8 9 7 8 9 1110
* = BCU 465T..D2
= BCU 465T..D3
** = BCU 465T..O
3.1.16 BCU 465T..B1
For cable selection and wiring, see page 67 (Project
planning information).
For the explanation of symbols, see page 88 (Leg-
end).
Test
N1N1 N1
s m
21 28 29
max. 2 A,
253 V
OCS**
V2
P
BCU..B1/1
1
2
UVS
3
PROFIBUS-DP
(BCU 465..C)
BCU 465T..L..B1
40 41 42 43 44 45 46 47
F3
l
l
30 31 32 33 34 35 36 37 38 50 51
L1 (L1)
N (L2)
PE
1B1A2B2A
OFF
ON
ON
OFF
BCU 460, BCU 465 · Edition 03.16l 28
Page 29
Function
3.2 BCU..P with 16-pin industrial plug connector
The burner control units BCU 460..P and BCU 465..P
can be supplied with an industrial plug connector (pursuant to VDE 0627). This 16-pin plug connector ensures fast connecting or disconnecting of units without
any additional wiring required. This simplifies replacing
units and reduces standstill times.
All signals to the higher-level control system, the mains
supply and the safety interlocks are routed via this plug,
see page 81 (Accessories).
BCU 460, BCU 465 · Edition 03.16l 29
Page 30
Function
L1, N, PE
DI
SPS
PLC
API
PROFIBUS DP
BCU..B
BUS1– 6
BCU..B
BUS1– 6
3.3 PROFIBUS DP
BCU..B1 features the same scope of functions and performance of a BCU® without a PROFIBUS connection.
PROFIBUS is a manufacturer-independent, open field-
P
BUS
1
bus standard for diverse applications.
PROFIBUS DP is a bus variant for communication between automation systems and distributed peripherals
at the field level, optimized for speed and low connection costs.
On PROFIBUS DP, the individual bus stations are connected via a 2-core shielded cable as standard.
The bus system transfers the control signals for start-
ing, resetting and for controlling the air valve to purge
the furnace or kiln or for cooling in start-up position
and heating during operation from the control system
(PLC) to the BCU..B1. In the opposite direction, it sends
operating status, the level of the flame signal and the
current program status.
2
BCU..B
3.3.1 Safety-related control signals
Signals from the safety interlocks and digital input are
transferred independently of the bus communication
by separate cables. The air valve used to purge the fur-
BUS1– 6
nace or kiln can either be activated via the PROFIBUS
or via a separate cable to terminal 22. The purging pro-
3
cess must be monitored by further measures, e.g. flow
monitoring.
BCU 460, BCU 465 · Edition 03.16l 30
Page 31
Function
3.3.2 BCSoft
The Windows software BCSoft allows extended access
to individual statistics, protocol functions, line recorders and the parameterization of the burner control unit
via an optical interface. Unit parameters which are not
relevant to safety can be set and adjusted to the specific application.
3.3.3 Configuration, MasterSlave procedure
PROFIBUS DP is structured as a MasterSlave system.
This allows mono-master or multi-master systems to be
implemented.
A distinction is made between three device types:
– DP Masters Class 1 (DPM1)
DPM1 devices are central controllers which exchange
data with the distributed stations (slaves) on the basis of a defined cycle. This includes, for instance, the
PLC, PC, CNC or VME systems with which the PROFI
BUS DP is operated.
– DP Masters Class 2 (DPM2)
DPM2 devices are programming, project planning or
operator-control devices. They are used for configuration and commissioning of the system or for system
operation and visualization in ongoing operation.
– DP Slaves
The devices which transmit input information from
the periphery to the master and which issue output
information from the master to the peripher y are re-
ferred to as “slaves”.
This also includes the BCU..B1.
3.3.4 Addressing
A maximum of 126 units (masters and slaves) can be
connected to a PROFIBUS DP system. Each station is
assigned an individual PROFIBUS address which can
be set between 0 and 126 using two code switches on
the BCU..B1 board.
BCU 460, BCU 465 · Edition 03.16l 31
Page 32
Function
A
P
A
P
▼
3.3.5 Network technology
All devices are connected in a bus structure (line). Up
to 32 stations (masters or slaves) can be connected in
a single segment. The beginning and end of each segment is fitted with an active bus terminator. Both bus
terminators must have a permanent power supply to
ensure error-free operation. The power supply for the
bus terminator is provided by the BCU. The bus terminator can be connected in the bus connection plug.
If more than 32 stations are implemented or if there is a
need to expand the network area, repeaters (amplifiers)
must be used to link the individual bus segments.
3.3.6 Configuration
When planning a PROFIBUS DP system, unit-specific
parameters of each station are to be taken into account.
To allow for simple and standardized planning, the pa-
rameters of the BCU..B1 have been summarized in a
so-called device master data file (GSD). The file structure is standardized so that it can be read by the planning devices of different manufacturers.
The GSD file is supplied on the BCSoft CD which is in-
cluded in the delivery of BCU..B1. The GSD file can also
be ordered at www.docuthek.com. The steps required
to copy the file are described in the instructions for the
automation system.
3.3.7 Bus communication
Input bytes (BCU ➔ master)
Bit Byte 0 Byte 1 Byte 2 Byte 3 Byte 4
0
1 Reserved
2
3
4
5
6
7
Output by tes (master ➔ BCU)
Bit Byte 0
0
1
2
3
4 Reserved
5 Reserved
6 Reserved
7 Reserved
on
on
DI
on
BCU 460/465 basic I/O
BCU 460/465 standard I/O
Reserved
messages)
See table on page
39 (Program status and fault
0–25.5 µA
255 steps
Reserved
BCU 460, BCU 465 · Edition 03.16l 32
Page 33
Function
I/O bytes: the programmer can choose the data to be
transferred.
Inputs Outputs
460/465 basic I/O 1 byte 1 byte
460/465 standard I/O 4 bytes 1 byte
480 basic I/O 1 byte 1 byte
480 standard I/O 5 bytes 1 byte
Baud rate: up to 1500 kbit/s.
The max. range per segment depends on the baud rate:
Baud rate [kbit/s] Range [m]
93.75 1200
18 7.5 1000
500 400
1500 200
The specified ranges may be increased by using repeat-
ers. No more than three repeaters should be connected
in series.
The specified ranges relate to bus cable type A (two-
core, shielded and twisted), e.g.
Siemens, Order No.: 6XV18300EH10, or
Lapp cable unitronic, Order No.: 2170220T.
BCU 460, BCU 465 · Edition 03.16l 33
Page 34
Function
A
Switch on BCU 460
In the event of fault signal:
Safety interlock (Limits)
00
01
02
Start-up position/Standby
If parameter P15 = 1:
flame simulation check
Start-up with ϑ signal
min. burner pause time t
has elapsed (P21)
If parameter P15 = 0:
flame simulation check
Safety time t
running (P22),
ignition in process,
V1 opens and
min. burner on time t
starts to elapse (P20)
If no flame detected:
max. 3 start-up attempts
or fault lock-out
reset
Wait until
SA
BCU 460..L
with air valve control features
the following additional functions.
3.4 BCU 460 program sequence
Normal start-up
If an “old” fault is still being signalled after
switching on, it will be necessary to reset
this first.
When the safety interlocks are closed, the
In start-up position, the air
valve can be opened for cool-
.
ing
BCU reverts to start-up position and con-
ducts a self-test. If it does not determine
a malfunction of the internal electronic
circuitry or of the flame sensor, the burner
can be started.
BP
Using parameter 31, it can be
determined whether the air
valve can be activated externally during start-up.
The flame simulation check is conducted
during start-up position or after applying
the start-up signal (ϑ), depending on pa-
rameter 15.
After the min. burner pause time t
BP
has
elapsed, the BCU opens valve V1 and
ignites the burner. The ignition time tZ is
B
The air valve can be set to open
A2
together with V1 (display
via parameter 30.
)
constant.
If a flame is detected during the safety
time t
, the flame proving period tFS starts
SA
after this safety time has elapsed. Valve V2
opens and the operation signalling contact
between terminals 16 and 17 closes.
▼
BCU 460, BCU 465 · Edition 03.16l 34
Page 35
Function
If no flame detected:
max. 3 start-up attempts
or fault lock-out
03
Flame proving period t
running (P23)
This completes start-up. An adjustable min.
burner on time tB ensures that the burner
FS
burns for a defined period even if the start-
up signal (ϑ) is switched off beforehand.
In the event of flame failure:
fault lock-out
04
04
00
Operation signalling
contact closes
and V2 opens
In the event of flame failure:
restart or
fault lock-out
Controlled shut-down
via ϑ signal
If min. burner on time t
has elapsed:
operation signalling
contact opens,
V1 and V2 close,
min. burner pause time t
starts to elapse (P21)
The burner can also be started manually
with the aid of the switch on the BCU. Volt-
The air valve can also be set to
open with V2 or to be activated
A4
externally (display
rameter 30.
) via pa-
age must be applied continuously to terminals 1, 4 and 5 in order for this to occur.
The BCU can also be operated in Manual
mode for start-up.
Start-up without flame signal
If no flame is detected during the safety
time t
, either a fault lock-out occurs or
SA
up to two further start-up attempts occur.
The required functions and, if applicable,
the number of start-up attempts must be
B
specified when ordering. (Parameter 10,
“Burner start-up attempts”).
Behaviour in the event of flame failure
BP
during operation
If the flame fails during operation, either
an immediate fault lock-out or a restart
occurs. This procedure can be set via the
optical interface (parameter 12, “Burner
restart”).
