Krom Schroder FCU 505, FCU 500 Operating Instructions Manual

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Operating instructions

Protective system control FCU 500 Furnace zone control FCU 505

Translation from the German

Contents

Protective system control FCU 500

Furnace zone control FCU 505 ............

Contents ..............................

Safety.................................

Checking the usage .....................

Installation ............................

Replacing the protective system/furnace

zone control ...........................

Cable selection.........................

Wiring ................................4

Connection diagram ....................6

FCU 500 ..............................6

FCU 505 .............................. 7

IC 20 connected to FCU..F1 ...............8

IC 20 E connected to FCU..F1..............9

IC 40 connected to FCU..F1 ..............10

RBW valve connected to FCU..F2 .......... 11

Frequency converter connected to FCU..F2 ..12

Adjustment ...........................

Commissioning........................

Manual mode .........................4

Assistance in the event of malfunction ....5

Replacing the fuse ......................21

Parameters and values .................

Legend...............................4

Technical data ........................4

Designed lifetime .......................25

Logistics .............................5

Accessories ..........................5

Certification ..........................6

Contact ..............................6

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

• ,  ,  ,  ... = 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.

Changes to edition 09.4

The following chapters have been changed: – Replacing the protective system/furnace zone

control

– Certification

GB-1

Checking the usage

The protective system control FCU 500 and furnace

zone control FCU 505 are designed for the monitoring and controlling of central safety functions in multiple burner systems on an industrial furnace.

The FCU500 controls multiple zones acting as the

central protective system control. The FCU505 is used for protective system and capacity control in individual furnace zones.

Type code

Code Description FCU 500 FCU 505

Q W C0 C1

F0 F1 F2

H0 H1

K0 K1 K2

Part designations

Mains voltage: 120 V AC, 50/60 Hz

Protective system control

Furnace zone control

230 V AC, 50/60 Hz

No valve proving system

With valve proving system

Capacity control:

none

with interface for actuator IC

with interface for RBW

Temperature monitoring:

none

with temperature monitoring

Connection terminals:

none

screw terminals

spring force terminals

Installation

▷

Installation position: vertically upright, horizontal or tilted to the left or right.

▷

The FCU mounting is designed for horizontally

aligned 35 × 7.5 mm DIN rails.

▷

If the DIN rail is aligned vertically, end clamps are required (e.g. Clipﬁx 35 by Phoenix Contact) to prevent the FCU from slipping.

▷

Install in a clean environment (e.g. a control cabinet) with an enclosure ≥ IP 54, whereby no condensation is permitted.

 LED display for program status and fault

messages

 Reset/Information button  On/Off button 4 Type label 5 Connection for opto-adapter 6 Power module, detachable 7 Power module type label 8 Parameter chip card

Type designation (FCU…), construction stage, input

voltage – see type label.

FCU

GB-2

Replacing the protective system/ furnace zone control

 Disconnect the system from the electrical power

supply.

 Disengage the FCU from the DIN rail.

4 5

6 Transfer the parameter values from the old FCU

to the new FCU.

▷ Remove the parameter chip card from the old

FCU and insert into the new FCU.

CAUTION

Malfunction (fault message

new FCUs must have the same hardware conﬁguration (see type designation on type label). The parameter chip card is not backward compatible. If the parameter chip card has been operated in an FCU with more recent ﬁrmware, it cannot be used in a device with older ﬁrmware.

▷

Alternatively, the parameters values can be read from the old FCU and then read back into the new FCU using the separate BCSoft software, see pages 13 (Adjustment) and 25 (Accessories).

7 Slide the power module back on. 8 Mount the FCU on the DIN rail again. 9 Reconnect the connection terminals. 0 Switch the system on again, see page 13

(Commissioning).

▷

Fault message

: Parameter chip card from FCU construction stage B or above has been inserted into FCU construction stage A, see also page 15 (Assistance in the event of malfunction).

)! The old and

Cable selection

▷

Use cables suitable for the type of operation and complying with local regulations.

▷

Signal and control line for screw terminals max. 2.5mm2, for spring force terminals max.

1.5mm2.

▷

Do not route FCU cables in the same cable duct as frequency converter cables or cables emitting strong ﬁelds.

▷

Control lines must fulﬁl the requirements of EN60204-1, Chapter12.

