Krom Schroder BCU 46, BCU 460, BCU 465, BCU 480 Operating Instructions Manual

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035158

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DK S N P GR

➔ www.docuthek.com

Operating instructions

Burner control unit BCU46x,480

Cert. version 03.19

Translation from the German

Safety

Please read and keep in a safe place

Please read through these instructions carefully before installing or operating. Following the installation, pass the instructions on to the operator. This unit must be installed and commissioned in accordance with the regulations and standards in force. These instructions can also be found at www.docuthek.com.

Explanation of symbols

• , 1 ,  , 3 ... = Action

▷ = Instruction

Liability

We will not be held liable for damage resulting from non-observance of the instructions and non-compliant use.

Safety instructions

Information that is relevant for safety is indicated in the instructions as follows:

DANGER

Indicates potentially fatal situations.

WARNING

Indicates possible danger to life and limb.

CAUTION

Indicates possible material damage.

All interventions may only be carried out by qualiﬁed gas technicians. Electrical interventions may only be carried out by qualiﬁed electricians.

Conversion, spare parts

All technical changes are prohibited. Only use OEM spare parts.

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Checking the usage

Burner control units BCU 460, 465 and480 are designed to control, ignite and monitor gas burners in intermittent or continuous operation. They replace the local control cabinet. Air and gas ﬂow monitoring as an option.

The outputs for controlling the burners, e.g. for ac-

tuator and valves, are activated via the replaceable power module LM400. All the parameters required for operation are saved on the integrated parameter chip card.

BCU 460, BCU 465

For directly ignited burners of unlimited capacity.

BCU 480

For pilot and main burners of unlimited capacity. Pilot and main burners can be monitored independently.

LM..F0

Power module without air control interface.

LM..F1, LM..F3

Power module with air control interfaces to connect an air valve (LM..F3) or actuator IC40 (LM..F1).

This function is only guaranteed when used within the

speciﬁed limits– see page29 (Technical data). Any other use is considered as non-compliant.

Type code

Code Description BCU 4 Series 4 burner control unit 60 65 80 Q W 1 2 3 8 P0 P1 P2 P3 P6 P7 C0 C1 C2 D0 D1 D2 0 1 2 3 0 1 2 3 K0 K1 K2

Mains voltage: 120 V AC, 50/60 Hz

230 V AC, 50/60 Hz

Ignition transformer duty cycle: 100%

industrial plug connector, 16-pin

No valve proving system

With TC and POC valve proving system

With POC valve proving system

No high temperature operation

For high temperature operation

Flameless operation

Input functions: none

auxiliary gas and LDS

Pressure switches: none

gas pressure switch

air and gas pressure switch

No connection plugs

Connection plugs with screw terminals

Connection plugs with spring force

Series 460 Series 465 Series 480

20%

100%

33%

Flange plate: none

standard

M32

Profibus

conduit

auxiliary gas

LDS

air pressure switch

terminals E0 E1

Energy supply: via safety interlocks

via L1

Code Description LM Power module 400 For series 4 Q W F0 F1 F3 O0 O1 O2 E0 E1 K0 K1 K2

Mains voltage: 120 V AC, 50/60 Hz

230 V AC, 50/60 Hz

Air actuator: none

with IC40 interface

with air valve control

Optional outputs: none

not fail-safe

fail-safe

Energy supply: via safety interlocks

via L1

No connection plugs

Connection plugs with screw terminals

Connection plugs with spring force

terminals

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Part designations

9

8

7

6

1

10

5

2

3

4

10

1 LED display for program status and fault

messages

 On/Off button 3 Reset/Information button 4 Connection for opto-adapter 5 BCU type label 6 Power module, replaceable 7 Power module type label 8 Parameter chip card, replaceable 9 Bus module, replaceable 10

M5 screw terminal for burner ground

Type designation (A), identiﬁcation number (B), con-

struction stage(C), year/week of manufacture(D), device number(E), device ID(F), voltage(G), frequency(H), ambient temperature in Celsius(I)/Fahrenheit(J), enclosure(K)– see type label.

Elster GmbH Osnabrück, Made in Germany

A

B

-

D EC

F

G

H

I J K

L

Installation

CAUTION

Please observe the following to ensure that the BCU is not damaged:

– The device must not be installed in a public

place. It must be accessible to authorized personnel only. Unauthorized personnel could make changes which could cause the system to become unsafe or dangerous.

– Dropping the device can cause permanent dam-

age. In this event, replace the entire device and associated modules.

▷ The following components are sealed: 1 upper

housing section,  power module, 3 bus module,

4 HMI. The BCU may only be installed and oper-

ated with undamaged seals.

4

1

2

▷ Installation position: vertical (cable glands point-

ing downwards) or down ﬂat.

8888

▷

Distance between BCU and burner: recommended <1m (3.3ft), max.5m (16.4ft).

▷

Afﬁx the sticker (with the program step/fault message description) in the required language (available as an accessory).

3

8888

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Screwing on the BCU

2.

From inside:

1 Open the cover of the BCU.

 Screw on the BCU with four screws, Ø4mm,

min. length 15mm.

Or

To the rear:

▷ The unit remains closed.

1 Attach the BCU with four self-tapping screws.

185 mm

7.28"

6.42"

163 mm

▷ Self-tapping screws (M6 x 20 mm) are supplied

with the unit.

▷ Other mounting options are available as acces-

sories:

Mounting Order No. Fastening set 74960422 External securing bars 74960414

Identiﬁcation

Each burner control unit can be labelled indi-

▷

vidually.

1 Pull out the labelling plate at the top right of the

housing.

Replacing the power module/bus module/parameter chip card

CAUTION

Please observe the following to ensure that the BCU is not damaged:

– Different power supply for the gas

valves. The following combinations of BCU and LM are allowed: BCU 4xx..E1 + LM..E1: power supply via L1, BCU 4xx..E0 + LM..E1: power supply via terminal35, power supply for air outputs via L1, BCU 4xx..E0 + LM..E0: power supply via terminal35.

1 Disconnect the unit from the electrical power

supply.

 Open the cover of the BCU. 3 Remove the connection plug from the power

and bus module.

▷ Power module and bus module are secured in

the BCU by retaining lugs A. The retaining lugs must be pushed away from the respective module carefully so that the power or bus module can be removed.

4 Remove the modules in the following order to

facilitate handling:

1. power module, . bus module,

3. parameter chip card (PCC).

A

3.

 Label as required and slide back in.

1.

▷ Installation of the modules in reverse order.

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Cable selection and installation

▷ Signal and control line for screw terminals max.

2.5mm2 (min.AWG24, max.AWG12), for spring force terminals max. 1.5mm2 (min.AWG24, max.AWG12).

▷

For the ionization and ignition cables, use un-

screened high-voltage cable: FZLSi 1/7 up to 180°C, Order No. 04250410, or FZLK 1/7 up to 80°C, Order No. 04250409.

▷

The control lines must be selected in accordance

with local/national regulations.

▷

External electrical interference must be avoided.

▷

Do not route BCU cables in the same cable

duct as frequency converter cables or cables

emitting strong ﬁelds.

Ionization cable, UVcable

▷ Cable length:

for internal ignition max. 5 m (16.4 ft), for external

ignition (double-electrode operation or UV con-

trol) max. 50m (164ft); observe the requirements

of the ignition transformer.

▷

The ﬂame signal is adversely affected by EMCin-

ﬂuences.

▷

Lay cables individually (with low capacitance)

and, if possible, not in a metal conduit.

Proﬁbus, Proﬁnet, EtherNet/IP

▷

Use only cable and plug components which

comply with the appropriate ﬁeldbus speciﬁca-

tions.

▷

Proﬁbus, Proﬁnet and EtherNet/IP are unen-

crypted ﬁeldbus protocols without authentica-

tion mechanisms.

▷ Use shielded RJ45 plugs. ▷ Cable length: max. 100m between 2subscrib-

ers.

▷

Proﬁnet/Proﬁbus installation guidelines, see

www.proﬁbus.com.

▷

Ethernet installation guidelines, see

www.odva.org.

Wiring

CAUTION

Please observe the following to ensure that the BCU is not damaged:

– Burner ground must be connected to the BCU

in order to avoid uncontrolled spark formation, especially in the case of single-electrode operation.

– Different power supply for the gas

valves. The following combinations of BCU and LM are allowed: BCU 4xx..E1 + LM..E1: power supply via L1, BCU 4xx..E0 + LM..E1: power supply via terminal35, power supply for air outputs via L1, BCU 4xx..E0 + LM..E0: power supply via terminal35.

– For use in an ungrounded mains system or for

mains supply between phases, install an isolating transformer with single-side grounding.

▷

Do not reverse phaseL1 and neutral conductorN. Do not connect different phases of a three-phase

▷

current system to the inputs.

▷ Check the following screw connections for the

correct tightening torque so as to ensure safe grounding of housing, cover, (connection) ﬂange plate and electronics unit as well as a good PE (ground) wire connection between the BCU and burner:

1

4

2

3

1 Cover screws: 2.4 Nm  PE terminals 3 Flange plate screws: 2.4 Nm 4 M5 screw terminal for burner ground: 1.8 Nm

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▷

Use plastic cable glands/conduit couplings with multiple cable grommet. These can be detached with the plug-in connection terminals.

▷ Do not supply voltage to the outputs. ▷

A short-circuit on the outputs causes one of the replaceable fuses to trip.