BCU 460, BCU 465 · Edition 03.16l 35
Page 36
Function
▼
00
A0
00
01
A1
01
Switch on BCU 465
In the event of fault signal: reset
Safety interlock (Limits)
Start-up position/Standby
The air valve can be
opened for cooling.
If parameter P15 = 1:
flame simulation check
Start-up with ϑ signal
Wait until min. burner pause time
t
BP
If parameter P06 = 1: verification of air
“no flow” state check
Pre-ventilation time after
safety shut-down running (P39–41)
Min. burner pause time t
running once again (P21)
has elapsed (P21)
BP
3.5 BCU 465 program sequence
Normal start-up
If an “old” fault is still being signalled after switching on, it will be
necessary to reset this first.
When the safety interlocks are
closed, the BCU reverts to start-up
position and conducts a self-test. If
it does not determine a malfunction
of the internal electronic circuitry or
of the flame sensor, the burner can
be started.
The flame simulation check is con-
ducted during start-up position or
after applying the start-up signal
(ϑ), depending on parameter 15.
After a safety shut-down, first the
pre-ventilation time after safety
shut-down elapses (parameters 39
– 41). Then the min. burner pause
time t
valve V1 and ignites the burner. The
ignition time tZ is constant.
runs. The BCU now opens
BP
If parameter P15 = 0:
flame simulation check
BCU 460, BCU 465 · Edition 03.16l 36
Page 37
If parameter P15 = 0:
flame simulation check
BP
running once again (P21)
▼
Function
A1
A2
A3
A4
Pre-ventilation time t
Safety time t
ignition in process,
V1 opens and
min. burner on time t
If parameter P30 = 1:
air valve opens with V1
If no flame detected or air flow decreases:
max. 3 start-up attempts
or fault lock-out
Flame proving period t
running (P23)
In the event of flame failure or air flow failure:
fault lock-out
Operation signalling contact closes and
V2 opens
running (P37)
VL
running (P22),
SA
starts to elapse (P20)
B
FS
If both flame and air flow are detected during the safety time tSA,
the flame proving period tFS starts
after this safety time has elapsed.
Valve V2 opens and the operation signalling contact between
terminals 16 and 17 closes. This
completes start-up. An adjustable
min. burner on time tB ensures that
the burner burns for a defined period even if the start-up signal (ϑ) is
switched off beforehand.
The burner can also be started
manually with the aid of the switch
on the BCU. Voltage must be applied continuously to terminals 1, 4
and 5 in order for this to occur.
The BCU can also be operated in
Manual mode for start-up.
In the event of flame failure or air flow failure:
BCU 460, BCU 465 · Edition 03.16l 37
restart
or fault lock-out
Page 38
A2
A3
A4
If parameter P30 = 1:
air valve opens with V1
If no flame detected or air flow decreases:
max. 3 start-up attempts
or fault lock-out
In the event of flame failure or air flow failure:
restart
or fault lock-out
Operation signalling contact closes and
V2 opens
Flame proving period t
FS
running (P23)
In the event of flame failure or air flow failure:
fault lock-out
Safety time t
SA
running (P22),
ignition in process,
V1 opens and
min. burner on time t
B
starts to elapse (P20)
Function
A4
A0
min. burner pause time tBP starts to elapse (P21)
Controlled shut-down
via ϑ signal
If min. burner on time t
the operation signalling contact opens and
Post-ventilation time t
V1 and V2 close
has elapsed:
B
running (P38)
NL
Start-up without flame signal/
without air flow
If no flame or no air flow is detected
during start-up, either a fault lock-
out occurs or up to two further
start-up attempts occur. The re-
quired functions and, if applicable,
the number of start-up attempts
must be specified when ordering
(parameter 10, “Burner start-up attempts”).
Behaviour in the event of flame
failure/air flow failure during
operation
If the flame or air flow fails during
operation, either an immediate fault
lock-out or a restart occurs. This
procedure can be set via the optical
interface (parameter 12, “Burner
restart”).
BCU 460, BCU 465 · Edition 03.16l 38
Page 39
Function
▼
3.6 Program status and fault messages
Program status
BCU switched off
Start-up position/Standby
Purge
Waiting time/Pause time
Safety time on start-up
Flame proving period
Normal operation
Air valve
Pre-ventilation
Post-ventilation
Cooling
POC (proof-of-closure)
POC (proof-of-closure)
POC (proof-of-closure)
High temperature operation
DISPLAY
– –
00
P0
1
2
3
4
10
A
A1
A0
A0
0
P
0
1
X
X
. .
P
Fault message (flashing)
BCU 460
BCU 465
BCU 465T
BCU 460..B1
BCU 465..B1
BCU 465T..B1
Flame simulation
Start-up without flame signal
Flame failure during flame proving period
Flame failure during operation
Too many remote resets
Air pressure switch “no flow” state
No air flow during purge
Fault Position indicator during star t-up
Valve not closed
Fault Position indicator in position X
No air flow in position X
Bus fault
BCU 460, BCU 465 · Edition 03.16l 39
Page 40
Function
Program status
DISPLAY
30
31
32
33
51
52
53
In Manual mode, two dots will blink on the display in program status 01 –04 .
* FS = input/output, safety circuit, NFS = input/output, control system.
Fault message (flashing)
EEPROM data change, NF S*
EEPROM data change, FS*
Undervoltage in power pack
Faulty parameterization
Bus module fault
Safety interlock failure
Permanent remote reset
Timing cycle too shor t
BCU 460
BCU 465
BCU 465T
BCU 460..B1
BCU 465..B1
BCU 465T..B1
BCU 460, BCU 465 · Edition 03.16l 40
Page 41
Parameters
▼
4 Parameters
Description Parameter Value range
Burner flame signal 01
0–99 μA
Program status on last fault 03 x0–x8
Switch-of f threshold of the flame amplifier 04
1–20 µA 1 µA
Air flow monitoring during purging (BCU 465..L) 06 0; 1 1
Air flow monitoring during operation (BCU 465..L) 07 0; 1 1
Delayed air flow monitoring (BCU 465) 08 0; 1 0
Position indicator input on BCU 465T..O (POC) 09 0; 1 1
Burner start-up attempts 10 1–3 1
Fault lock-out or restart 12 0; 1 0
Safety time during operation t
for V1 and V2 14 1; 2 s 1 s
SB
Flame-simulation check in star t-up position/standby 15 0; 1 1
Minimum burner on time t
B
Minimum burner pause time t
Safety time on start-up t
Flame proving period t
SA
FS
BP
20 tSA–25 s t
21 0–250 s 0 s
22 3; 5; 10 s
23 0–25 s 0 s
Air valve control on BCU..L 30 0; 1; 2; 3 0
Air valve control on BCU..L 31 0; 1 0
Behaviour of the air valve af ter a fault lock-out 32 0; 1 1
High temperature operation in the case of BCU..D2 or BCU..D3 33 2; 3
Manual mode limited to 5 minute s 34 0; 1 1
UVS check 35 0; 1 0
Low fire over run-time t
after a controlled shut-down 36 0; 5; 15; 25 s 0 s
KN
Factory
default
setting
Adjustable*
BCU 460
(BCU
460..B1)
BCU 465
(BCU
465..B1)
BCU 465T
(BCU
465 T..B1 )
**
**
**
**
** ** **
** ** **
SA
** ** **
** ** **
** ** **
BCU 460, BCU 465 · Edition 03.16l 41
Page 42
Parameters
Description Parameter Value range
Pre-ventilation time t
Post-ventilation time t
Pre-ventilation time after safety shut-down (BCU 465..L) 39 0–250 s 0 s
Pre-ventilation for restart/start-up attempts (BCU 465..L) 40 0; 1 1
Pre-ventilation after re set (BCU 465..L) 41 0; 1 1
= standard, = available.
* Adjustable using BC Sof t sof tware and a PC opto-adapter
** Please quote in your order
0 = Function inactive,
1 = Function active.
before start-up (BCU 465..L) 37 0–250 s 0 s
VL
after a c ontrolled shut-down (BCU 465..L) 38 0–3 s 0 s
NL
Factory
default
setting
4.1 Scanning the parameters
During operation, the 7-segment display shows the pro-
gram status, see page 39 (Program status and fault
messages).
The flame signal and all following parameters of the
BCU can be scanned one after the other by repeatedly
pressing the Reset/Information button (for 2 seconds).
In the event of a fault, the BCU halts the program run,
the display blinks and it then displays the cause of the
fault in coded form.
Adjustable*
BCU 460
(BCU
460..B1)
BCU 465
(BCU
465..B1)
** **
** **
** **
BCU 465T
(BCU
465 T..B1 )
BCU 460, BCU 465 · Edition 03.16l 42
Page 43
Parameters
4.2 Flame control
4.2.1 Burner flame signal
Parameter 01
Flame signal of the burner, display in µA , measuring
range: 0–30 µA.
4.2.2 Switch-off threshold of the flame amplifier
Parameter 04
The sensitivity at which the burner control unit still de-
tects a flame can be set between 1 and 20 µA.
Example: in the case of UV control with the UV sensor
UVS, the signal of the burner to be monitored is influenced by other burners.
The set value can be incremented in parameter 04 so
that only the flame of the system’s “own” burner is detected.
The measured flame signal of the system’s “own” burner
should be at least 3 µA (empirical value) higher than the
set switch-off threshold.