▷ Avoid external electrical interference.

GB-3

Wiring

▷

Do not reverse phase L1 and neutral conductor N.

▷ Do not install different phases of a three-phase

current system at the inputs.

▷ Do not connect voltage to the outputs. ▷

A short-circuit on the outputs causes one of the

replaceable fuses to trip.

▷

Ensure that the inputs at terminals 1 to 4 and

44 are only supplied with 24 V DC.

▷

24 V DC power supply: + at terminal 62, - at terminal 61.

▷

Ensure that the 24 V DC outputs at terminals

41 and 42 are not connected to mains voltage.

▷ Do not set the remote reset so that it operates

automatically in cycles.

▷ Wire the safety circuit inputs via contacts (relay

contacts) only.

▷ The unit features an output for fan control (termi-

nal58). This single-pole contact can be loaded with a max. of 3A. The max. start-up current of the fan motor may not exceed a value of max. 6A for 1s– use an external contactor if required.

▷

The limiters in the safety interlock (linking of all the

relevant safety control and switching equipment for the use of the application, for example, safety temperature limiter) must isolate terminal46 from the voltage supply. If the safety interlock is interrupted, the display shows a blinking a warning signal and all of the FCU’s control 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 FCU.

▷

Functions of terminals 51, 65, 66, 67 and 68 are

dependent on parameter values:

Terminal Dependent on parameter

51 69 65 70 66 71 67 72 68 73

See page 22 (Parameters and values).

 Disconnect the system from the electrical power

supply.

 Before wiring the FCU, ensure that the yellow

parameter chip card has been installed in the FCU– see page 3 (Replacing the protective system/furnace zone control).

▷

Screw terminals or spring force terminals are available for the FCU– see page 25 (Accessories).

 Wire as shown on the connection diagram– see

page6 (Connection diagram).

▷ Ensure a good PE (ground) wire connection to

the burner control units and burners.

FCU..H

▷

Use type K NiCr-Ni, type N NiCrSi-NiSi or type S Pt10Rh-Pt Class 1 double thermocouples only.

Thermocouple

Temperature range

(°C) Type K NiCr-Ni -40 to 1000 Type N NiCrSi-NiSi -40 to 1000 Type S Pt10Rh-Pt 0 to 1600

▷

Parameter 22 = 1: Type K double thermocouple NiCr-Ni

▷

Parameter 22 = 2: Type N double thermocouple NiCrSi-NiSi

▷

Parameter 22 = 3: Type S double thermocouple Pt10Rh-Pt

▷ STM:

Parameter 20 = 1: High temperature operation with STM. Position the double thermocouple at the coldest point in the furnace so that it can reliably detect whether the spontaneous ignition temperature (>750°C) has been exceeded.

▷ STL:

Parameter 20 = 2: Maximum temperature monitoring using STL. Position the double thermocouple at the warmest point in the furnace so that it can reliably detect whether the maximum permitted temperature has been exceeded.

▷ STL and STM:

Parameter 20 = 3: High temperature operation

with STM and maximum temperature monitoring with STL. Position the double thermocouple in the furnace in such a way that it can reliably detect whether the spontaneous ignition temperature (>750°C) has been exceeded and also whether the maximum permitted furnace temperature has been exceeded.

FCU..C

▷

Parameter 51 = 1: Tightness test before furnace start-up.

▷

Parameter 51 = 2: On; tightness test after furnace shut-down, after a fault lock-out or after mains on.

▷

Parameter 51 = 3: On; tightness test before furnace start-up and after furnace shut-down.

▷

Parameter 51 = 4: Permanent via proof of closure function (POC).

GB-4

Safety interlock output in the case of higher

24 25 26 2718 19 20

50 5130 31 32 33 34 35 36 37 38

max. 2 A

253 V

max. 2 A

253 V

power requirement

▷

The burner start enable signal is issued to the

connected burner control units or automatic burner control units via the safety interlock output (terminal 57). For burner control units or automatic burner

▷

control units whose safety interlock input has a power consumption of ≤ 2 mA, the power (max. 0.5 A, cos ϕ = 1) of the FCU is sufﬁcient to directly activate them.