▷ Do not set the remote reset so that it operates

(automatically) in cycles.

▷ Wire the safety circuit inputs via contacts (relay

contacts) only.

▷

The limiters in the safety interlock (e.g. safety

temperature limiter, emergency stop) must isolate terminal35, as well as the optional safetyrelevant inputs, e.g. at terminals 36 to 41, if these are parameterized, from the voltage supply. If the safety interlock is interrupted, the display shows a blinking

as a warning signal and all of the

51

BCU’s gas valve outputs are disconnected from the electrical power supply.

▷

Connected control elements must be equipped with protective circuits in accordance with the manufacturer’s instructions. The protective circuit prevents high voltage peaks which can cause malfunctioning of the BCU.

▷ Install the ignition cable in the BCU in the desig-

nated cable duct1 and feed it out of the BCU on the shortest possible route via the cable gland.

▷

Screw terminals or spring force terminals are

available for the BCU: Screw terminals, Order No. 74924876, spring force terminals, Order No. 74924877. 3 Wire as shown on the connection diagram, see

from page7 (Connection diagram). 4 After wiring, close the housing cover again and

tighten the cover screws to 2.4Nm.

2

1

▷

Observe the maximum duty cycle for the ignition transformer (see manufacturer’s instructions). Adjust the minimum pause timetBP (parameterA062) correspondingly, if required.

▷

All functions of the inputs at terminals 1 to 7 and 35to41, as well as of contacts 80to 82, 85to87, 90to 92 and 95to97, depend on parameters I050toI074.

1 Disconnect the system from the electrical power

supply.

 Before wiring, ensure that the yellow parameter

chip card has been inserted in the BCU.

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Connection diagram

BCU 460/LM..F0

92 91 90

The connection diagram shows BCU..E1 with

▷

LM..E1.

▷ Legend– see page29 (Legend).

LM 400..F0

N1

85 86 87

82 81 80 95 96 97

UA-Sk

N1

V1 V2 V3

62 32

61 31

60 30

V3

V2

V1

PE PE PE

38

BCU 460

N

N1

29

L

59

U

p

TC

2

37

N1

N

28

L

58

40 41

39

LDS

35

7

F2

(BCU..E0)

F1

(BCU..E1)

F 3,15 A

6

HT

5

F3 3,15 A

4

3

N1

2

1

Start 1

N1

1

O

L

L1

I

UVS

230 V

BM

51 21

36

N1

N

27

L

57

N1

56 26

N1

55 25

N1

54 24 BM

52 53

PE

Z

2322

I

PE N

N

PE

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BCU 460/LM..F3

▷

The connection diagram shows BCU..E1 with

LM..E1.

▷ Legend– see page29 (Legend).

67

92 91 90

85 86 87

82 81 80 95 96 97

LM 400..F3

Luft

v

UA-Sk

N1

V1 V2 V3

65 34 66

62 32

61 31

60 30

Luft

V3

V2

V1

PE PE PE PE

38

BCU 460

N

N1

29

L

59

U

p

TC

2

37

N1

N

28

L

58

40 41

39

LDS

35

7

F2

(BCU..E0)

F1

(BCU..E1)

F 3,15 A

6

HT

A

P

5

F3 3,15 A

4

3

N1

2

1

Start 1

N1

1

O

L

L1

I

UVS

230 V

BM

51 21

36

N1

N

27

L

57

N1

56 26

N1

55 25

N1

54 24 BM

52 53

PE

Z

2322

I

PE N

N

PE

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BCU 465/LM..F3

▷

The connection diagram shows BCU..E1 with

LM..E1.

▷ Legend– see page29 (Legend).

97

67

95 96

62 32

61 31

60 30

Luft

65 34 66

V3

V2

V1

PE PE PE PE

92 91 90

85 86 87

80

82 81

LM 400..F3

Luft

v

UA-Sk

N1

V1 V2 V3

38

BCU 465

N

N1

29

L

59

U

p

TC

2

37

N1

N

28

L

58

40 41

36

N1

N

27

L

57

39

F3 3,15 A

N1

1

I

O

UVS

230 V

BM

51 21

N1

56 26

N1

55 25

N1

54 24 BM

52 53

PE

2322

PE N

menox

P

LDS

HT

A

35

7

6

5

4

3

F2

(BCU..E0)

F1

(BCU..E1)

F 3,15 A

2

1

N1

Start 1

L

L1

DW 2DW 1

PE PE

Z

I

N

PE

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BCU 480/LM..F3

▷

The connection diagram shows BCU..E1 with

LM..E1.

▷ Legend– see page29 (Legend).

97

95 96

92 91 90

85 86 87

80

82 81

LM 400..F3

Luft

V

UA-Sk

67

66

65 34

63 33

62 32

61 31

60 30

Luft

PE

V4

V3

V2

V1

PE PE PE PE

N1

N1 N1

N1

V1 V2 V3 V4

38

N

BCU 480

N1

29

L

59

U

p

TC

2

37

N1

N

28

L

58

40 41

36

N1

N

27

L

57

39

F3 3,15 A

N1

56 26

N1

55 25

N1

54 24

BM

UVS

230 V

52 53

BM

PE

51 21

2

1

I

O

2322

PE N

N

PE

LDS

35

7

F2

(BCU..E0)

F1

F 3,15 A

(BCU..E1)

6

HT

A

P

5

4

3

2

1

Start 1 Start 2

L

L1

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82 81

80

95 96

97

85 86 87

92 91 90

40 41

39

E0

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IC 40 connected to BCU/LM..F1 (staged control)

▷ Parameter I020 = 2.

▷ Set IC 40 to operating mode 11, see Actuator

IC40 operating instructions or technical information bulletin at www.docuthek.com.

N1

56 26

57

N1

N27L

36

58

N1

N28L

37

22 21 20

N1

N29L

38

59

mA

19 18 16 15 14 12 11 10 87 54 21

A

D

BCU..F1

90°

41

56 26

N1

0°➔90°

66 67

64 6540

L N

AC

DC

IC 40

M

R..

PE

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Flame control

BCU 480

L1

61 31

V2

60 30

V1

62 32

V3

N28L

58

37

TC

N27L

57

36

N29L

59

38

F3 3,15 A

O

UA-Sk

V1 V2 V3 V4

82 81 80 95 96 97

85 86 87

55 25N156 26

N1

p

U

2

3

1

2

4 657

40 41

35

39

P

LDS

Start 1 Start 2

A

PE PE PE PE

HT

F 3,15 A

F1

(BCU..E1)

F2 (BCU..E0)

BCU 480

N1

22

BM

23

51 21BMPE

N1

1

2

UVC 1

4 3 2 1

54 24 PE

PEN1

22

23

1

2

LM 400..F3

▷ BCU 460, 465 = 1 ﬂame ampliﬁer ▷ BCU 480 = 2 ﬂame ampliﬁers ▷

In the case of UV control, use Elster UV sensors for intermittent operation (UVS5,10) or ﬂame detectors for continuous operation (UVC1).

BCU 460, 465 Double-electrode operation:

▷

See from page 7 (Connection diagram), BCU 460/LM..F0, BCU 460/LM..F3 and BCU465/LM..F3.

Ionization/single-electrode operation:

▷ Parameter I004 = 0.

N1

1

51 21

BM

UVS

230 V

PE

BCU 480 Pilot burner = single-electrode operation/

main burner = ionization:

▷ Pilot burner in single-electrode operation ▷ Ionization control for main burner ▷ Parameter I004 = 0.

1

2

I

PELN

51 21

BM

2322

PE

230 V

52 53

UVS

BM

N1

54 24

UV control:

UVS 5, 10

▷ Parameter A001 ≥ 5 µA. ▷ Parameter I004 = 1.

1

51 21

UVC 1

▷ Parameter I004 = 2.

1

51 21

22

Z

N1

BM

PE

UVS

Z

N1

BM

PE

UVC 1

Z

PE

5222

BM

UVS

230 V

PE

5222

BM

1 2 3

54 24 PE

BM

4 3

2

1

N1

Pilot burner = single-electrode operation/

main burner = UVS:

Pilot burner = single-electrode operation/

main burner = UVC 1:

GB-12

▷ Parameter A001 ≥ 5 µA. ▷ Parameter I004 = 3.

N1

2

1

51 21BMPE

23

▷ Parameter I004 = 4.

N1

2

1

51 21

BM

22

23

UVS

PE

UVC 1

4 3 2 1

1 2 3

5222

230 V

BM

UVS

PE

BM

PEN1

N1

54 24 PE

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Pilot burner = UVS/main burner = ionization:

N1

FU

▷ Parameter A002 ≥ 5 µA. ▷ Parameter I004 = 5.

51 21

N1

BM

2

1

23

PE

123

UVS

230 V

PE

5222

BM

Pilot burner = UVC/main burner = UVC:

▷ Parameter I004 = 2.

N1

2

1

51 21

BM

22

23

4

3

UVC 1

PE

BM

2

1

4 3

UVC 1

2 1

N1

54 24 PE

PEN1

Pilot burner = UVC/main burner = ionization:

▷ Parameter I004 = 7.

2

1

51 21

BM

22

23

4

3

2

UVC 1

PE

BM

1

N1

54 24 PE

PEN1

Pilot burner = UVC/main burner = UVS:

▷ Parameter A002 ≥ 5 µA. ▷ Parameter I004 = 8.