BCU 460, BCU 465 · Edition 03.16l 43
Page 44
Parameters
▼
4.2.3 High temperature operation in the case of BCU..D2 or BCU..D3
Parameter 33
Operation of firing systems at temperatures above
750°C. The BCU features a fail-safe DI input (DI = Digi-
tal Input). This input supports the “High temperature
operation” function. If firing systems are operated
above 750°C, the system is considered to be a high
temperature equipment (see EN 7462). Flame control
must be in operation until the furnace wall temperature
has exceeded 750 °C.
Frequently, flame control is dispensed with so as to
achieve a particularly high flexibility of the installation.
This means that no incorrect flame signals, e.g. signals
from a UV sensor which are interpreted as extraneous
signals due to reflection of UV radiation, may lead to
faults.
When the DI input is activated, the burner control unit
reverts to this operating mode, i.e.: the BCU operates
without evaluation of the flame signal. The safety
function of the device-internal flame control system
is placed out of operation.
In High temperature mode, the gas valves are opened
without flame control.
The precondition for this operating mode is that an ex-
ternal flame supervision device ensures the presence of
the flame in fail-safe manner indirectly via the temperature. For this purpose, we recommend a safety temper-
ature monitor with double thermocouple (DIN 3440).
Sensor discontinuity, sensor short-circuit, failure of a
component or mains failure must set the installation to
a safe state.
The voltage may be applied to the DI input (terminal
6) so as to activate High temperature operation only
when the temperature at the furnace wall has exceeded
750°C. The BCU then starts the burner as usual but
without monitoring the presence of the flame.
88 04 02 03 00
1
5
ϑ
4
DI
6
7
9
V1
12
14 V2
16-17
18-19
t
Z
t
SA
t
FS
t
If the temperature in the furnace chamber drops below
750°C, the DI input must be disconnected from the
electrical power supply and the furnace must then be
operated with flame control.
BCU 460, BCU 465 · Edition 03.16l 44
Page 45
Parameters
t
t
The BCU then responds, depending on setting:
Parameter 33 = 2 (BCU..D2)
88 04 04 02 03 01
1
5
ϑ
4
DI
6
7
9
V1
12
14 V2
16-17
18-19
t
Z
t
t
W
SA
t
FS
t
The BCU switches off the burner and restarts with
flame simulation check (recommended in the case of
UV control with UVS).
Parameter 33 = 3 (BCU..D3)
88 04 04
1
5
ϑ
4
DI
6
7
9
V1
12
14 V2
16-17
18-19
The burner remains in operation and the BCU performs
flame control again (recommended in the case of ionization control or UV control with UVD).
If no flame signal is present when High temperature operation is deactivated, the burner control unit performs
a fault lock-out, regardless of parameter 33.
04
88 04
1
5
ϑ
4
DI
6
7
9
V1
12
14 V2
16-17
18-19
Note the requirements of the Standards!
BCU 460, BCU 465 · Edition 03.16l 45
Page 46
Parameters
4.2.4 UVS check
Parameter 35
An automatic restart of the burner control unit can be
activated every 24 hours via this parameter. The time
starts each time the start-up signal (ϑ) is applied.
Parameter 35 = 0: unlimited burner operation.
Parameter 35 = 1: an automatic restart is activated
once every 24 hours.
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 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.
BCU 460, BCU 465 · Edition 03.16l 46
Page 47
Parameters
t
88 00 02 . . . 01
t
W
V1
4.3 Behaviour in start-up position/standby
4.3.1 Flame-simulation check in start-up position/ standby
Parameter 15
This defines the instant for the flame simulation check.
88 00 02 . . . 01
V1
t
W
Parameter 15 = 0: The flame simulation check is con-
ducted after applying the start-up signal (ϑ) during the
waiting time tW.
Parameter 15 = 1: The flame simulation check is con-
ducted provided no start-up signal (ϑ) is applied (during
the so-called start-up position/standby). This allows
fast start-up of the burner since there is no waiting time
tW.
The burner must have been switched off for at least 4 s
before start-up in order for the flame simulation check
to be conducted correctly.
What is an extraneous signal?
An extraneous signal is an incorrect signal which is
detected as a flame signal out of sequence. If the BCU
t
88 02 . . . 00
V1
t
460 or BCU 465 notices such an extraneous signal
during the flame simulation check, it starts the flame
simulation delay time t
for 25 s. If the extraneous sig-
LV
nal is discontinued during this period, the burner can
start up. Otherwise, a fault lock-out occurs. 01 blinks
on the display.
Flame simulation check in standby position (parameter
15 = 1):
01
t
LV
8800
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
Flame simulation check on start-up (parameter 15 = 0):
00 01 88
t
LV
01
18-19
1
4
ϑ
7
12
V1
9
14
V2
t
The flame simulation check of the burner is active until
valve V1 is enabled.
BCU 460, BCU 465 · Edition 03.16l 47
Page 48
Parameters
4.3.2 Position indicator input on BCU 465T..O (POC)
Parameter 09
For applications in accordance with the requirements of
NFPA 86:2003 with more than 117 kW (400,000
BTU/h), two gas solenoid valves are required, one of
which is to be equipped with a position indicator.
BCU 465T..O
12 21
V1
V2
OCS
M
mA
Parameter 09 = 1: A signal is sent to the BCU via the
position indicator on the gas solenoid valve V1 stating whether the valve is closed or open. In standby, the
switch must be closed. During start-up and operation,
the switch must be open. This ensures that valve V1 is
open or closed.
BCU 460, BCU 465 · Edition 03.16l 48
Page 49
Parameters
4.3.3 Minimum burner pause time tBP
Parameter 21
Programmable time between 0 and 250 s.
01 00
t
t
Z
BP
t
SA
t
FS
88 04 02 03 04
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
An immediate restart of the burner after a controlled
shut-down is prevented by the pause time. The pause
time starts when the burner is switched off. If a start-up
signal (ϑ) is applied before expiry of this time, start-up is
delayed until the end of the pause time.
After the pause time, the burner is started if the start-
up signal (ϑ) is applied.
The minimum burner pause time t
serves to adapt the
BP
program sequence to the requirements of the application.
The time should be set such that the system can be
moved to ignition position, i.e. air valves or butterfly
valves can be closed and, possibly, gas can be flared off,
before a restart occurs.
Example of application
L1, N, PE
DI
PLC
BCU 460..L
VG..N
VR..R
DI
5
6
3
12
P
26
A
22
GIK..B
23 4
µC
P
19
18
17
16
9
BIO
BIC
BCU 460, BCU 465 · Edition 03.16l 49
Page 50
Parameters
4.4 Behaviour during start-up
4.4.1 Safety time on start-up tSA
Parameter 22
88 04 02 03 00
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
Z
t
SA
t
FS
This indicates the safety time on start-up tSA for the
burner.
4.4.2 Minimum burner on time t
B
Parameter 20
Programmable time in the range from minimum safety
time on start-up t
to maximum 25 s during which the
SA
burner remains in operation.
In the case of brief activation of the start-up signal input (ϑ) (e.g. with a pulse), the burner on time t
ed, and the burner remains in operation for at least this
period. This time is independent of the pre-ventilation
time.
t
B
is start-
4.4.3 Flame proving period t
FS
Parameter 23
88 04 02 03 00
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
Z
t
SA
t
FS
t
Programmable time between 0 and 25 s.
This time elapses before the BCU starts the next pro-
gram step so as to give the flame time to stabilize.
4.4.4 Burner start-up attempts
Parameter 10
This indicates the number of possible start-up attempts
of the burner.
In accordance with EN 7462, a maximum of three start-ups
are permitted in specific cases if the safety of the installation
is not impaired. Note the requirements of the Standards!
If no flame is detected or, in the case of BCU 465, if the
air flow fails during start-up, either a fault lock-out occurs or up to two further start-up attempts occur. The
required functions and, if applicable, the number of
start-up attempts must be specified when ordering.
▼
BCU 460, BCU 465 · Edition 03.16l 50
Page 51
Parameters
1 start-up attempt
Parameter 10 = 1
02
t
Z
t
SA
88 02 00
1
5
4
7
9
V1
12
14 V2
16-17
18-19
t
If no flame forms or, in the case of BCU 465, if the air
flow fails during start-up, a fault lock-out is performed
after expiry of time tSA. The display blinks and shows
the cause of the fault.
2–3 start-up attempts
Parameter 10 = 2–3
01 02
t
Z
t
SA
t
Z
t
t
SA
W
880200
1
5
ϑ
4
7
9
12
14 V2
16-17
18-19
V1
t
If several start-up attempts are set at the works and if
the BCU detects an installation fault during start-up, it
closes valve V1 after the safety time tSA has expired and
attempts to start up again. After the last programmed
start-up attempt has been completed, the burner control unit conducts a fault lock-out. The display blinks
and shows the cause of the fault.
BCU 460, BCU 465 · Edition 03.16l 51
Page 52
Parameters
4.5 Behaviour during operation
4.5.1 Safety time during operation tSB for V1 and V2
Parameter 14
This indicates the safety time during operation t
valves V1 and V2.
The default in accordance with EN 298 is 1 s.
The BCU has also the available option of t
SB
longing the time increases the installation availability
in the case of brief-duration signal fades (e.g. fades of
the flame signal or, on BCU 465, in the case of pressure
switch drop-out).
In accordance with EN 7462, the safety time of the
installation during operation (including closing time of
the valves) may not exceed 3 s.
Note the requirements of the Standards!
4.5.2 Fault lock-out or restart
Parameter 12
This parameter determines whether the BCU starts a
one-off restart or performs an immediate fault lock-out
for the burner after an installation fault (flame failure or
failure of air flow).
for
SB
of 2 s. Pro-
BCU 460, BCU 465 · Edition 03.16l 52
Page 53
Parameters
W
4.5.3 Immediate fault lock-out after installation fault
Parameter 12 = 0: Fault lock-out after installation fault.