▷

In the event that a higher output current is required, the output current can be increased by means of a contact multiplier using two contactors. Design the circuit as follows:

90°➔0°

0°➔90°

53 54 55 56 57 5849 50 51 52

Input BCU/IFD

5AT

3.15AT × 0.6

F = I

k1k1

k2k2

▷

BCU with power supply for valves and ignition transformer via safety interlocks (terminal 5)

7 8 119 10 1 2 13 14 15

230 V AC

N N

≤ 2.5 A

▷

In the event that a higher output current is required, the output current can be increased by means of a contact multiplier using three contactors. Design the circuit as follows:

Input BCU

Terminal 22

13 14 15 16 17

53 54 55 56 5749 50 51 52

Input BCU

FCU 500

11 12

FCU 500

Terminal 5

× 0.6

F = I

k3 k1

GB-5

Connection diagram

FCU 500

▷ Legend– see page24 (Legend).

LDS

13 14 15 16 17 1811 123 41 2

3.15AT

90°➔0°

0°➔90°

53 54 55 56 57 5849 50 51 52

5AT

K2 K1

IN × 0.6

k11

k21

P69

max

PZH

Gas

min

PZL

FCU 500

47 48

P72

P71 P73

Gas

Air

min

Air

PDZ

PZL

STL

STM/

+ - + -

5 6 7 8

P70

0.6 x I

Output

+24 V DC

61 62

41 42 44 45

+24 V

0 V

GB-6

FCU 505

▷ Legend – see page 24 (Legend).

LDS

STM/

STL

+ - + -

K2 K1

IN × 0.6

k11

90°➔0°

13 14 15 16 17 1811 123 41 2

3.15AT

0°➔90°

53 54 55 56 57 5849 50 51 52

5AT

k21

P69

max

PZH

Gas

min

PZL

FCU 505

47 48

P72

P71 P73

Gas

Air

min

Air

PDZ

PZL

5 6 7 8

P70

0.6 x I

Output

+24 V DC

61 62

41 42 44 45

0 V

+24 V

GB-7

IC 0 connected to FCU..F

LDS

STW/

STB

▷ Parameter 40 = 1. ▷

Continuous control via three-point step controller.

6 7 8

47 48

FCU 500

13 14 15 16 17 1811 12

3.15AT

5AT

0°➔90°

90°➔0°

53 54 55 56 57 5849 50 51 52

L1 N PE

90°➔0°

S11

0°➔90°

3 2 116 67 4812 1115 13

S3 S4

IC 20

S10

0°

90°

S1S2

GB-8

IC 0 E connected to FCU..F

LDS

STW/

STB

▷ Parameter 40 = 1. ▷ Continuous control via analogue input.

6 7 8

FCU 500

47 48

3.15AT

0°

OUT

20 19 18 3 2 167 4812 11

1 2 3 4 5 6

90°

+ +

131516

5AT

13 14 15 16 17 1811 12

90°➔0°

0°➔90°

53 54 55 56 57 5849 50 51 52

L1 N

IC 20..E

0°

90°

➔

0°

90°

517

S10

µC

GB-9

IC 40 connected to FCU..F

LDS

STW/

STB

▷ Parameter 40 = 2. ▷ Continuous control via analogue input. ▷ Set IC 40 to operating mode 27, see operating

instructions Actuators IC 20, IC 40, IC 40S.

7 8

FCU 500

47 48

22 21 20

13 14 15 16 17 1811 12

3.15AT

5AT

90°➔0°

0°➔90°

53 54 55 56 57 5849 50 51 52

19 18 16 15 14 12 11 10 8 7 5 4 2 1

IC 40

L N

R..

GB-10

RBW valve connected to FCU..F

LDS

STW/

STB

+ - + -

LDS

+ - + -

STW/

STB

▷ Parameter 40 = 3.

Continuous control via three-point step controller

5 6 7 8

Continuous control via analogue input

5 6 7 8

FCU 500

47 48

0°➔90°

RBW

5AT

90°➔0°

13 14 15 16 17 1811 12

COM

AUTO

53 54 55 56 57 5849 50 51 52

R B W

13 14 15 16 17 1811 12

L1 N

FCU 500

47 48

5AT

COM

53 54 55 56 57 5849 50 51 52

AUTO

OUT

PLC

+ F -

0°➔90°

RBW

L1 N

GB-11

Frequency converter connected to FCU..F

LDS

+ - + -

STW/

STB

▷ Parameter 40 = 4. ▷ Continuous control via speed-controlled fan.