22

N1

2

1

51 21

BM

23

4

3

2

UVC 1

UVS

230 V

PE

52

BM

1

1 2

UVS

3

PEN1

N1

54 24 PE PE

Adjustment

In certain cases, it may be necessary to change the parameters set at the factory. Using the separate software package BCSoft and an opto-adapter, it is possible to modify parameters on the BCU, such as the safety time or the behaviour in the event of a ﬂame failure. 1 Set the parameters using BCSoft.

▷

For reasons of network security, it is not possible to access the unit via the network using BCSoft.

▷

The software package and the opto-adapter are

available as accessories.

▷

Changed parameters are saved on the integrated parameter chip card.

▷

The factory settings are secured with a program-

mable password. The default password is 1234. We recommend changing the password upon commissioning.

▷

Hardware parameters (e.g. type of ﬂame control or type of air actuator) are set via interface parameters I004 to I074.

▷ Once parameters have been changed, a check

is automatically carried out to ensure that the changes have been accepted and the display shows

Press the Reset/Information button on theBCU.



.

V

FY

▷

The ﬁrst parameter value that was changed is

displayed.

Press the Reset/Information button again.

3

▷ The next parameter value that was changed is

displayed.

▷ Repeat this procedure until

is displayed.

Y

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3 Press the Reset/Information button on theBCU

to conﬁrm the new parameter settings.

Commissioning

▷

During operation, the 7-segment display shows the program status:

Standby

00

Delay

H0

Approaching minimum capacity

A

Cooling

A0

Fan run-up time

01

Pre-ventilation

A1

Approaching maximum capacity

A

Delay

H1

Pre-purge

P0

Pre-purge

P1

Approaching ignition capacity

A

Valve check Safety time 1 t

02

Safety time 1 t

A2

Flame proving period 1 t

03

Flame proving period 1 t

A3

Burner 1 operation

04

Burner 1 operation

A4

Burner 2 waiting time

05

Delay

A5

Delay time during burner 2 waiting time

H5

Safety time 2 t

06

Safety time 2 t

A6

Flame proving period 2 t

07

Flame proving period 2 t

A7

Burner 2 operation

08

Burner 2 operation

A8

Delay

H8

Device Off

––

Data transfer (programming mode) (blinking dots) Manual mode

0.0.

Low NOx operation in program stepXX

XX

High temperature operation in program

XX

stepXX

▷

Units with SafetyLink function (BCU with bus module BCM..S1) may only be commissioned using BCSoft. Further information can be found in Technical Information bulletin BCU46x or BCU480.

SA1

SA2

FS1

FS2

WARNING

Risk of explosion! Check the system for tightness before commissioning. Do not start the BCU until the parameter settings and wiring are correct and the faultless processing of all input and output signals complies with the local standards.

1 Switch on the system.

▷ The display shows

 Switch on the BCU by pressing the On/Off but-

ton.

▷ The display shows ▷

The display blinks and indicates

table fault message is signalled. Reset the BCU

by pressing the Reset/Information button.

▷ The display blinks without indicating “E”. A warn-

ing message is signalled. Once the fault has been

eliminated, the display stops blinking and the

BCU continues the program run.

BCU 460..F0 3 Apply the start-up signal to terminal1.

▷ The display shows ▷

The display shows 02. The gas valves open and

the burner ignites. Safety time1 starts to elapse.

▷ The display indicates 03 during ﬂame proving

period1.

▷ The display shows

tion.

BCU 46x..F1, BCU 46x..F3

▷ If the air actuator is activated externally for cool-

ing in the start-up position, the display indicates

.

A0

3 Apply the start-up signal to terminal1.

▷ The display indicates 01 or A1 if the air actua-

tor has been activated.

▷ The display indicates 02 or A2 if the air actua-

tor has been opened. The gas valves open and

the burner ignites. Safety time1 starts to elapse.

▷

The display indicates 03 during ﬂame prov-

ing period1 or A3 if the air actuator has been

opened.

▷ The display indicates 04 or A4 if the air actua-

tor has been opened. The burner is in operation.

BCU 480..F1/F3

▷ If the air actuator is activated externally for cool-

ing in the start-up position, the display indicates

.

A0

3 Apply the start-up signal to terminal1.

▷ The display indicates 01 or A1 if the air actua-

tor has been opened.

▷ The display indicates 02 or A2 if the air actua-

tor has been opened. The gas valves open, the

pilot burner (burner1) ignites and safety time1

starts to elapse.

▷

The display indicates 03 during ﬂame prov-

ing period1 or A3 if the air actuator has been

opened.

GB-14

.

––

.

00

.

01

. The burner is in opera-

04

EXXX

. A reset-

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▷

....S X

The display indicates 04 or A4 if the air ac

tuator has been opened. The pilot burner is in operation.

▷ The display indicates 06 or A6 if the air actua-

tor has been opened. The main burner (burner2) ignites and safety time2 starts to elapse.

▷

The display indicates 07 during ﬂame prov-

ing period2 or A7 if the air actuator has been opened.

▷

The display indicates 08 or A8 if the air ac

tuator has been opened. The main burner is in operation. The controller enable signal has been issued.

▷ After 3 seconds in this position, the μA value for

the ﬂame signal

XX.X

is displayed instead of the

program status.

3 Press the Reset/Information button for 1s.

▷ The display shows ▷

The BCU will start the second stage of the burner.

▷ The display runs to

After 3 seconds in this position, the μA value

▷

S. . .3.

. .0.4.

(step3).

.

for the ﬂame signal is displayed instead of the

-

program status.

BCU 46x/LM..F1/F3  Press the Reset/Information button for 1s.

▷ The display shows

S. . .1.

(step1).

▷ The BCU will start to purge the burner.

Manual mode

▷ For adjustment of the burner control unit or for

fault-ﬁnding.

▷

In Manual mode, the BCU operates independently of the status of the inputs for start-up signal (terminal1), external air valve control (terminal4) and remote reset (terminal2). The function of the controller enable/emergency stop input (terminal35) is retained.

▷ Manual mode is terminated by switching off the

BCU or in the event of a power failure.

▷

Parameter A067 = 0: Manual mode unlimited in time.

▷

Parameter A067 = 1: the BCU will terminate Manual mode 5minutes after the last time the Reset/Information button is pressed. It switches to the start-up position/standby (display

1 Switch on the BCU while holding the Reset/

Information button. Hold the Reset/Information button until 4dots start to ﬂash in the display.

00

▷ The display shows

WARNING

Risk of explosion! The pre-purge time is not included in the program. Maintain state P.0. until the combustion chamber has been adequately ventilated.

3 Press the Reset/Information button for 1s.

▷ The display shows ▷ The BCU will start the ﬁrst stage of the burner. ▷

The display runs to

than a 0 appears if the air actuator is activated).

▷

After 3 seconds in this position, the μA value for the ﬂame signal is displayed instead of the program status.

4 Press the Reset/Information button for 1s.

).

▷ The display shows ▷

The BCU will start the second stage of the burner.

▷ The display runs to ▷ After 3 seconds in this position, the μA value for

the ﬂame signal

. .P.0.

.

S. . .2

(step2).

. .0.2.

S. . .3.

. .0.4. ( . .A.4.

XX.X

. .0.3.

or

(an A rather

(step3).

).

is displayed instead of the

program status.

....

Air actuator control: The air actuator is activated externally (parameter A048 = 0). 5 Press the Reset/Information button for 1s.

▷

If the Reset/Information button is pressed briefly, the current step in Manual mode is shown and

S.X.X.X.

is displayed.

▷

If the Reset/Information button is pressed for >1s, the BCU proceeds to the next program step.

▷ The display shows ▷ The BCU will open the air actuator. ▷

Each time the button is pressed, the air actuator is closed or opened again.

The air actuator opens under program control (parameter 48 = 1, , 3, 4, 5 or 6).

▷

The air actuator opens under program control

S . .4

(step4).

with valves V1, V2, V3 or when it reaches the operating position.

5 Press the Reset/Information button for 1s.

▷ The display shows

S. . .4

(step4).

▷ The BCU will start the shut-down procedure.

BCU 460/LM..F0  Press the Reset/Information button for 1s.

▷ The display shows

S. . .2.

(step2).

▷ The BCU will start the ﬁrst stage of the burner.

. .0.2.

▷ The display runs to

or

. .0.3.

.

BCU 480  Press the Reset/Information button for 1s.

▷ The display shows

S. . .1.

(step1).

▷ The BCU will start to purge the burner. ▷ The display shows

. .P.0.

.

GB-15

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WARNING

Risk of explosion! The pre-purge time is not included in the program. Maintain state P.0. until the combustion chamber has been adequately ventilated.

3 Press the Reset/Information button for 1s.

▷ The display shows ▷ The BCU will start the pilot burner. ▷

The display runs to

appears if the air actuator is activated).

▷ After 3 seconds in this position, the μA value for

the ﬂame signal program status.

4 Press the Reset/Information button for 1s.

▷ The display shows ▷

The BCU will start the ﬁrst stage of the main

burner.

▷ The display runs to ▷ After 3 seconds in this position, the μA value for

the ﬂame signal program status.

Air actuator control:

The air actuator is activated externally

(parameter A048 = 0). 5 Press the Reset/Information button for 1s.

▷ The display shows ▷ The BCU will open the air actuator. ▷ The display shows ▷

Each time the button is pressed, the air actuator is closed or opened again.