04
t
SB
88 04
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
After an installation fault (flame failure or failure of air
flow), the burner control unit performs a fault lock-
out within the safety time during operation tSB. This
involves disconnecting the power from the gas valves
and, if applicable, the ignition transformer. The fault
signalling contact closes, the display blinks and shows
the current program status, see table on page 39
(Program status and fault messages).
See also parameter 32, page 59 (Behaviour of the air
valve after a fault lock-out).
After a fault lock-out, the burner control unit can be
reset, either with the button on the front panel or using
an external button. Several burner control units can be
reset in parallel using the external button.
The BCU cannot be reset by mains failure. The fault
signalling contact does, however, open as soon as the
mains voltage fails.
Restart following flame failure
Parameter 12 = 1: Restart after installation fault.
1x
88 04 04 02 03 01
1
5
ϑ
4
7
9
V1
12
>2 s
t
t
SB
t
Z
t
t
SA
FS
14 V2
16-17
18-19
t
If the BCU detects an installation fault (flame failure or
failure of air flow) after a minimum operating time of 2 s,
the valves are closed and the operation signalling contact is opened within time tSB.
The burner control unit now attempts to restart the
burner once. If the burner does not function, a fault
lock-out is performed. The display blinks and shows the
cause of the fault.
In accordance with EN 7462, a restart may be conducted only if the safety of the installation is not impaired. Restart is recommended for burners which occasionally display unstable behaviour during operation.
The precondition for a restart is that activation of the
restart allows the burner to restart as intended (in all
operating phases). In this case, it must be ensured that
the program sequence started by the BCU matches the
application.
BCU 460, BCU 465 · Edition 03.16l 53
Page 54
Parameters
4.5.4 Program status on last fault
Parameter 03
This indicates the program status in which the last
burner fault occurred.
Example: the unit indicates that the safety interlocks
have been interrupted with a blinking
Parameter 03 can now be used to scan in what program
status the BCU was when the fault was detected.
51
.
BCU 460, BCU 465 · Edition 03.16l 54
Page 55
Parameters
4.6 Air valve control on BCU..L
Parameter 30, “Air valve control ”
Parameter 31, “Air valve can be activated externally on
start-up”
Parameter 32, “Air valve closed/can be activated in the
event of malfunction”
The BCU..L features an adjustable air valve control. The
display shows that purging is currently being carried
out with
activated for cooling or heating. The BCU supports the
following functions:
4.6.1 Purge
In the case of multiple burner applications, burners with
mechanical combustion air supply are used. The air for
combustion and pre-purge is supplied by a central fan
controlled by a separate logic. This logic determines the
purging time.
The BCU..L..E1 (BCU with adapted power management)
supports centrally-controlled pre-purge or post-purge.
The BCU..L is informed that purging is currently being
performed by input 22. It then opens the air valve, regardless of the status of the other inputs (purging has
priority). The display indicates
On BCUs without power management, input 22 and in-
put 5 (safety interlocks) must be activated for purging,
see from page 13 (Connection diagrams).
P0
. A indicates that the air valve is being
P0
.
BCU 460, BCU 465 · Edition 03.16l 55
Page 56
Parameters
4.6.2 Cooling in start-up position/standby
The air valve can be activated externally by input 23 for
cooling in the start-up position. During activation of the
air valve, the display shows
A0
, indicating that cooling
is currently being carried out.
Parameters 30 and 31 determine the behaviour of the
air valve during burner start.
4.6.3 Air valve opens in the case of external activation (not during start-up)
88 A4 02 03 00 A0
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
16-17
18-19
t
t
Z
FS
t
SA
t
Parameter 30 = 0: The air valve opens if it is activated
externally by input 23.
Parameter 31 = 0: The air valve remains closed during
start-up even if it is activated externally.
These settings are required on burners on which the
gas/air ratio is controlled by a pneumatic air/gas ratio
control system link and which also need to be started at
low fire, e.g. on two-stage-controlled burners, see page
8 (BCU 460..L: Two-stage-controlled burner). In
this case, activation of the air valve during burner start
via input 23 must be prevented.
External control allows switchover between low fire and
high fire during operation.
BCU 460, BCU 465 · Edition 03.16l 56
Page 57
Parameters
4.6.4
Air valve opens in the case of external activation
(even during start-up)
A0
t
t
Z
FS
t
SA
Parameter 30 = 0: The air valve opens if it is activated
externally by input 23.
Parameter 31 = 1: The air valve can be activated even
during start-up.
These settings may be selected only if the burner can
start with full air capacity.
4.6.5 Air valve opens with valve V1
t
t
Z
FS
t
SA
88 A4 A2 A3 00 A0 00
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
16-17
18-19
88 A4 A2 A3 00 00 A0
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
16-17
18-19
t
t
Parameter 30 = 1: The air valve opens simultaneously
with valve V1.
It can be activated externally via input 23 for cooling
the burner in the start-up position/standby.
4.6.6 Air valve opens with valve V2
00 A0
t
t
Z
FS
t
SA
88 A4 02 03 00
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
16-17
18-19
t
Parameter 30 = 2: The air valve opens simultaneously
with valve V2.
It can be activated externally via input 23 for cooling
the burner in the start-up position/standby.
BCU 460, BCU 465 · Edition 03.16l 57
Page 58
Parameters
4.6.7 Low fire over run-time tKN after a controlled
shut-down
Parameter 36
Value range 0, 5, 15 or 25 s
This parameter is applicable to systems with pneumatic
air/gas ratio control system and On/Off control.
Parameter 36 t
= 0: Without low fire over-run, the gas
KN
circuit is closed immediately owing to the quick-closing
gas valve in the case of On/Off control. The air circuit
closes more slowly. The air flowing in during the closing
time increases the O2 percentage in the combustion
chamber.
Parameter 36 t
= 5, 15 or 25 s: The air valve is closed
KN
with deactivated start-up signal (ϑ). The gas valve remains open for tKN. This means that the burner, after
deactivation of the start-up signal (ϑ), is initially adjust-
ed down to low fire and then switched off completely.
Using the low fire over-run function reduces the O
per-
2
centage in the furnace atmosphere.
Flame control is still operational.
Can be used only in the case of a pneumatic air/gas ra-
tio control system and On/Off control.
Its must be ensured that no excess gas occurs.
BCU 460..L
VG..N
VR..R
L1, N, PE
DI
P
PLC
DI
6
3
A
P
5
23 4
22
µC
12
26
GIK..B
9
BIO
BIC
t
KN
88 00 A4
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
16-17
18-19
19
18
17
16
t
BCU 460, BCU 465 · Edition 03.16l 58
Page 59
Parameters
4.6.8 Behaviour of the air valve after a fault lock-out
Parameter 32
This determines whether the air valve can be activated
in the case of a fault lock-out.
Parameter 32 = 0: The air valve is closed in the event of
a fault. It cannot be activated externally.
Parameter 32 = 1: The air valve can be activated exter-
nally by input 23 even during a fault, e.g. for cooling.
BCU 460, BCU 465 · Edition 03.16l 59
Page 60
Parameters
4.7 Extended air control with BCU 465..L
For use on recuperative burners, the BCU 465..L fea-
tures an extended air control which meets the specific
requirements of such burners.
4.7.1 Air flow monitoring during purging (BCU
465..L)
Parameter 06
This parameter determines whether the air flow is moni-
tored during pre-purge.
Parameter 06 = 0: The air flow is not monitored during
pre-purge.
Parameter 06 = 1: The air flow is monitored during pre-
purge (pressure switch signal at terminal 21), i.e.
Check of the LOW signal (pressure switch contact
open)
No air may flow before pre-purge. A LOW signal must
be applied to the pressure switch. If the LOW signal is
not applied, the BCU performs a fault lock-out after expiry of a delay time (as long as the flame simulation delay time t
failed.
). Fault message: 0, “no flow” state check
LV
Check of the HIGH signal (pressure switch contact
closed)
The air must flow and a HIGH signal must be applied to
the pressure switch during pre-purge. If the HIGH signal is not applied, the BCU performs a fault lock-out after expiry of the testing time (as long as the safety time
on start-up). Fault message:
P
, no air flow.
BCU 460, BCU 465 · Edition 03.16l 60
Page 61
Parameters
4.7.2 Pre-ventilation time tVL before start-up (BCU
465..L)
Parameter 37
Value range 0–250 s
This can be set in 0.1 s steps in the range 0 to 10 s,
in 1 s steps in the range 10 to 250 s.
This parameter is used to determine the time during
which the air valve is already open before normal startup. This time may also be used for pre-purge.
Suitable for burners starting with full air capacity.
Parameter 37 > 0 up to max. 250 s:
A1
t
t
Z
LV
t
SA
88 A2 A4 00
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
21
16-17
18-19
t
(Parameter setting for this example sequence:
P15 = 1, P23 = 0, P30 = 1, P37 > 0), see page 41 (Parameters). The gas valve does not open until the pressure switch has switched.
After the start-up signal (ϑ) has been applied and after
the flame simulation check and “no flow” state check
have been conducted successfully, the air valve is
opened. Start-up of the burner commences as usual
with no interruption of the air after expiry of the programmable pre-ventilation time tVL.
BCU 460, BCU 465 · Edition 03.16l 61
Page 62
Parameters
4.7.3 Air flow monitoring during operation (BCU
465..L)
Parameter 07
This parameter determines whether the air flow is moni-
tored during operation.
Parameter 07 = 0: The air flow is not monitored during
operation.