5 6 7 8

FCU 500

47 48

PLC

0–100%

5AT

Target = actual

13 14 15 16 17 1811 12

COM

53 54 55 56 57 5849 50 51 52

PDZ

AUTO

DI 3DI 2DI 1

GB-12

Adjustment

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

▷

The software package and the opto-adapter

are available as accessories– see page 25 (Accessories).

▷

Changed parameters are saved on the integrated parameter chip card.

▷

The factory settings are secured with a program-

mable password. If the password has been changed, the end cus-

▷

tomer can look up the changed password in the plant documentation or ask the system supplier.

Commissioning

▷

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

Device Off

––

Start-up position/standby

Switch-on delay/min. pause time

Waiting for purge signal from furnace FCU

Waiting for start enable

Approaching minimum capacity

“No ﬂow” state check on fan

Fan run-up time t

Approaching maximum capacity

Air pressure cut-out check

Pre-purge

Approaching ignition capacity

Valve check Controller enable switch-on delay

Waiting for burner operating signal

Operation/controller enable

Post-purge

Controlled air ﬂow

Remote control (with OCU)

U I

Data transfer (programming mode) High temperature mode

X.X.

(blinking dots) Manual mode

0.0.

WARNING

Risk of explosion! Check the system for tightness before commissioning. Do not start the FCU until you are certain that the wiring is correct, the parameters have been set correctly and all input and output signals are being processed perfectly by means of conducting a function check and reading the parameters on the device.

 Switch on the system.

▷ The display indicates

 Switch on the FCU by pressing the On/Off button.

▷ The display indicates ▷

If the display blinks (fault), reset the FCU by pressing the Reset/Information button, see also page

15 (Assistance in the event of malfunction).

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

▷ The display indicates

are checked during the switch-on delay time/ min. pause time.

▷ The display indicates ▷ The display indicates

out check starts.

▷ The display indicates ▷ FCU..C1: the valve check runs in parallel to pre-

purge. If the valve check lasts longer than prepurge, the display indicates

▼

––

The safety interlocks

. The fan starts.

. The air deﬁciency cut-

. Pre-purge starts.

GB-13

▷

The display indicates

. After pre-purge (and the

end of the valve check on FCU..C1), the valves in the gas inlet section are opened.

▷

The display indicates

. The FCU issues the

enable signal to the burner control units to start the burners.

High temperature operation

The FCU..H1 is ﬁtted with an integrated temperature

module for high temperature operation. As soon as the FCU has received the signal from the connected double thermocouples that the temperature deﬁned in parameter24 has been reached, a signal is sent to the high temperature inputs of the burner control

units by the output at terminal 18. If voltage is applied to the high temperature inputs, the burner ﬂames will no longer be monitored by the burner control units.

WARNING

Risk of explosion! High temperature operation is only permitted if the temperature in the furnace chamber is so high that the gas/air mixture is reliably combusted. In countries where EN746/NFPA86 is applicable, if the furnace wall temperature is greater than or equal to 750°C (1400°F), the ﬂame may be monitored by a fail-safe temperature monitoring device that complies with the standard. Only if the temperature is greater than or equal to 750°C (1400°F) may voltage be applied to the high temperature inputs of the burner control units. Comply with the local safety regulations.

▷ In high temperature mode, the two dots in the

display are lit permanently.

The ﬂame control system is placed out of op-

▷

eration.

▷

Once the furnace temperature falls below the value deﬁned in parameter24, terminal18 is isolated from the voltage supply. The burner control units continue operating with ﬂame control, depending on their setting.

Manual mode

▷

For adjustment of the furnace system or for fault-ﬁnding.

▷

In Manual mode, the FCU operates independently of the status of the inputs for start-up signal (terminal1), controlled air ﬂow (terminal2) and remote reset (terminal3). The function of the controller enable/emergency stop input (terminal46) is retained.

▷ Manual mode is terminated by switching off the

FCU or in the event of a power failure.

▷

Parameter 67 = 0: Manual mode unlimited in time. The furnace may continue to be operated manually in the event of failure of the control system or the bus.

▷

Parameter 67 = 1: The FCU 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

 Switch on the FCU while holding the Reset/In-

formation button. Hold the Reset/Information button until the two dots in the display start to blink.