▷ Press the On/Off button to switch the unit off.

The air actuator opens under program control

(parameter 48 = 1, , 3, 4, 5 or 6).

The air actuator opens under program control

▷

with valves V1, V2, V3, V4 or when it reaches the operating position.

▷

If the Reset/Information button is pressed for 1s, the display shows starts the shut-down procedure.

S. . .2.

(step2).

. .0.4.

(an A rather than a 0

XX.X

is displayed instead of the

S. . .3.

(step3).

. .0.8.

.

XX.X

is displayed instead of the

S. . .4.

(step4).

. .A.4.

.

S. . .4.

(step4) and the BCU

Assistance in the event of malfunction

DANGER

To avoid harm to persons and damage to the unit,

please observe the following:

– Electric shocks can be fatal! Before working

on possible live components, ensure the unit is disconnected from the power supply.

– Fault-clearance must only be undertaken by

authorized trained personnel!

▷ Faults may be cleared only using the measures

described below.

▷

If the BCU does not respond even though all faults have been remedied: remove the unit and return it to the manufacturer for inspection.

▷

In the event of a fault lock-out, the fault signalling contact closes, the display blinks and shows the current program step. The gas valves are disconnected from the electrical power supply.

After a fault lock-out, the BCU must be reset

manually using the button on the front panel or the remote reset input (terminal2).

The BCU cannot be reset by mains failure (non-

volatile fault lock-out). The fault signalling contact does, however, open as soon as the mains voltage fails.

? Faults ! Cause

• Remedy

? The 7-segment display does not light up. ! Mains voltage is not applied.

• Check the wiring, apply mains voltage (see type

label).

0 1E

A 1E

E 01

? The display blinks and indicates

!

The BCU has detected an incorrect flame signal

or

E A1

.

without the burner having been ignited (extraneous signal).

• Direct the UV sensor exactly at the burner to be

monitored.

!

The UV tube in the UV sensor is defective (service

life ended) and issues a continuous flame signal.

• Replace the UV tube, see UV sensor operating

instructions.

!

Flame signal through conductive ceramic insula-

tion.

• Increase value of parameterA001 in order to

adapt the switch-off threshold of the flame amplifier for burner1.

GB-16

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0 2E

A 2E

? Start-up – no ignition spark – the display

blinks and indicates

! The ignition cable is too long.

• Shorten it to 1 m (max. 5 m).

! Gap between spark electrode and burner head

is too great.

• Adjust gap to max. 2mm.

!

Ignition cable has no contact in the terminal boot.

• Screw the cable on ﬁrmly.

!

Ignition cable has no contact in the ignition trans-

former.

• Check the connection.

! Ignition cable has short-circuited to ground.

• Check installation, clean the spark electrode.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

? Start-up without ﬂame – no gas supply – the

display blinks and indicates

! A gas valve does not open.

• Check the gas pressure.  • Check voltage supply to the gas valve.

! There is still air in the pipe, e.g. after installation

work has been carried out or if the system has not been in operation for a long period.

• “Purge” the pipeline and reset the BCU.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

E 02

or

E A2

E 02

.

or

E A2

.

! Terminal boot not properly connected to ﬂame

rod.

! Gas/air ratio incorrect. !

Flame not contacting burner ground as the result

of excessively high gas or air pressure.

! Burner or BCU not (adequately) grounded. ! Short-circuit or discontinuity on the ﬂame signal

cable.

! Soiled UV sensor. ! UV sensor wiring is defective.

• Remedy fault.

0 5E

?

The display blinks and indicates

A 5E

E 05

E A5

or

! The BCU has detected an incorrect flame sig-

nal without burner2 (main burner) having been ignited (extraneous signal).

• Direct the UV sensor exactly at burner 2 to be

monitored.

!

The UV tube in the UV sensor is defective (service

life ended) and issues a continuous flame signal.

• Replace the UV tube, see UV sensor operating

instructions.

! Flame signal through conductive ceramic insula-

tion.

• Increase value of parameterA002 in order to

adapt the switch-off threshold of the ﬂame ampliﬁer for burner2.

0 8E

A 8E

.

0 2E

A 2E

?

Start-up– ﬂame burning – nevertheless, the

display blinks and indicates the pilot burner/burner (burner1) or

E 07

on the main burner (burner).

! Flame failure on start-up.

• Read off the ﬂame signal.

▷

If the ﬂame signal is lower than the switch-off threshold for the ﬂame signal from burner1 (parameterA001) or burner2 (parameterA002), this may be attributable to the following causes:

!

The set value for the cut-off sensitivity is too high.

!

Short-circuit on the ﬂame rod as the result of

soot, dirt or moisture on the insulator.

0 3E

A 3E

0 6E

A 6E

E 02

or

0 7E

E 03

E 06

A 7E

on

or

! Flame rod not correctly positioned at the ﬂame

edge.

? Operation – ﬂame burning – burner inter-

rupted– the display blinks and indicates

E 08

E A8

or

! Flame failure during operation or during delayed

controller enable.

• Read off the ﬂame signal, see page25 (Read-

ing off the ﬂame signal, fault messages and parameters).

▷

If the ﬂame signal is lower than the switch-off threshold for the ﬂame signal from burner2 (parameterA002), this may be attributable to the following causes:

!

The set value for the cut-off sensitivity is too high.

!

Short-circuit on the ﬂame rod as the result of

soot, dirt or moisture on the insulator.

.

! Flame rod not correctly positioned at the ﬂame

edge.

! Gas/air ratio incorrect. !

Flame not contacting burner ground as the result

of excessively high gas or air pressure.

! Burner or BCU not (adequately) grounded.

GB-17

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! Short-circuit or discontinuity on the ﬂame signal

cable.

! Soiled UV sensor.

• Remedy fault.

1 0E

? The display blinks and indicates ! Actuation of the remote reset input is faulty. ! Too many remote resets. More than 5resets

have been conducted within the last 15minutes, either automatically or manually.

! Consecutive fault caused by a previous fault

whose actual cause has not been remedied.

• Pay attention to previous fault messages.

• Remedy cause.

▷ The cause will not be remedied by performing a

reset every time a fault lock-out occurs.

• Check whether remote reset complies with

standards (EN746 allows resetting only under supervision) and correct if necessary.

▷ The BCU may only be reset manually under su-

pervision.

• Press the Reset/Information button on theBCU.

E 10

.

1 1E

? The display blinks and indicates ! Too many restarts for burner1. More than 5re-

starts initiated within the last 15minutes.

• Check burner settings.

▷

Ensure that the ﬂame signal is above the switchoff threshold during operation.

• Check the settings for capacity control during

operation.

• Press the Reset/Information button on theBCU.

E 11

.

1 2E

? The display blinks and indicates ! Too many restarts for burner2. More than 5re-

starts initiated within the last 15minutes.

• Check burner settings.

▷

Ensure that the ﬂame signal is above the switchoff threshold during operation.

• Check the settings for capacity control during

operation.

• Press the Reset/Information button on theBCU.

E 12

.

2 1E

? The display blinks and indicates ! Inputs 40 and 41 are activated simultaneously.

E 21

.

• Check input 41.

▷

Input 41 may only be activated if the valve is open.

• Check input 40.

▷ Input 40 may only be activated if the valve is in

the position for ignition capacity.

2 2E

? The display blinks and indicates ! The butterﬂy valve position is not constantly sig-

nalled back to theBCU.

• Check the wiring and ensure that the position for

max. capacity/ignition capacity of the butterﬂy valve is constantly signalled back via terminals 41 and 42.

3 0E

? The display blinks and indicates ! Abnormal data change in the parameters set for

theBCU.

• Reset the parameters to their original values using

the BCSoft software.

• Establish the cause of the fault to avoid repeat

faults.

• Ensure that the cables have been installed prop-

erly– see page5 (Cable selection and installation).

• If the measures described above do not help,

remove the unit and return it to the manufacturer for inspection.

3 1E

3 2E

? The display blinks and indicates ! Supply voltage too low or too high.

• Operate the BCU in the speciﬁed mains voltage

range (mains voltage +10/-15%, 50/60Hz).

! An internal device error occurred.

• Remove the unit and return it to the manufacturer

for inspection.

3 3E

? The display blinks and indicates ! Faulty parameterization.

• Check parameter settings using BCSoft. ! An internal device error occurred.

• Remove the unit and return it to the manufacturer

for inspection.

GB-18

E 22

.

E 30, E 31

E 32

.

E 33

.

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43E

? The display blinks and indicates ! Faulty actuation of the air valve. ! Voltage is applied to the air valve outputs

(65–67).

• Check the wiring and ensure that the voltage

outputs and inputs have the same polarity and are not reversed.

! Fuse F3 defective.

• Replace fuse F3. ! An internal device error occurred.

• Replace the power module.

• Remove the unit and return it to the manufacturer

for inspection.

E 34

.

53E

? The display blinks and indicates ! Bus module and control unit are incompatible.

• Check the bus system and PLC for compatibility. ! Bus module does not support the selected func-

tion.

• Check the setting of parameterA075.

E 35

.

• Check parameterA056 (Measurement timeVp1)

and change using BCSoft.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

4 1E

? The display blinks and indicates ! The downstream gas solenoid valve (V2, V3 or

V4) is leaking.

• Check the downstream solenoid valve. ! The gas pressure switch DGpu/2 for the tightness

test has been set incorrectly.

• Check the inlet pressure.