Parameter 07 = 1: The air flow is monitored during op-
eration (pressure switch signal at terminal 21), i.e.
Check of the LOW signal (pressure switch contact
open) before starting the program run
No air may flow before the program run is started. A
LOW signal must be applied to the pressure switch. If
the LOW signal is not applied, the BCU performs a fault
lock-out after expiry of a delay time (as long as the
flame simulation delay time t
). Fault message: 0,
LV
“no-flow” state check failed.
Check of the HIGH signal (pressure switch contact
closed) after activating the air valve
The air must flow and a HIGH signal must be applied to
the pressure switch after the air valve has been activated. If the HIGH signal is not applied within a specified
testing time (as long as the safety time on start-up t
SA
the BCU performs a fault lock-out. Fault message: ,
no air pressure in operating state.
If the air pressure drops during operation, the BCU
conducts either a fault lock-out (fault message:
a restart as in the event of flame failure. Should restart
2
fail, fault message
is displayed.
),
4
) or
BCU 460, BCU 465 · Edition 03.16l 62
Page 63
Parameters
4.7.4 Delayed air flow monitoring (BCU 465)
Parameter 08
Supplementary setting for parameter 07
Is the gas to be released with or without pressure
switch signal?
Parameter 08 = 0: Gas is released only with pressure
switch signal.
Parameter 08 = 1: Gas is released even without pres-
sure switch signal. The scan is conducted after a delay
time.
4.7.5 Post-ventilation time t
after a controlled
NL
shut-down (BCU 465..L)
Parameter 38
Value range 0–3 s
88 00 A0 A4
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
21
16-17
18-19
t
NL
t
The air valve remains open for the programmed time
after the start-up signal (ϑ) has been deactivated. The
burner control unit closes the air valve after expiry of
the post-ventilation time tNL.
BCU 460, BCU 465 · Edition 03.16l 63
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Parameters
4.7.6 Pre-ventilation time after safety shut-down (BCU 465..L)
Parameter 39
Value range 0 – 250 s
This can be set in 1 s steps.
This determines the time for which pre-purge is to occur
after a safety shut-down.
A1
t
VL
A1
t
t
t
BP
Z
VL
t
SA
88 A2 A4 01
1
5
ϑ
4
7
9
V1
12
14 V2
A
23
26
21
16-17
18-19
t
With this function, the combustion chamber can be
purged after a safety shut-down in compliance with
standards, especially on radiant tube burners. This task
is not implemented by a central control system but by
the BCU 465. See also parameters 40 and 41.
4.7.7 Pre-ventilation for restart/start-up attempts (BCU 465..L)
Parameter 40
This parameter determines whether the pre-ventilation
time (parameter 39) is to run after a restart or after the
start-up attempts.
Parameter 40 = 0: The pre-ventilation time is deactivated on restart and in the case of several start-up attempts.
Parameter 40 = 1: The pre-ventilation time is activated
in the case of restart and several start-up attempts.
4.7.8 Pre-ventilation after reset (BCU 465..L)
Parameter 41
This parameter determines whether the pre-ventilation
time (parameter 39) is to run in the case of a reset after
a fault lock-out.
Parameter 41 = 0: The pre-ventilation time is deactivated after a reset.
Parameter 41 = 1: The pre-ventilation time is activated
after a reset with the start-up signal (ϑ).
BCU 460, BCU 465 · Edition 03.16l 64
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Parameters
4.8 Manual mode
For convenient setting of the burner or analyzing faults.
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.
In this operating mode, the burner control unit operates
independently of the status of the inputs (apart from
the pre-purge input and the safety interlocks).
Each time after the button is pressed again, the BCU
moves to the next section of the program sequence
and stops there. The flame signal is indicated instead of
the operating status after approx. 3 s when the operating status is reached.
On units with air valve control, the air valve can be
opened and closed repeatedly by pressing the button
during operation.
4.8.1 Manual mode limited to 5 minutes
Parameter 34
Parameter 34 determines when Manual mode is terminated.
Parameter 34 = 0: Manual mode is not limited in time.
If this function has been selected, operation of the furnace may be continued manually in the event of failure
of the central control system.
Parameter 34 = 1: Manual mode ends automatically
five minutes after the last time the button was pressed.
The BCU then moves abruptly back to start-up position/
standby.
Manual mode can always be terminated independently
of parameter 34 by switching off the BCU.
BCU 460, BCU 465 · Edition 03.16l 65
Page 66
Selection
5 Selection
T -3 -5 -10 /1 /2 L 5 15 25 W R 1 2 3 8 GB1)P D2 D3 S2 – 3 A O2)U C B1 /1 E1
BCU 460
BCU 465
= standard, = available. 1) Not available for BCU..T. 2) Only available for BCU..T.
5.1 Type code
Code Description
BCU Burner control unit
4 Series 4
60
65
3; 5; 10 Safety time on start-up t
1; 2 Safety time during operation t
L* Air valve control
5*; 15*; 25* Low fi re over-run time [s]
W
R
1*
2*
3*
8*
GB* Front fi lm in English with additional stickers in D, F, I, NL, E
P* Industrial plug connector
D2*
D3*
S2*–3* Number of start-up attempts
A*
O*
U*
C*
B1* For PROFIBUS DP
/1* 9-pin DSub bus plug connector
E1* Power management via phase (L1)
* If “none”, this specifi cation is omitted. Please quote the default parameter settings when ordering.
Mains voltage: 230 V AC, 15/+10% , 50/60 Hz
High temperature operation in conjunction with: … UVS
Preparation for UV sensor for continuous operation UVD 1
Order example
BCU 4655/1LW3GBACE1
Standard version
Extended air control
SA
SB
115 V AC, 15/+10%, 50/60 Hz
Ignition transformer: TZI 515/100
T ZI 725 /20
T ZI 7,5 12 /1 00
TZI 7,520/33
... ionization sensor or UVD
Air fl ow monitoring
Position indicator feedback
Additional signal distribution
[s]
[s]
BCU 460, BCU 465 · Edition 03.16l 66
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Project planning information
6 Project planning information
6.1 Cable selection
Use mains cable suitable for the type of operation and
complying with local regulations.
Signal and control line: max. 2.5 mm
Cable for burner ground/PE wire: 4 mm
Burner ground connector may also be located outdoors.
Do not route BCU cables in the same cable duct as
frequency converter cables or cables emitting strong
fields.
6.1.1 Ionization cable
Use unscreened high-voltage cable, see page 81
(Accessories).
Recommended cable length: max. 50 m.
Lay cable individually and, if possible, not in a metal
conduit.
Install well away from mains cables and interference
from electro-magnetic sources.
Do not lay together with ignition cable.
6.1.2 Ignition cable
Use unscreened high-voltage cable, see page 81
(Accessories).
Cable length for integrated ignition. max. 5 m (16.4 ft).
Avoid external electrical interference. The longer the ig-
nition cable, the lower the ignition capacity.
2
.
2
.
Lay cable individually and, if possible, not in a metal
conduit.
Do not lay UV/ionization cable and ignition cable to-
gether and lay them as far apart as possible.
Screw the ignition cable securely into the ignition trans-
former and feed it out of the unit on the shortest pos-
sible route (no loops) – use the left-hand M20 plastic
cable gland.
Only use radio interference suppressed electrode plugs
(with 1 kΩ resistor) for ignition electrodes, see page
81 (Accessories).
6.1.3 UV cable
Recommended cable length: max. 50 m.
Install well away from mains cables and interference
from electro-magnetic sources.
Do not lay together with ignition cable.
6.2 Ignition electrode
6.2.1 Electrode distance
Gap between electrode and burner ground:
2 mm ± 0.5 mm.
6.2.2 Star electrodes
We recommend using 7.5 kV ignition transformers on
burners with star electrodes.
BCU 460, BCU 465 · Edition 03.16l 67
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Project planning information
6.3 Calculating the safety time tSA
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Project planning information
6.4 Minimum burner on time
Even if the start-up signal (ϑ) is applied only briefly, the
time set under parameter 20 elapses. The minimum
burner on time tB can be extended beyond the safety
time tSA to max. 25 s.
The signal input for the burner start-up signal cannot
be used for a safety shut-down because the BCU controls the valves until the minimum burner on time has
elapsed.
88 04 02 03 00
1
5
ϑ
4
7
V1
12
14 V2
9
16-17
18-19
t
SA
t
B
t
6.5 Safety interlock (Limits)
The limiters in the safety interlock (linking of all the rel-
evant safety control and switching equipment for the
use of the application, for example STL (safety temperature limiter), Gas
purge...) must isolate terminal 5 from the voltage supply.
If the safety interlock is interrupted, the display shows a
blinking
51
to indicate a fault.
min
, Gas
, tightness control, pre-
max
6.6 Protection of safety-relevant outputs
When commissioning, do not switch the safety-relevant
outputs to a short-circuit.
Before switching on, ensure that outputs 7, 12 and 14
are not overloaded (> 3 A), using an ohmmeter, for ex-
ample.
All safety-relevant outputs of the BCU are fused with
an internal, replaceable fuse, see page 13 (Connec-
tion diagrams). This affects the outputs for ignition, gas
valve V1 and gas valve V2.
In the event that the second internal, non-replaceable
fuse for these outputs blows, the unit must be sent to
the manufacturer for repair.
6.7 Emergency stop
6.7.1 In the event of fire or electric shock
If there is a risk of fire, electric shock or similar, inputs
L1, N and 5 (safety interlocks) of the BCU should be
disconnected from the electrical power supply – this
should be reflected in the wiring on site.