▷ If the Reset/Information button is pressed, the

current step in Manual mode is shown. After the button has been held for 1 second, the next step will be shown. The FCU now executes its program sequence until the display indicates

FCU..F with IC 0

▷

Following controller enable (display IC20 can be opened and closed as required.

 Press the Reset/Information button.

▷

If the button continues to be held down, the actuator opens further until maximum capacity has been reached.

▷ The display indicates ▷

Once the button has been released, the butterﬂy

with blinking dots.

A.1.

valve stops in the relevant position.

 Press the Reset/Information button again.

▷

If the button continues to be held down, the actuator closes further until minimum capacity has been reached.

▷ The display indicates

with blinking dots.

A.0.

▷ A change of direction takes place each time the

button is released and pressed again. When the butterﬂy valve has reached its ﬁnal position, the dots disappear.

FCU 500..F with IC40, FCU500..F with RBW or frequency converter

▷

Following controller enable (status display is possible to approach binary positions between minimum and maximum capacity.

), actuator

0.8.

), it

GB-14

Assistance in the event of malfunction

DANGER

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

? 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).

2 1

? The display blinks and indicates ! Inputs 51 and 52 are activated simultaneously.

• Check input 51.

▷

Input 51 may only be activated if the valve is open.

• Check input 52. ▷ Input 52 may only be activated if the valve is in

the ignition position.

2 2

? The display blinks and indicates ! Valve IC 20 has been wired incorrectly.

• Check the wiring. Wire the outputs and inputs

of connection terminals 52–55 as shown in the connection diagram – see page 8 (IC 20 connected to FCU..F1).

! The unit has suffered an internal fault in the power

module.

• Replace the power module.

1 0

? 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 FCU may only be reset manually under su-

pervision.

• Press the Reset/Information button on the FCU.

2 0

? The display blinks and indicates ! Voltage is applied to the output at terminal 56.

• Check the wiring and ensure that the voltage outputs and inputs have the same polarity and are not reversed.

! The unit has suffered an internal fault in the power

module.

• Replace the power module.

2 3

? The display blinks and indicates ! The valve position is not constantly signalled

back to theFCU.

• Check the wiring and ensure that the open/ignition position of the valve is constantly signalled back via terminal52.

2 4

? The display blinks and indicates ! Faulty activation via the bus. Requirements for

“Open” and “Close” set simultaneously.

• Ensure that “Open” and “Close” are not activated simultaneously.

3 0

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

theFCU.

• 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 properly– see page3 (Cable selection).

GB-15

• If the measures described above do not help, remove the unit and return it to the manufacturer for inspection.

3 1

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

theFCU.

• 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 properly– see page3 (Cable selection).

• If the measures described above do not help, remove the unit and return it to the manufacturer for inspection.

3 2

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

• Operate the FCU in the speciﬁed mains voltage range (mains voltage +10/-15%, 50/60Hz).

! The unit has suffered an internal fault.

• Remove the unit and return it to the manufacturer for inspection.

3 8

? The display blinks and indicates ! Interruption of signal at the “Fan feedback” input

(terminal44).

• Check voltage supply to terminal44.

• Check the setting of parameter31.

4 0

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

• Check the gas solenoid valve V1.

! The gas pressure switch DGpu/2 (DGpu¾) for

the tightness test has been set incorrectly.

• Check the inlet pressure.

• Set DGpu/2 (DGpu¾) to the correct inlet pressure.

• Check the wiring.

! The test pressure between V1 andV2 has not

decreased.

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

• Change parameter56 (Measurement time) using BCSoft.

• If the fault cannot be remedied by doing this, remove the unit and return it to the manufacturer for inspection.

3 3

? The display blinks and indicates ! Faulty parameterization.

• Check parameter settings using BCSoft.

! The unit has suffered an internal fault.

• Remove the unit and return it to the manufacturer for inspection.

3 6

? The display blinks and indicates ! The unit has suffered an internal fault.

• Remove the unit and return it to the manufacturer for inspection.

3 7

? The display blinks and indicates ! Faulty feedback from contactors.

• Check voltage supply to terminal 68– see page 5 (Safety interlock output in the case of higher power requirement).

• Check the setting of parameter73.

4 1

? The display blinks and indicates ! The gas solenoid valve V2 or V3 is leaking.