• Set DGpu/2 to the correct pressure.

• Check the wiring. ! The test period is too long.

• Check parameterA056 (Measurement timeVp1)

and change using BCSoft.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

E 41

.

4 4E

3 6E

? The display blinks and indicates ! Voltage is applied to the device outputs.

• Check the wiring and ensure that the voltage

outputs and inputs have the same polarity and are not reversed.

! Fuses defective.

• Replace the fuses. ! An internal device error occurred.

• Replace the power module.

• Remove the unit and return it to the manufacturer

for inspection.

E 36

.

4 0E

? The display blinks and indicates ! The gas solenoid valve V1 is leaking.

• Check the gas solenoid valve V1. ! The gas pressure switch DGpu/2 for the tightness

test has been set incorrectly.

• Check the inlet pressure.

• Set DGp

• Check the wiring. ! The test pressure between V1 andV2 has not

decreased.

• Check the installation. ! The test period is too long.

/2 to the correct inlet pressure.

u

E 40

.

? The display blinks and indicates ! Faulty pressure switch signal.

• Check the wiring and setting of the pressure

switch/gas valve.

5 1

? The display blinks and indicates ! Interruption of signal at the “Safety interlock/

Controller enable/Emergency stop” input (terminal35).

• Check voltage supply to terminal35.

5 2

? The display blinks and indicates ! The BCU is permanently reset by remote reset.

• Check remote reset activation (default termi-

nal=2 or bus).

• To reset the unit, only apply voltage to the remote

reset terminal for approx. 1second.

E 44

51

52

.

GB-19

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5 3

8 9E

9 4E

9 5E

9 6E

? The display blinks and indicates ! The time between two starts is less than the

min.time (timingcycle).

• Comply with max. number of start-ups (n) per

minute:

t

SA

[s] Ignition transformer ID number [n/min.]

3 5 6

10 3

3 5 2

10 1

3 5 4

10 2

3 5 3

10 2

Device type

BCU..Q1

34340581

BCU..Q2

34340582

BCU..Q3

34340583

BCU..Q8

34340584

BCU..W1

34340585

BCU..W2

34340586

BCU..W3

34340587

BCU..W8

34340588

53

Max.

number

.

6

3

6

4

5 4

? The display blinks and indicates ! Faulty feedback signal of the control element

position for ignition capacity.

• Check wiring from central actuator to BCU (ter-

minal39).

• Check whether parameter I072=13 (LDS ignition

position check) and A089=2.

54

.

5 7E

? The display blinks and indicates ! Faulty actuation of the input for high tempera-

ture operation. The BCU is prompted to go into menox mode, even though there is no signal for high temperature operation (>750°C).

• Check the wiring.

E 57

.

9 7E

? The display indicates

E 97, E 98

! System fault – the BCU has performed a safety

shut-down. The cause may be a unit defect or abnormal EMC inﬂuence.

• Ensure that the ignition cable has been installed

properly– see page5 (Cable selection and installation).

• Ensure that the EMC regulations for the sys-

tem are satisﬁed– particularly for systems with frequency converters – see page 5 (Cable selection and installation).

• Reset the unit.

• Disconnect the burner control unit from the mains

supply and then switch it on again.

• Check mains voltage and frequency.

• If the measures described above do not help, the

unit has probably suffered a hardware defect– remove the unit and return it to the manufacturer for inspection.

or

E 99

9 8E

.

9 9E

E 89, E 94, E 95, E 96

9 1E

? The display blinks and indicates ! Flame ampliﬁer is defective.

• Check the wiring. ! Fuses defective.

• Replace the fuses.

• If the measure described above does not help,

the unit has probably suffered a hardware defect– remove the unit and return it to the manufacturer for inspection.

E 91

.

,

8 0E

? The display blinks and indicates ! Burner 1 ﬂame ampliﬁer is defective.

• Remove the unit and return it to the manufacturer

for inspection.

E 80

.

8 5E

? The display blinks and indicates ! Burner 2 ﬂame ampliﬁer is defective.

• Remove the unit and return it to the manufacturer

for inspection.

E 85

.

9 2E

? The display blinks and indicates ! DC voltage is supplied to the inputs. ! The signal inputs and L are supplied with different

phases of a three-phase current system.

• Check the wiring and ensure that the device and

the inputs are supplied with the same phase.

9 4E

? The display blinks and indicates ! The inputs are supplied with different phases of

a three-phase current system.

GB-20

E 92

E 94

.

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• Check the wiring and ensure that the device and

the inputs are supplied with the same phase.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

9 7E

? The display blinks and indicates ! No PCC.

• Insert compatible PCC. ! Contact problems on the power module.

• Remedy contact problems. ! Power module is defective.

• Replace power module.

• If the measures described above do not help, the

unit has probably suffered a hardware defect– remove the unit and return it to the manufacturer for inspection.

E 97

.

AE

? The display blinks and indicates ! No “Minimum capacity reached” signal from

actuator.

• Check the butterﬂy valve and the function of the

limit switches in the actuator.

• Check the wiring.

• Check the actuator.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

E A

.

AE

EE

? The display blinks and indicates ! Internal communication with bus module has

suffered a fault.

• Connected control elements must be equipped

with protective circuits in accordance with the manufacturer’s instructions.

▷

This prevents high voltage peaks which can

cause malfunctioning of the BCU.

• Use interference-suppressed terminal boots

(1kΩ).

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

! Bus module is defective.

• Replace the bus module.

E E

.

0E

? The display blinks and indicates ! Faulty connection to master.

• Check the connection.

• Check whether the slave is conﬁgured in the

master.

E 0

.

1E

? The display blinks and indicates ! No “Maximum capacity reached” signal from

actuator.

• Check the butterﬂy valve and the function of the

limit switches in the actuator.

• Check the wiring.

• Check the actuator.

• If the fault cannot be remedied by doing this,

remove the unit and return it to the manufacturer for inspection.

AE

? The display blinks and indicates ! No “Ignition capacity reached” signal from actua

tor.

• Check the butterﬂy valve and the function of the

limit switches in the actuator.

• Check the wiring.

• Check the actuator.

E A

.

? The display blinks and indicates ! Incorrect K-SafetyLink address.

• Check that the set address matches the address

conﬁgured for K-SafetyLink.

• Only use addresses in the range of 0x001

to0xFEF.

2E

? The display blinks and indicates ! Plausibility check failed, K-SafetyLink conﬁgura-

tion invalid.

.

• Check SafetyLink conﬁguration in BCSoft and

transfer to the device again.

-

4E

? The display blinks and indicates ! K-SafetyLink awaiting conﬁguration.

GB-21

E 1

E 2

E 4

.

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• Create a SafetyLink project with BCSoft and

transfer the conﬁguration to the device.

1E

5E

? The display blinks and indicates ! Slave conﬁguration check not executed or failed.

• Start and complete the veriﬁcation of the con-

ﬁguration in the SafetyLink master assigned to the slave using BCSoft.

E 5

.

7E

? The display blinks and indicates ! Incompatible or defective bus module.

• Replace bus module with a functional device (for

K-SafetyLink).

E 7

.

8E

? The display blinks and indicates ! The unit is accessed by two or more devices

with the same address.

• Check the conﬁguration in BCSoft.

▷ Each device must have a unique address.

• Remove any device with an incorrect address

conﬁguration from the network or reconﬁgure it.

• Check the correct assignment of the master and

slave devices using the veriﬁcation procedure.

E 8

.

9E

? The display blinks and indicates ! The unit is accessed by one or more devices

with unknown addresses.

• Check the conﬁguration in BCSoft.

Each slave may only be assigned to one master.

▷

• Remove any device with an incorrect address

conﬁguration from the network or reconﬁgure it.

• Check the correct assignment of the master and

slave devices using the veriﬁcation procedure.

CCE

E 9

.

? The display blinks and indicates ! No input signal for the valve proof of closure

switch (POC) during standby.

• Check the wiring.

▷ Mains voltage must be supplied to the BCU (ter-

minals36, 37 and 38) if the valve is closed and no voltage is to be applied if the valve is open.

• Check that the proof of closure switch and valve

function perfectly, replace defective valves.

E 1

.

8E

? The display blinks and indicates ! The BCU is receiving no information as to wheth-

er the POC switch contact is still open.

• Check the wiring.

▷

During start-up, mains voltage must be supplied to the BCU (terminals36, 37 and 38) if the valve is closed and no voltage is to be applied if the valve is open.

• Check that the proof of closure switch and valve

function perfectly, replace defective valves.

E 8

.

0E

? The display blinks and indicates ! The “no ﬂow” state check of the air pressure

switch has failed.

• Check the function of the air pressure switch.

▷ Before the fan is switched on, there must be no

high signal at the input for air monitoring (terminals36/37) when air monitoring is activated.

E 0

.

1E

? The display blinks and indicates ! The operating check of the air pressure switch

has failed. The air monitor has not switched after activation of the air supply.

• Check the air monitor wiring.

• Check the air pressure switch setpoint.

•

Check the function of the fan or air supply.

E 1

.

? The display blinks and indicates ! Incorrect or defective parameter chip card (PCC).

• Only the intended parameter chip card is to be

used.

• Upload the current parameter settings again.

• Replace defective parameter chip card.

E CC

.

PE

? The display blinks and indicates ! The input signal (terminal37) for the air pressure

switch has dropped out during pre-purge.