6.7.2 Triggered by the safety interlock (limits)
The safety interlock turns off the power to the input 5,
such as in the event of low air pressure or similar.
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Project planning information
6.8 Reset
6.8.1 Parallel reset
Several automatic burner control units can be reset in
parallel using an external button. The BCU cannot be
reset by mains failure.
6.8.2 Permanent remote reset
Permanent remote reset gives rise to a malfunction. If
a remote reset signal is permanently applied to terminal 3, 52 flashes on the display to indicate a fault.
Reset with a pulse < 1 s.
6.8.3 Automatic remote reset (PLC)
In the case of automatic remote reset (PLC), the reset
pulse duration should not exceed 1 second. Check
compliance with Standards.
If a fault is acknowledged by remote reset too often, er-
10
ror
(Too many remote resets) is displayed. The error
can only be acknowledged with the Reset/Information
button on the unit.
The burner malfunction must be remedied. The malfunction cannot be remedied by changing the method
of activation.
6.9 Burner start
A furnace start may only be initiated, if it has been en-
sured using an appropriate procedure that there is no
combustible mixture in the combustion/processing
chamber, in the connected areas or in the exhaust gas
system (heat exchanger, dust collector). This can be
achieved by pre-purge, which occurs immediately before ignition or within the period specified in the operating instructions.
In the case of multiple burner applications, pre-purge is
not necessary after a controlled burner shut-down.
Note the requirements of the Standards. For exceptions,
see Standards.
6.10 Restart and start-up attempts
The precondition for a restart/start-up attempt is that
activation of the restart allows the burner to restart as
intended (in all operating phases). In this case, it must
be ensured that the program sequence started by the
BCU matches the application.
In accordance with EN 7462, a maximum of three
start-ups are permitted in specific cases if the safety of
the installation is not impaired. Note the requirements
of the Standards!
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Project planning information
6.11 Fault signalling
The fault signalling contact opens, as soon as the mains
voltage fails.
6.12 Overload protection
To protect the unit against overload by frequent cycling,
the BCU may not start up more than n times per minute.
Excessive cycling triggers a fault message (flashing
53
). The max. number (n) per minute depends on the
safety time tSA and the ignition transformer used.
t
SA
s
3 51 5/1 00 6
5 51 5/1 00 6
10 5 15/10 0 3
3 725/ 20 3
5 725/ 20 2
10 72 5/2 0 1
3 7,5 12 /100 6
5 7,5 12 /100 4
10 7,5 12 /10 0 2
3 7,520/33 4
5 7,520/33 3
10 7,520/33 2
Ignition transformer TZI Max. number n/min.
6.13 Installation
Recommended installation position: vertical (cable
glands pointing downwards).
When installing, ensure that there is suf ficient space to
open the BCU.
From inside
Open BCU and screw on with four screws (O 4 mm, min.
length 15 mm).
From outside
185 mm
7.28"
6.42"
163 mm
Screw on the closed unit to the rear with 4 self-tapping
screws (enclosed).
Otherwise, mount with external securing bars or the
fastening set, see page 81 (Accessories).
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Project planning information
6.14 Wiring
The BCU is suitable for hard wiring only. Do not reverse
phase and neutral conductor. Different phases of a
three-phase current system must not be installed at
the BCU.
No voltage may be connected to the valve and ignition
outputs.
No gas valve may be connected to the air valve output
(terminal 26).
See page 13 (Connection diagrams) onwards.
6.15 BCU and BCU..E1 (with and without adapted power management)
The BCU is available as a replacement unit for existing
systems in which a BCU is already in operation.
We recommend using a BCU with power management
(BCU..E1) when planning new systems. It features a
new power management scheme for simplified installation and control. The power for the ignition transformer
and valves is supplied via the phase (terminal 1) and
must no longer be supplied by the safety interlocks. No
effort and expenditure is thus required for coupling
contactors and their safety devices.
6.16 Signal distributor board
An additional signal distributor board (terminals
30–38) can be ordered for wiring additional relays, etc.
(BCU..C).
Protecting the control with an additional fuse F3 makes
troubleshooting easier in the event of a short-circuit
downstream of the pressure switch.
BCU 465..C
M L
40 41 42 43 44 45 46 47
F3
5
22
23
21 28 29
P
m
N
N
l
30 31 32 33 34 35 36 37 38 50 51
A
l
L1 (L1)
N (L2)
PE
Unit replacement
A BCU without power management may not be re-
placed with a BCU with power management (BCU..E1).
The reverse also applies, i.e. a BCU..E1 may not be re-
placed with a BCU without power management.
BCU 460, BCU 465 · Edition 03.16l 72
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Project planning information
6.17 PROFIBUS DP
6.17.1 Safety-related control signals
Signals from the safety interlocks and digital input are
transferred independently of the bus communication
by separate cables.
The purge signals can be transferred via the bus com-
munication or by a separate cable.
6. 17. 2 Wiring the PROFIBUS plug connector
BCU..B1/1
1B1A2B2A
ON
OFF
PROFIBUS DP
The PROFIBUS plug connector must be ordered sepa-
rately, see page 81 (Accessories).
Data cables A and B must not be reversed.
The power supply for the bus terminator is provided by
the BCU. The bus terminator can be connected in the
PROFIBUS plug connector.
Ensure an equipotential bond between the different
slaves and masters.
ON
OFF
cable must be used. The shield must be connected to
protective earth on both sides using wide-area shield
clips that ensure good conductivity.
In addition, it must be ensured that all cables leading to
and from the BCU
®
be installed as far away as possible
from cables emitting strong fields (e.g. frequency converter cables).
6. 17. 4 Unit replacement
A BCU..B1 (for PROFIBUS) may only be replaced by a
BCU..B1. BCUs without a PROFIBUS connection may
not be replaced by a BCU..B1.
6. 17. 3 EMC
To achieve a high immunity of the system against elec-
tromagnetic interference radiation, a shielded data
BCU 460, BCU 465 · Edition 03.16l 73
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Project planning information
6. 17. 5 Status and fault messages for PROFIBUS DP
This table can be used to program the master.
Input bytes (BCU ➔ master)
Byte 2
0
0
0
1
1
2
3
4
5
5
5
6
6
6
7
Display
00
A0
A0
01
A1
*
A1
02
A2
*
03
A3
*
04
A4
*
05
A5
*
0
C0
06
A6
*
C2
2
07
A7
*
Status signal
Byte 0, Bit 2 = 0
Start-up position/standby
Post-ventilation
Cooling
Waiting time/Pause time Flame simulation
Pre-ventilation
Safety time on start-up Start-up without flame signal
Flame proving period Flame failure during flame proving period
Operation Flame failure during operation
Waiting time, main burner Flame simulation, main burner
Safety time on start-up, main burner Start-up without fl ame signal, main burner
Flame proving period, main burner Flame failure during flame proving period, main burner
Fault signal
Byte 0, Bit 2 = 1
Air monitor break contact check
Fault Position indicator during star t-up
Fault Position indicator during safet y time
Fault Air supply during safety time
BCU 460..B1
BCU 465..B1
BCU 460, BCU 465 · Edition 03.16l 74
Page 75
Project planning information
Input bytes (BCU ➔ master)
Byte 2
7
7
8
8
8
9
9
10
11
12
30
31
33
51
52
53
99
* Display on BCU..L upon activation of the air valve during program step x
** FS = input /output, safety circuit, NFS = input /output, control system
= standard, = available
Display
C3
3
08
A8
*
C4
4
P0
P
10
1
A
30
31
33
51
52
53
88
Status signal
Byte 0, Bit 2 = 0
Operation, main burner Flame failure during main burner operation
Purge
EEPROM data change, NF S**
EEPROM data change, FS**
Faulty parameterization
Fuse F1 defective or safety interlocks
discontinuit y
Permanent remote reset
Timing cycle too shor t
Fault signal
Byte 0, Bit 2 = 1
Fault Position indicator during flame proving period
Fault Air supply during flame proving period
Fault Position indicator during operation
Fault Air supply during operation
Fault Air supply during purging
Too many remote resets
Fault Air supply during pre-ventilaton
Fault Air supply during post-ventilation
Internal error/negative flame current
BCU 460..B1
BCU 465..B1
BCU 460, BCU 465 · Edition 03.16l 75
Page 76
Project planning information
1 3
N
1 4 1 5
50 51
V3
V2
A
V1
VG..N
VR..R
BIO
BIC
VG..N
BCU 460..L
L1
ϑ
12
V2
1426
3
23
4
9 50
51
18
19/20
6.18 Third gas valve (can be shut down) on
BCU 460..L and BCU 465
Units with air valve control have an additional contact
(terminal 50/51), which closes at the same time as the
air valve.
This can be used to activate a third gas valve. To do this,
the output of valve V1 or V2 must be used as auxiliary
energy (as a result of the required flame monitoring).
The following application describes a two-stage-con-
trolled burner without a pneumatic air/gas ratio control
system. V2 and the air valve are activated simultaneously. However, V2 may not be activated during purging.
BCU 460, BCU 465 · Edition 03.16l 76
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Project planning information
6.19 BCU switched off
In general, the BCU cannot be activated when no mains
voltage is applied or the burner control unit is switched
off.
The fault signalling contact is only closed when the unit
is supplied with voltage and switched on.
6.20 Note on EC-type examination
Since EN 298 (1993) does not describe all functions of
the BCU, the operator is responsible for ensuring that
all parameters and functions are matched to the respective application.
6.21 Mains switch
The mains switch in the unit isolates the BCU on two
poles from the mains. It does not meet the requirements of EN 501561:2004 (5.2.2 Disconnecting
switch) set out in chapter 5 for a device to disconnect
the power supply.
Although the mains switch cannot be used for discon-
necting from the electrical power supply in accordance
with EN 50156, it does allow the burner to be isolated
functionally from the central control system. This func-
tion is required for manual operation and, in the case of
PROFIBUS units, to switch off the unit without causing
bus errors.
Disconnection for electrical maintenance work is to be
implemented with an external switch per unit or group
only, in accordance with Standard EN 50156.
6.22 SIL/PL level for thermoprocessing equipment
Since thermoprocessing installations include different
safety functions, it is not possible to determine a single
SIL/PL level for an entire installation, but this must be
determined separately for every safety function of the
installation.
See also page 86 (Safety-specific characteristic values).
BCU 460, BCU 465 · Edition 03.16l 77
Page 78
Project planning information
6.23 Changing parameters
In certain cases, it may be necessary to change the
default settings. Using a separate software package
and a PC opto-adapter, it is possible to modify certain
parameters on the BCU, such as the switch-off threshold of the flame amplifier, the behaviour in the event
of a flame failure or whether the pilot burner is to burn
permanently in the case of pilot and main burner monitoring.
The software package with PC opto-adapter, as well as
“Changed parameters” stickers, are available as acces-
sories – see page 81 (Accessories).
The unit parameters set at the factory are specified in
the enclosed delivery note.
Document changed parameters in BCSoft using the
protocol function and enclose the protocol with the
plant documentation.
If a replacement is ordered for a BCU with changed parameters, refer to the protocol for details.
BCU 460, BCU 465 · Edition 03.16l 78
Page 79
Flame control
7 Flame control
7.1 With ionization sensor
The BCU generates an alternating voltage (230 V AC)
between the sensing electrode and burner ground. The
flame rectifies this voltage. Only the DC signal (> 1 µA) is
detected by the burner control unit.
A flame cannot be simulated.
Ignition and monitoring with a single electrode is possible.
7. 2 With UV sensor
A UV tube inside the UV sensor detects the ultraviolet
light of a flame. It does not respond to sunlight, incandescent bulb light or infrared radiation emitted by hot
workpieces or red-hot furnace walls.
In the event of incident UV radiation, the UV sensor rectifies the supplied alternating voltage. As with ionization control, the burner control unit only detects this DC
signal.
When using UV sensors of Type UVS, the burner control
unit may be used for intermittent operation only. This
means that operation must be interrupted at least once
every 24 hours. This can be programmed by setting parameter 35 to 1.
Further information can be found in brochure UVS at
ww w.docuthek.com.
The burner control unit BCU..U is prepared for UV sen-
sor UVD 1. This enables continuous operation.
For flame control with UVD sensor, safety-specific characteristic values are available for the Safety Integrity
Level SIL.
Further information can be found in TI UVD 1 at www.
docuthek.com.
BCU 460, BCU 465 · Edition 03.16l 79
Page 80
Flame control
7.3 Via the temperature in high temperature equipment
High temperature equipment is defined as a thermo-
processing installation, in which the wall temperature of
the combustion chamber and/or the processing chamber exceeds 750°C.
Burner control units BCU..D2 and BCU..D3 feature a
special “High temperature operation” function, see
page 44 (High temperature operation in the case of
BCU..D2 or BCU..D3).
During heating up, standard monitoring methods (ionization or UV) must be used for flame control. When
the working temperature has exceeded 750°C, indirect
flame control can be taken over by a central monitoring
device. When the DI input (terminal 6) is activated, the
burner control unit reverts to this operating mode.
Important: in “High temperature operation” (HT operation), i.e. with the DI input being activated, burner control units BCU..D2 (D3) do not evaluate the flame signal.
The safety function of the burner control unit’s flame
control is deactivated during this operating phase.
BCU 460, BCU 465 · Edition 03.16l 80
Page 81
Accessories
8 Accessories
8.1 High-voltage cable
FZLSi 1/7 up to 180°C,
Order No.: 04250410.
FZLK 1/7 up to 80°C,
Order No.: 04250409.
8.2 Industrial plug connector, 16-pin
Order No.: 74919469
8.3 PROFIBUS plug connector
Variosub PROFIBUS plug connector, 9-pin, with deacti-
vatable bus terminator, Order No.: 74960431
GSD files for BCU Profibus DP on BCSoft CDROM, Order No. 74960436, or at www.docuthek.com
Bibliography
– PROFIBUS Specification, EN 50170 Vol. 2 (version
1.0).
– Installation Guideline for PROFIBUS DP/FMS, avail-
able from the Profibus User Organization (PUO).
– PROFIBUS Technology and Application, Order No.:
4.001, available from the PUO.
– M. Popp, The New Rapid Way to PROFIBUS DP, a text-
book for system operators.
– M. Popp, PROFIBUS DP Principles, Tips and Tricks for
Users.
– www.profibus.com
BCU 460, BCU 465 · Edition 03.16l 81
Page 82
Accessories
D-49018 Osnabrück, Germany
Achtung, geänderte Parameter!
Die Angaben auf dem Typenschild
gelten nicht mehr in vollem Umfang.
Aktuelle Parameter direkt auslesen.
Important, changed parameters!
The details on the type label are no
longer completely accurate. Read the
current parameters direct from the
unit.
Attention, paramètres modifiés !
Les informations figurant sur la plaque
signalétique ne sont plus valables
dans leur intégralité. Veuillez vous
référer directement aux paramètres
actualisés.
8.4 BCSoft
The current software can be downloaded from our In-
ternet site at http://ww w.docuthek.com. To do so, you
need to register in the DOCUTHEK.
8.4.1 Opto-adapter
With USB interface, cable length 3 m, including BCSoft
CDROM.
Order No.: 74960437.
8.5 “Changed parameters” stickers
Affix on the connection dia-
gram of the BCU following
changes to unit parameters set
at the factory.
100 pcs,
Order No.: 74921492.
BCU 460, BCU 465 · Edition 03.16l 82
Page 83
Accessories
225 mm
174 mm
8.6 External securing bar
212 mm
185 mm
200 mm
Order No.: 74960414
ø 4mm
8.7 Fastening set
22 mm
12 mm
7 mm
230 mm
45 mm
222 mm
263 mm
16.5 mm
20 mm
Order No.: 74960422
8.8 Radio interference suppressed electrode plugs
Angle plug, 4 mm, interference-suppressed,
Order No. 04115308.
Straight plug, 4 mm, interference-suppressed,
Order No. 04115307.
Straight plug, 6 mm, interference-suppressed,
Order No. 04115306.
BCU 460, BCU 465 · Edition 03.16l 83
Page 84
Technical data
▼
9 Technical data
Mains voltage:
230 V AC, 15/+10%, 50/60 Hz,
115 V AC, 15/+10%, 50/60 Hz
For grounded and ungrounded mains.
Inherent consumption: approx. 9 VA plus inherent consumption of the integrated ignition transformer.
Voltage to inputs and valves = mains voltage.
Signal and control line: max. 2.5 mm
Cable for burner ground/PE wire: 4 mm
Cable gland:
5 cable glands with multiple seal inserts for cable diam-
eters of up to 7 mm,
BCU..P: with 2 cable glands with multiple seal inserts
for 4 cables of up to 7 mm in diameter and an industrial
chassis plug. Each BCU is supplied for two cable glands
with one seal insert each for cable diameters between 7
and 12 mm.
Input voltage of signal inputs:
115 V AC 230 V AC
Signal “1” 80–126.5 160–253
Signal “0” 0–20 0–40
2
.
2
.
Output current:
max. 1 A, cos ϕ = 1, for the valve outputs (or SRC outputs),
but total current for valves and ignition transformer:
max. 2.5 A.
Fail-safe inputs and outputs:
All the inputs and outputs marked “
” (see page 13
(Connection diagrams)) may be used for safety tasks.
Flame control with UV detector or ionization sensor.
Flame signal for
ionization control: 1 – 28 μA,
UV control: 1 – 35 μA.
For intermittent or continuous operation.
Maximum length of ignition cable with integrated electronic ignition: 5 m (16.4 ft).
Maximum length of ionization/UV cable: 50 m (164 ft).
Input current of signal inputs:
Signal “1”: typ. 2 mA
BCU 460, BCU 465 · Edition 03.16l 84
Page 85
Technical data
Fuses in unit:
F1: 3.15 A, slow-acting, H, pursuant to IEC 1272/5.
Fuse for protecting the safety-relevant ignition, valve
1, valve 2 and air valve outputs (terminals 7, 12, 14 and
26): 5 A, slow-acting, not replaceable.
F3 (only for BCU.. A, BCU..C and BCU..U):
3.15 A, slow-acting, H, pursuant to IEC 1272/5.
Operation and fault signalling contacts:
Signalling contact for mains voltage, max. 2 A, 253 V,
not internally fused.
Number of operating cycles:
Relay outputs: 250,000 pursuant to EN 298,
Mains switch: 1,000,
Reset/Information button: 1,000.
Ambient temperature:
20 to +60°C,
no condensation permitted.
Enclosure: IP 54 pursuant to IEC 529.
Weight: approx. 5 kg depending on version.
Ignition
transformer
TZI 515/100W 230 50 (60) 0.45 (0.35) 5000 15 (11)
T ZI 725 /20 W 230 50 (60) 1.1 (0.8) 7000 25 (18)
TZI 7,512/100W 230 50 (60) 0.6 (0.45) 7500 12 (9)
TZI 7,520/33W 230 5 0 (60) 0.9 (0.7) 7500 20 (15)
T ZI 51 5/100R 115 50 (60) 0.9 (0.7) 5000 15 (11)
T ZI 725 /20 R 115 50 (60) 2.2 (1.6) 7000 25 (18)
T ZI 7,5 12 /1 00 R 115 50 (6 0) 1.2 (0.9) 7500 12 (9)
TZI 7,520/33R 115 50 (60) 1.8 (1.35) 75 00 20 (15)
* Values in ( ) apply to 60 Hz.