• Check the air supply during the purging process.

GB-22

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.

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• Check the electrical wiring of the air pressure

switch.

• Check voltage supply to terminal37.

• Check the air pressure switch setpoint.

2E

6E

? The display blinks and indicates

E 4, E 5, E 6, E 7

! The input signal for the air pressure switch has

dropped out during start-up/operation at program stepX (02to08).

!

Failure of the air supply at program stepX

• Check the air supply.

• Check the air pressure switch setpoint.

3E

7E

or

E 8

4E

5E

8E

E 2, E 3

.

0

? The display blinks and indicates ! No connection established between BCU

andPLC.

• Check the wiring.

• Check the PLC program to ensure that the net-

work name and IPconﬁguration of the BCU are valid.

• Switch on the PLC. Or ? A bus fault is indicated on the automation

system.

! The PROFIBUS DP data trafﬁc has suffered a

fault.

! Bus cable interrupted.

• Check cable. ! Incoming and outgoing bus cables confused in

the plug.

• Check the wiring. ! A and B cables confused.

• Check the wiring. ! Terminal resistors connected incorrectly.

• Switch on the terminal resistors on the ﬁrst and

last subscriber in the segment and switch them off for all other subscribers.

! Incorrect PROFIBUS address set.

• Correct the address setting – switch the unit off

and then on again to save the address.

! Bus cables too long.

• Reduce cable length or baud rate – see

page14 (Commissioning).

▷

If the transfer rate is reduced, remember that this will increase the signal running times to and from the individual units.

0

.

! Poor shielding.

• Check whether the shield is connected to the

shield clips in the PROFIBUSDP plugs in full and over a wide area.

! Poor equipotential bond.

• Check whether the PROFIBUS DP shield is con-

nected at all points to the same ground potential via the grounding system of the units.

• If necessary, an equipotential bonding cable must

be laid.

▷ If faults occur sporadically in the PROFIBUSDP

,

system, and are only indicated brieﬂy in the bus master, the following points in particular should be checked:

– Terminal resistors, – Shielding, – Cable lengths/routes, – Equipotential bond, – Use of interference-suppressed spark electrode

terminal boots (1kΩ).

▷

For information on planning and the structure of a Proﬁnet network and the components to be used (e.g. cables, lines and switches), see www.proﬁbus.com or the instructions for the automation system.

1

? The display blinks and indicates

▷ Fault occurs on devices with ﬁeldbus communi-

cation with address check (A080=1) only.

! An invalid or incorrect address has been set on

the bus module.

• Assign the correct address (001toFEF) to the

bus module.

2

? The display blinks and indicates ! The bus module has received an incorrect con-

figuration from thePLC.

•

Check whether the correct GSD file was imported.

3

? The display blinks and indicates

▷ Fault occurs on devices with ﬁeldbus communi-

cation with address check (A080=1) only.

! The BCU has been assigned an invalid network

name or has not been assigned a network name in thePLC.

1

2

3

.

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• Assign a network name corresponding to the

F1

F2

F3

default network name (bcu-460-xxx) or use the default name as a suffix of an individually assigned name in the following form: “individualpartofnamebcu-460-xxx”.

▷

“xxx” stands for the address set on the device

(e.g. 4A5).

4

? The display blinks and indicates ! PLC in STOP position.

• Check whether the PLC can be started.

4

.

TO

Replacing the fuse

▷

The device fuses F1, F2 and F3 can be removed

for inspection.

▷ The fuses are located under the power module.

CAUTION

BCU..E0 and BCU..E1 do not have the same power supply connection. Always replace fuse F1 or F2 such that the required power supply is ensured.

▷ F1 = BCU..E1: power supply via L1. ▷

F = BCU..E0: power supply via safety interlocks.

• Disconnect the system/BCU from the electrical

power supply.

• Open the BCU.

• Remove the power module.

? The display blinks and indicates ! The ambient temperature is too high for the BCU

(excessive temperature).

▷ The display disappears as soon as the tempera-

ture has dropped to the specified setpoint.

OT

.

TU

2E

6E

UT

.

E 0, E 1

E 9

or

3E

7E

.

? The display blinks and indicates ! The ambient temperature is too low for the BCU

(insufficient temperature).

▷ The display disappears as soon as the tempera-

ture has risen to the specified setpoint again.

0E

4E

1E

5E

8E 9E

? The display blinks and indicates

E 2, E 3, E

! The signal for monitoring the min. gas pressure

(terminals36, 37 and 38) has dropped out at program stepX (00to09).

• Check the wiring.

• Check the gas pressure.

4, E 5, E 6, E 7, E 8

• Remove fuse F1, F2 or F3 and check for correct

functioning.

F3

F2

F1

,

▷

When replacing the fuse, use only the approved

fuse type: F1, F2, F3: T 3.15A H, pursuant to IEC 60127-2/5.

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Reading off the ﬂame signal, fault messages and parameters

▷ If the unit is switched on, information about the

ﬂame signal intensity, the last 10event messages (e.g. Power ON, error E002) and the parameter values can be read off by repeatedly pressing the Reset/Information button.

Display Information

F1 F2

H0

to

H9 001

to

999

* Only on BCU 480

• Press the Reset/Information button for approx.

2s until the display indicates

• Release the button. The display indicates the

ﬂame signal intensity inµA.

• Press the Reset/Information button again for

2s to go to the next item of information (event message, parameter value). Each time the button is released, the corre-

▷

sponding event message or parameter value is displayed.

▷ To go to one of the last event messages or to a

parameter more quickly, hold the Reset/Infor mation button pressed down for longer (≥2s).

▷ If the button is pressed brieﬂy, the display indi-

cates what parameter number is currently being displayed.

▷

The normal program status is displayed again

approx. 60seconds after the last time the button is pressed.

▷ For the parameters and the corresponding val-

ues, see Technical Information bulletins BCU46x and BCU 480.

Flame signal intensity: Burner 1

*

Burner 2* Last event message to tenth to last event message Parameter 001 to parameter 999

F1

.

Parameters and values

Application parameters

Parameter name

Parameter No.

Parameter value

Switch-off threshold1

A001

2 – 20 = µA

Switch-off threshold2

A002

2 – 20 = µA

Flame simulation check

0 = In standby

A003

1 = Upon start-up

High temperature operation

0 = Off 2 = Burner 1 UVS Burner 2 UVS

A006

3 = Continuous operation 6 = Burner 1 UVS Burner 2 ionization

Burner 1 start-up attempts

1 = 1 start-up attempt

A007

2 = 2 start-up attempts 3 = 3 start-up attempts

Burner 2 start-up attempts

1 = 1 start-up attempt

A008

2 = 2 start-up attempts 3 = 3 start-up attempts

Restart

0 = Off 1 = Burner 1 2 = Burner 2

A009

3 = Burner 1 and burner 2 (pilot and main burners) 4 = Max. 5 times in 15 min. for burner1 5 = Max. 5 times in 15 min. for burner2

-

6 = Max. 5 times in 15 min. for burners1 and2 Low air pressure protection delay

0 = Off

A016

1 = On

Safety time operation

A019

0; 1; 2; 3; 4 = Time in seconds

Pre-ventilation/ﬂameless

A028

0 – 250 = Time in seconds

Cooling priority

0 = Start-up overrides cooling

A029

1 = Cooling overrides start-up

Staged cooling

0 = Start-up overrides cooling

A030

1 = Stage 2 via signal at terminal5 2 = After delay time

Staged cooling delay

A031

0 – 6000 = Time in seconds

Pre-purge time tPV

A034

0 – 6000 = Time in seconds

Pre-ventilation

A036

0 – 250 = Time in seconds

Over-run time

A039

0 – 60 = Time in seconds

Running time selection 0 =

Off; position check

1 =

A041

On; for min./max. capacity

2 =

On; for maximum capacity 3 = On; for minimum capacity Running time

A042

0 – 250 = Time in seconds

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Parameter No.

A043

A044

A048

A049

A050

A051

A052

A056

A059

A060

A061

A062

A064

A067

A074

Parameter name Parameter value

Over-run

0 = Off 1 = Post-ventilation 2 = Low ﬁre; actuator feedback 3 = Low ﬁre; time-bound

Controller enable signal delay timetRF 0 – 250 = Time in seconds Air actuator control 0 =

Opens on external activation

1 =

Opens with gas stage1

2 =

Opens with gas stage2

3 =

Controller enable op./standby

4 =

Opens with V4 burner 1

5 =

Controller enable following operating signal

6 =

Opens with gas stage3 Air actuator can be activated externally on start-up 0 =

Cannot be activated

1 =

Can be activated externally Air actuator in the event of fault 0 =

Cannot be activated

1 =

Can be activated externally Valve proving system

0 = Off

1 =

Tightness test before start-up

2 =

Tightness test after shut-down 3 = Tightness test before start-up and after

shut-down 4 = POC function Relief valve (VPS)

0 = V0

1 = V1

2 = V2 3 =

V3

4 = V4 5 = V5

Measurement time Vp1 0 – 3600 = Time in seconds Valve opening time 1 tL1 2 – 25 = Time in seconds POC test period

=

Time in seconds

0 – 250

Minimum operating time tB

0 – 6000

=

Time in seconds

Minimum pause time tBP

0 – 3600

=

Time in seconds

Flameless operation

0 = Upon next burner start

1 = Immediate burner start

2 = Immediate switchover

Operating time in Manual mode

0 = Unlimited 1 = 5 minutes

Combustion mode

0 = Flame mode

1 = menox

2 = HT without ignition 3 =

HT without burner1 start 4 =

FLOX

Parameter name

Parameter No.

Parameter value

Air actuator (bus) 0 = Of

f

1 = MAX to MIN

2 = MAX to LOW FIRE

A075

3 =

MAX to IGNITION

4 = MAX to MIN; red. purge ﬂow 5 = MAX to IGN; r

ed. purge ﬂow Function of V5 0 = Of

f

1 = Flame mode

A076

2 = Flameless operation 3 =

Operation Auxiliary gas function 0 = Of

f

1 = Flame mode

A077

2 = Flameless operation 3 =

Operation Burner application

0 =

Burner 1

1 =

Burner 1 with pilot gas

2 =

Burner 1 & burner 2 3 =

Br. 1 & Br. 2 with pilot gas 4 =

Two-stage burner 1

5 =

A078

Br. 1 & two-stage br.2

11 =

menox 1/0 and burner 1/0

12 =

menox 1/0 and burner L/H/O

13 =

menox 1/0 with 2 gas paths

14 = menox L/H/O with 2 gas paths

21 =

CBFF ﬂame

22 =

CBFF ﬂame Flox

Gas pilot

0 = With shut-down

A079

1 = In continuous operation

2 = With shut-down & restart

Fieldbus communication

0 = Off

A080

1 = With address check

2 = No address check

K” Safety Link

0 =

1 =

Off

On

A081

Safety interlocks (bus) 0 =

Off

1 =

Via FS bus

2 =

A085

Via terminal 3 =

Via NFS bus 4 =

Via FS bus or terminal 5 =

Via FS bus and terminal FLOX800 (bus) 0 =

Off

1 =

Via FS bus

2 =

A086

Via terminal 3 =

Via NFS bus 4 =

Via FS bus or terminal 5 =

Via FS bus and terminal

GB-26

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Parameter name

Parameter No.

Parameter value

Purge (bus)

0 =

Off

1 =

A087

Via FS bus

2 =

Via terminal

3 =

Via NFS bus

4 =

Via NFS, FS bus or terminal

5 =

Via NFS, FS bus and terminal

High temperature operation (bus)

0 =

Off

1 =

Via FS bus

2 =

A088

Via terminal

3 =

Via NFS bus

4 =

Via FS bus or terminal

5 =

Via FS bus and terminal

LDS (bus)

0 =

Off

1 =

Via FS bus

2 =

A089

A093

A094

A095

A096

A097

Via terminal

3 =

Via NFS bus

4 =

Via FS bus or terminal

5 =

Via FS bus and terminal

Pre-ignition time

0 – 5 = Time in seconds

Safety time 1 t

2

–

15 = Time in seconds

Flame proving period 1 t

0

–

25 = Time in seconds

Safety time 2 t

2

–

10 = Time in seconds

Flame proving period 2 t

0

–

25 = Time in seconds

SA1

SA2

Parameter name

Parameter No.

Parameter value

Function of sensor 1 0 =

No function

1 =

APS Purge

2 =

APS Stage 1

3 =

APS Purge & Stage 1

4 =

APS Stage 2

5 =

APS Purge & Stage 2

6 =

APS Stage 1 & Stage 2

7 =

APS Purge & Stage1 & Stage2

8 =

APS Flameless

9 =

APS Purge & Flameless

10 =

APS Stage 1& Flameless

11 =

APS Purge&Stage1&Flameless

12 =

APS Stage 2 & Flameless

13 =

APS Purge&Stage2&Flameless

14 =

A101

FS1

FS2

A102

A103

APS Stage 1&2 & Flameless

15 =

APS Purge & Stage1&2 & Flameless

32 =

APS External Low

33 =

APS External Low & Purge

34 =

APS External High

35 =

APS External High & Purge

36 =

APS External Low & High

37 =

APS Ext. Low&High & Purge

48 =

POC V1

49 =

POC V2

50 =

POC V3

51 =

POC V4

52 =

POC V5

53 =

TC

54 =

GPS Flame mode

55 =

GPS Flameless operation

56 =

GPS Operation

Function of sensor 2

▷

See parameter

A101 for parameter values

Function of sensor 3

▷

See parameter

A101 for parameter values

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Interface parameters

▷ Interface parameters I040 to I099 are set at the

factory and normally do not need to be adjusted.

CAUTION

Changing the default settings of the interface parameters will change the functions of the inputs at terminals 1 to 41 and terminals 85 to 90, see page7 (Connection diagram).

Parameter No.

I004

I020

I040

I050

I051

I052

I053

I054

Parameter name Parameter value

Flame control

0 = Ionization 1 = UVS 2 = UVC 3 = Ionization 1 and UVS 2 4 = Ionization 1 and UVC 2 5 = UVS 1 and ionization 2 6 = UVC 1 and UVC 2 7 = UVC 1 and ionization 2 8 = UVC 1 and UVS 2

Air actuator

1 = IC 20 2 = IC 40 3 = RBW 4 = Frequency converter 5 = Air valve

Function of terminal 64

0 = Off 1 = Controller enable 2 = V5 3 =

Bus output 1

Contact 80, 81/82 function

0 = Off

1 = Ready signal

2 = Air signal 3 = Purge signal 4 = Cooling air valve 5 = Flue gas valve

6 = Fault signal

7 = Burner 1 operating signal

8 = Burner 2 operating signal

Contact 90, 91/92 function

▷

See parameter

I050 for parameter values

Function of contact 95/96

▷

See parameter

I050 for parameter values

Function of contact 95/97

▷

See parameter

I050 for parameter values

Contact 85/86, 87 function

▷

See parameter

I050 for parameter values

Parameter No.

Parameter name Parameter value

Function of input 1

0 = Of

1 = Sensor 1

2 = Sensor 2 3 = Sensor 3 4 = Safety interlocks 5 = Air

6 = Cooling air

7 = Air actuator R1

I061

8 = Air actuator R2

9 = Start 1

= Start 2

10 11 = Reset 12 = Purge 13 = LDS 14 = HT 15 = Flame mode 16 = Flameless operation 17 = menox 19 = Auxiliary gas

I062

I063

I064

I065

I066

I067

I068

I069

I070

I071

I072

I073

I074

Function of input 2

▷

See parameter

Function of input 3

▷

See parameter

Function of input 4

▷

See parameter

Function of input 5

▷

See parameter

Function of input 6

▷

See parameter

Function of input 7

▷

See parameter

Function of input 35

▷

See parameter

Function of input 36

▷

See parameter

Function of input 37

▷

See parameter

Function of input 38

▷

See parameter

Function of input 39

See parameter

▷

Function of input 40

▷

See parameter

Function of input 41

See parameter

▷

f

I061 for parameter values

GB-28

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P

PZ

PZH

PZL

PDZ

P

xx

M

0°➔90°

90°

Legend

pu/2

Ready for operation

Safety interlocks (limits)

HT

High temperature operation

Gas valve

Air valve

Burner

Purge

Controlled air ﬂow

Burner operating signal

Start-up signal (BCU)

Pressure switch for tightness control (TC)

Pressure switch for maximum pressure

Pressure switch for minimum pressure

Differential pressure switch

Input signal depending on parameterxx

Control element with butterﬂy valve

Tightness control

TC

Half of the inlet pressure

Outlet pressure

p

d

GZL

Valve with proof of closure switch

Input/Output, safety circuit

xx

Optional input

Approaching/checking ignition position

Approaching max. capacity

Checking position for max. capacity

I

Current consumption of sensor/contactor

N

Technical data

Ambient conditions

Avoid direct sunlight or radiation from red-hot surfaces on the unit. Avoid corrosive inﬂuences, e.g. salty ambient air

.

or SO

2

The unit may only be stored/installed in enclosed

rooms/buildings that are not accessible to the public.

This unit is not suitable for cleaning with a high-

pressure cleaner and/or cleaning products. Ambient temperature:

-20 to +70°C (-4 to +158°F), no condensation permitted. Storage temperature: -20 to +70°C (-4 to +158°F).

Transport temperature = ambient temperature.

Enclosure: IP65 pursuant to IEC529. Safety class: 1. Pollution degree: internal environment:2, external environment:4. Permitted operating altitude: < 2000 m AMSL.

Mechanical data

Weight: 5 kg. Dimensions (W × H × D): 200 × 230 × 135 mm. Connections: Screw terminals: nominal cross-section 2.5mm², wire cross-section (rigid) min. 0.2mm², wire cross-section (rigid) max. 2.5mm², wire cross-section AWG/kcmil min.24, wire cross-section AWG/kcmil max.12. Spring force terminals: nominal cross-section 2 x 1.5 mm², wire cross-section min. 0.2 mm², wire cross-section AWG min.24, wire cross-section AWG max.16, wire cross-section max. 1.5mm².

Electrical data

Mains voltage: BCU..Q: 120VAC, -15/+10%, 50/60Hz, ±5%, BCU..W: 230VAC, -15/+10%, 50/60Hz, ± 5%. Power consumption: 10VA, for grounded and ungrounded mains. Flame control: with UV sensor or ﬂame rod. For intermittent or continuous operation. Flame signal current: Ionization control: 1 – 25 μA, UV control: 1 – 35 μA. Ionization cable, UV cable: max. 50 m (164ft). Contact rating: Valve outputs V1, V2, V3 andV4 (terminals60, 61, 62, 63 and64): max.1A each, cosφ Actuator outputs (terminals 65, 66 and 67): max.1A each, cosφ=1. Air valve output (terminal 65): max.1A, cosφ=1. Ignition transformer (terminal 51): max.2A.