V AC Hz* A* V mA*
Input Output
9.1 BCU..B1
External fuse: 12 A per zone.
9.2 PROFIBUS DP
Manufacturer ID: 0x05DB.
ASIC type: SPC3.
SYNC and FREEZE-capable.
Baud rate detection: automatic.
Min. cycle time: 0.1 ms.
Diagnostic bytes: 6 (DP Standard).
Parameter bytes: 7 (DP Standard).
BCU 460, BCU 465 · Edition 03.16l 85
Page 86
Technical data
9.3 Safety-specific characteristic values
In the case of ionization control,
suitable for Safety Integrit y Level
Diagnostic coverage DC 92.7%
Type of subsystem Type B to EN 615082, 7.4.3.1.4
Mode of operation
Mean probability of dangerous
failure PFH
Mean time to dangerous failure
MTTF
Safe failure fraction SFF 98.8%
D
d
The specified values apply for the combination with
ionization electrode (sensor) and a unit of the BCU 400
series.
No characteristic values are available for flame control
with UVS sensor.
For flame control with UVD sensor, safety-specific
characteristic values are available for the Safety Integ-
rity Level SIL. Further information can be found in TI
UVD 1 at w ww.docuthek.com.
SIL 3
High demand mode pursuant to EN
615084, 3.5.12
1.92 x 108 1/h
MTTFd = 1 / PFH
D
Relationship between the Performance Level (PL)
and the Safety Integrity Level (SIL)
PL SIL
a –
b 1
c 1
d 2
e 3
Pursuant to EN ISO 138491:2006, Table 4, the BCU
can be used up to PL e.
Max. ser vice life under operating conditions: 20 years
after date of production.
For a glossary of terms, see page 89 (Glossary).
For further information on SIL /PL, see w ww.k-sil.de
BCU 460, BCU 465 · Edition 03.16l 86
Page 87
Technical data
A
200 mm (7.87")
50
mm
(1.97")
200 mm (7.87")
55
mm
(2.17")
185 mm
7.28"
4,5 mm
0.177"
88
B
C
D
E
6.42"
163 mm
Die-cast aluminium housing with plug-in terminal
blocks and plug-in M20 cable glands or (16-pin) plug
connector for input signals and optionally pre-assembled cables for output signals.
9.4 Control elements
A: Optical interface.
B: Labelling field for individual labelling of the system
components.
C: 2-digit 7-segment display.
D: Mains switch to isolate the BCU on two poles from
the mains.
E: Reset/Information button to reset the system after
a fault or to scan parameters on the display.
9.5 Installation
Recommended installation position: vertical (cable
glands pointing downwards).
Open the BCU and attach with four screws ∅ 4 mm or
screw on the closed unit using the external securing bar,
see page 81 (Accessories).
Electrical connection via plug-in connection terminals
(2.5 mm
removed in order to facilitate installation. When installing, ensure that there is sufficient space to open the
BCU.
2
) and plug-in cable glands. The latter can be
BCU 460, BCU 465 · Edition 03.16l 87
Page 88
Legend
88
A
10 Legend
Display
Air pressure switch (electrical connection)
Blinking displ ay
88
Ready
Safety interlocks (Limits)
Start-up signal
DI
Digital input
Ignition transformer
Gas valve
Air valve
P
Purge
Ext. air valve control
Flame signal
Operating signal
Fault signal
Reset
Input signal
Output signal
Flame simulation check
t
Waiting time ≥ 2 s
W
Safety time on start-up 3 s, 5 s or 10 s
t
SA
Safety time during operation < 1 s or < 2 s
t
SB
Ignition time 2 s, 3 s or 6 s
t
Z
Flame simulation delay time 25 s
t
LV
Flame proving period 0–25 s
t
FS
Air pressure switch
Minimum burner on time tSA up to max. 25 s
t
B
Minimum burner pause time 0–25 s
t
BP
Low fire over-run time 0 s, 5 s, 15 s or 25 s
t
KN
Pre-ventilation time 0–250 s
t
VL
Post-ventilation time 0–3 s
t
NL
Input/Output, safety circuit
BCU 460, BCU 465 · Edition 03.16l 88
Page 89
Glossary
11 Glossary
11.1 Waiting time tW
88 00 02 . . . 01
V1
t
W
Once the start-up signal ϑ has been applied, the wait-
ing time tW starts to elapse. During this time, a self-test
is conducted to detect errors in internal and external
circuit components. If no malfunction is detected, the
burner will start up.
11.2 Safety time on start-up tSA
This refers to the period of time between switching on
and switching off of the gas valve, when no flame signal
is detected. The safety time on start-up tSA (3, 5 or 10 s)
is the minimum operating time of the burner and burner
control unit.
11.3 Ignition time tZ
If no malfunction is detected during the waiting time
tW, the ignition time tZ then starts to elapse. Voltage is
supplied to the pilot gas valve V1 and the ignition transformer and the burner is ignited. The duration of the
ignition time is either 2, 3 or 7 seconds (depending on
safety time tSA selected).
t
11.4 Flame simulation/Flame simulation delay time tLV
01
t
LV
An extraneous signal (flame simulation) is a flame sig-
nal that is detected, although there should be no flame
according to the program sequence. If such an extraneous signal is detected, the flame simulation delay time
tLV starts to elapse. If the flame simulation is discontinued during the flame simulation delay time tLV, star t-up
can be initiated or operation continued. Otherwise, a
fault lock-out occurs.
8800
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
BCU 460, BCU 465 · Edition 03.16l 89
Page 90
Glossary
230V~
33 34 35 36 37
38
(BCU 460..L)
50 51
l
F3
(BCU 460..C)
40 41 42 43 44 45 46 47
Test
BCU 460
11.5 Safety time during operation tSB
04
t
SB
If the flame fails during operation, the valve outputs are
disconnected within the safety time tSB.
The default safety time during operation t
ance with EN 298 is 1 second. In accordance with
EN 7462, the safety time of the installation during
operation (including closing time of the valves) may not
exceed 3 s.
Note the requirements of the Standards!
11.6 Flame signal
If a flame is detected, the flame detector will supply a
flame signal.
11.7 Fault lock-out
In the event of a fault lock-out, all valves and the ignition transformer are disconnected from the electrical
power supply, and a fault is signalled. Resetting must
take place manually following a fault lock-out.
88 04
1
5
ϑ
4
7
9
V1
12
14 V2
16-17
18-19
t
in accord-
SB
11.8 Safety interlocks (Limits)
The limiters in the safety interlock (linking of all the rel-
evant safety control and switching equipment for the
use of the application, e.g. safety temperature limiter,
minimum/maximum gas pressure) must isolate input
from the voltage supply.
11.9 Pilot gas valve V1
The start fuel flow rate for the burner is released by pilot
gas valve V1. It opens when the safety time on start-up
tSA starts to elapse. It remains open until the burner is
switched off again by a controlled shut-down or fault
lock-out.
11.10 Main gas valve V2
Once the safety time on start-up tSA has elapsed, the
main gas valve V2 is opened. It remains open until the
burner is switched off or a fault is signalled.
11
12 13 14 15 18 19 20 26 2722
v1
V1
N1N1 N1
v2
max. 2 A,
V2
n
16 17
253 V
s
max. 2 A,
253 V
l
23
A
P
30 31 32
BCU 460, BCU 465 · Edition 03.16l 90
Page 91
Glossary
11.11 Continuous operation
The gas burner runs continuously for more than 24
hours.
11.12 Air valve
The air valve can be used
– for cooling,
– for purging,
– to control the burner capacity in ON/OFF mode and
in High/Low mode when using a pneumatic air/gas
ratio control system.
11.13 Diagnostic coverage DC
Measure of the effectiveness of diagnostics, which may
be determined as the ratio between the failure rate of
detected dangerous failures and the failure rate of total
dangerous failures
NOTE: Diagnostic coverage can exist for the whole or
parts of a safety-related system. For example, diagnostic coverage could exist for sensors and/or logic system
and/or final elements. Unit: %.
from EN ISO 138491:2008
11.14 Mode of operation
High demand mode or continuous mode
Operating mode, where the frequency of demands for
operation made on a safety-related system is greater
than one per year or greater than twice the proof-test
frequency
from EN 615084:2001
11.15 Safe failure fraction SFF
Fraction of safe failures related to all failures, which are
assumed to appear
from EN 13611/A2:2011
11.16 Probability of dangerous failure PFHD
Value describing the likelihood of dangerous failure per
hour of a component for high demand mode or continuous mode. Unit: 1/h.
from EN 13611/A2:2011
11 .17 Mean time to dangerous failure
MTTFd
Expectation of the mean time to dangerous failure
from EN ISO 138491:2008
BCU 460, BCU 465 · Edition 03.16l 91
Page 92
Feedback
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✔
ascascac
Kromschröder AG
Michael Rehkamp
m.rehkamp@kromschroeder.com
Osnabrüc
k
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Postfach 2809 · 49018 Osnabrück
Strotheweg 1 · 49504 Lotte (Büren)
Germany
Tel +49 541 12140
Fax +49 541 1214370
info@kromschroeder.com
ww w.kromschroeder.com
BCU 460, BCU 465 · Edition 03.16l
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