GB-29

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.

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Total current for the simultaneous activation of the

valve outputs (terminals 60, 61, 62, 63 and64) and of the ignition transformer (terminal51), protected by F1/F2: max.2.5A.

Total current for the simultaneous activation of the

outputs for air valve and actuator (terminals 65, 66 and67): max.2A. Signalling contact for operating and fault signals: max.1A, cosφ=1 (external fuse required). Number of operating cycles:

The fail-safe outputs (valve outputs V1, V2, V3

andV4) and the air valve output are monitored for correct functioning and are thus not subject to a max. number of operating cycles. Control actuator (terminals60, 61, 62, 63 and64):

1,000,000,

signalling contact for operating signals (terminals95, 96 and97):

1,000,000,

signalling contact for fault signals (terminals80, 81 and82): max. 25,000, On/Off button: max. 10,000, Reset/Information button: max. 10,000. Input voltage of signal inputs:

Rated value 120 VAC 230 VAC Signal “1” 80 – 132 V 160 – 253 V Signal “0” 0 – 20 V 0 – 40 V

Signal input current:

Signal “1” max. 5 mA

Fuses, replaceable, F1/F2/F3: T 3.15A H, pursuant to IEC 60127-2/5. Does not meet the requirements for safety extra-low voltage (SELV/PELV).

Designed lifetime

This information on the designed lifetime is based on

using the product in accordance with these operating instructions. Once the designed lifetime has been reached, safety-relevant products must be replaced.

Designed lifetime (based on date of manufacture): 10years. You can ﬁnd further explanations in the applicable

rules and regulations and on the afecor website

(www.afecor.org). This procedure applies to heating systems. For

thermoprocessing equipment, observe local regu-

lations.

Safety instructions

Scope of application: as set out in “Industrial thermoprocessing equipment– Part 2: Safety requirements for combustion and fuel handling systems” (EN746-2) when used with fuels and oxidants.

The BCU4 is suitable for continuous operation (pur-

suant to EN298:2012-12, Section 3.126) and for

intermittent operation (pursuant to EN298:2012-11, Section 3.127). Action:

Type 2 pursuant to EN60730-1.

Behaviour under fault conditions:

The output signals are switched off electronically

in accordance with the criteria of automatic action type B.V.AC.AD.AF.AG.AH (pursuant to EN 607302-5:2015, Section 6.4.3.). Maximum reaction time in the event of a ﬂame failure:

This corresponds to the safety time during operation

and can be parameterized to between 1and4s. Software class: Corresponds to software classC which operates in a similar double-channel architecture with comparison.

Interfaces

Type of wiring:

Attachment type X to EN 60730-1. Grounding: via PE wire connection. Internal voltages are neither SELV nor PELV. Floating contacts meet the requirements for SELV.

Communication

Safety over EtherCAT over EtherCAT) is used for K-SafetyLink communication. Safety over EtherCAT® is a registered trademark and patented technology licensed by Beckhoff Automation GmbH, Germany.

The K-SafetyLink technology complies with SIL3

in accordance with EN61508 and is standardized

pursuant to IEC61784-3-12 and ETG5100. Safety over EtherCAT® uses the fail-safe principle which means that a safe state is restored in the case of an inactive signal. In the case of communication

errors, all signals are interpreted as inactive. Safety-relevant data are transmitted on the basis of the black channel principle. All devices connected to the communication system

must meet the requirements for safety extra-low voltage (SELV/PELV) (EN6730-1).

The end user must ensure the unique setting and

parameterization of the SafetyLink address within the Ethernet network.

The setting and assignment of the addresses must be

veriﬁed before commissioning using the veriﬁcation

procedure described in the extended documentation.

®

technology (FSoE, FailSafe

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Logistics

174 mm

200 mm

Transport

Protect the unit from external forces (blows, shocks, vibration).

Transport temperature: see page 29 (Technical

data).

Transport is subject to the ambient conditions de-

scribed. Report any transport damage on the unit or packaging without delay. Check that the delivery is complete, see page3 (Part designations).

Storage

Storage temperature: see page 29 (Technical data). Storage is subject to the ambient conditions described. Storage time: 6months before using for the ﬁrst time. If stored for longer than this, the overall service life will be reduced by the corresponding amount of extra storage time.

Packaging

The packaging material is to be disposed of in ac-

cordance with local regulations.

Disposal

Components are to be disposed of separately in accordance with local regulations.

Accessories

BCSoft

The current software can be downloaded from our

Internet site at http://www.docuthek.com. To do so, you need to register in the DOCUTHEK.

Opto-adapter PCO 00

Including BCSoft CD-ROM, Order No. 74960625.

Fastening set

▷

To ensure a gap between the BCU and the

mounting surface with higher temperatures.

22 mm

16.5 mm

12 mm

7 mm

20 mm

230 mm

45 mm

263 mm

222 mm

74960422

External securing bars

▷ The external securing bars are screwed on from

inside the unit.

225 mm

212 mm

185 mm

74960414

Bus module BCM 400

Communication interface for connecting the BCU to an automation system.

Ø 4mm

Connection plug set

For wiring the BCU.

74924876 74924877

Connection plugs with screw terminals, Order No. 74924876. Connection plugs with spring force terminals, Order No. 74924877.

Bus module Bus system Order No. BCM 400S0B1/1-0 Proﬁbus 74960690 BCM 400S0B2/3-0 Proﬁnet 74960691 BCM 400S0B3/3-0 EtherNet/IP 74960692

Set of language stickers

To afﬁx to the cover, with program step/fault message de-

scriptions in English, French, Dutch, Spanish and Italian, Order No. 34336970.

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Certiﬁcation

Declaration of conformity

We, the manufacturer, hereby declare that the products BCU460, BCU465 and BCU480 comply with the requirements of the listed Directives and Standards.

Directives: – 2014/30/EU – 2014/35/EU

Regulation: – (EU) 2016/426 – GAR

Standards: – EN 298:2012 – EN 1643:2014 – EN 60730-2-5 – EN 61508:2010, suitable for SIL 3

The production is subject to the surveillance proce-

dure pursuant to Regulation (EU) 2016/426 AnnexIII

paragraph3.

Elster GmbH

Scan of the Declaration of conformity (D,GB)– see

www.docuthek.com

1)

There is no need for any additional EMC measure-

ment when installed.

1)

SIL, PL

For systems up to SIL 3 pursuant to EN61508. Pursuant to EN ISO 13849-1, Table 4, the BCU can

be used up to PLe.

Safety-speciﬁc characteristic values Diagnostic coverage DC 91.3%

Type of subsystem

Type B to EN 61508-

2:2010 High demand mode

Mode of operation

pursuant to EN61508-4:2010

32.9 × 10-9 1/h on Mean probability of dangerous failure PFH

Mean time to dangerous failure MTTF

d

BCU4xx..F1,

38.3 × 10-9 1/h on

D

BCU4xx..F3

1/PFH

D

Safe failure fraction SFF 99.0%

Mean probability of dangerous failure PFHD (70°C) of individual safety functions

Burner control with 2 gas valves Burner control with 3 gas valves Valve check Proof of closure 3.3 × 10-9 1/h Flame control 8.4 × 10

Temperature monitoring 2.2 × 10

Air pressure switch monitoring 3.3 × 10 Gas pressure switch monitoring 3.3 × 10 Purge with air pressure switch 4.3 × 10 K-SafetyLink 1.0 × 10 Safety interlocks (limits) 2.2 × 10 Valve check with redundant pres-

sure switch Air pressure switch monitoring

with red. pressure switch Gas pressure switch monitoring

with red. pressure switch Purge with red. air pressure

switch

23.2 × 10-9 1/h

28.5 × 10-9 1/h

15.0 × 10-9 1/h

-9

1/h

-9

1/h

-9

1/h

-9

1/h

-9

1/h

-9

1/h

-9

1/h

12.9 × 10-9 1/h

1.3 × 10-9 1/h

-9

1.3 × 10

2.3 × 10

-9

1/h

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FM approved

Factory Mutual (FM) Research Class:

7610 “Combustion Safeguards and Flame Sensing

Systems” Suitable for applications pursuant to NFPA 86.

Directive on the restriction of the use of hazardous substances (RoHS) in China

Scan of the Disclosure Table China RoHS2 – see certiﬁcates at www.docuthek.com

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Contact

If you have any technical questions, please contact your local branch ofﬁce/agent. The addresses are available on the Internet or from ElsterGmbH.

We reserve the right to make technical modiﬁcations in the interests of progress.

Strotheweg 1, D-49504 Lotte (Büren)

Elster GmbH

Tel. +49 541 1214-0

Fax +49 541 1214-370

hts.lotte@honeywell.com, www.kromschroeder.com

GB-34

Krom Schroder BCU 46, BCU 460, BCU 465, BCU 480 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Safety

Checking the usage

Installation

Replacing the power module/bus module/parameter chip card

Cable selection and installation

Wiring

Connection diagram

Flame control

Adjustment

Commissioning

Manual mode

Assistance in the event of malfunction

Parameters and values

Legend

Technical data

Safety instructions

Logistics

Accessories

Contact