• Check the gas solenoid valves V2/V3.

! The gas pressure switch DGpu/2 (DGpu¾) for

the tightness test has been set incorrectly.

• Check the inlet pressure.

• Set DGpu/2 (DGpu¾) to the correct inlet pressure.

• Check the wiring.

! The test period is too long.

• Change parameter56 (Measurement time) using BCSoft.

• If the fault cannot be remedied by doing this, remove the unit and return it to the manufacturer for inspection.

4 2

? The display blinks and indicates ! Test volume V ! The gas solenoid valve V3, one of the burner-side

valves or the pipework is leaking.

• Check the gas solenoid valves and pipework.

GB-16

is leaking.

! The gas pressure switch DGpu/2 (DGpu¾) has

been set incorrectly.

• Check the inlet pressure.

• Set DGpu/2 (DGpu¾) to the correct inlet pressure.

• Check voltage supply to terminal 45 (65).

! The set test period Vp1+Vp2 is too long.

• Change the test period using parameter57.

• If the fault cannot be remedied by doing this,

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

4 4

? The display blinks and indicates ! The FCU could not supply one of the test vol-

umes (Vp1 orVp2).

! The FCU could not reduce the pressure of Vp1

• Faulty wiring of the activated valves.

• Check valve actuation.

• Faulty wiring of the pressure switches.

• Check voltage supply to terminal 46 (65).

orV

5 2

? The display blinks and indicates ! The FCU is being permanently reset.

• Check voltage supply to terminal3.

• Apply voltage to terminal3 only for reset, approx.

1second.

6 0

? The display blinks and indicates ! The safety temperature limiter (STL) has detected

an overtemperature condition.

• Check the temperature control.

• Check the wiring of terminals 5, 6, 7 and8.

! The double thermocouple is defective.

• Replace the double thermocouple.

• If the fault cannot be remedied by doing this,

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

4 5

? The display blinks and indicates ! Faulty valve actuation. ! Reversed valve connection.

• Check the wiring of the valves.

5 0

? The display blinks and indicates ! Interruption of signal at the “Enable/Emergency

stop” input (terminal46).

• Check voltage supply to terminal46.

• Check the setting of parameter10.

5 1

? The display blinks and indicates ! Short-circuit on one of the outputs of the safety

circuit.

• Check the wiring.

• Check ﬁne-wire fuseF1 (3.15A, slow-acting,H).

▷

The ﬁne-wire fuse can be replaced once the

power module has been removed, see also page 21 (Replacing the fuse)

• Then check the faultless processing of all input and output signals.

! The unit has suffered an internal fault in the power

module.

• Replace the power module.

6 2

? The display blinks and indicates ! A cable discontinuity has been detected in the

thermocouple at terminals 5 and 6.

• Check the wiring of terminals 5 and6.

• Replace the double thermocouple.

• If the fault cannot be remedied by doing this,

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

6 3

? The display blinks and indicates ! A cable discontinuity has been detected in the

thermocouple at terminals 7 and 8.

• Check the wiring of terminals 7 and8.

• Replace the double thermocouple.

• If the fault cannot be remedied by doing this,

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

GB-17

6 4

? The display blinks and indicates ! A malfunction (sensor short-circuit) has been de-

tected in the thermocouple at terminals 5 and6.

• Check the wiring of terminals 5 and 6.

• Replace the double thermocouple.

• If the fault cannot be remedied by doing this,

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

7 0

? The display blinks and indicates ! The connected burner control units have not

signalled “Operating position reached (burner started)” within the time deﬁned by parameter47.

• Check voltage supply to “Operating signal” input (terminal4).

• Check the setting of parameter47.

? The display blinks and indicates ! A malfunction (sensor short-circuit) has been de-

tected in the thermocouple at terminals 7 and8.

• Check the wiring of terminals 7 and 8.

• Replace the double thermocouple.

• If the fault cannot be remedied by doing this,

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

6 5

6 6

? The display blinks and indicates ! Limit value of the temperature difference set via

Parameter 23 between the thermocouples at terminals 5 and 6, and terminals 7 and 8 has been exceeded.

• Check parameter 23 and adjust correctly.

• Replace the double thermocouple.

• If the fault cannot be remedied by doing this,

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

6 7

? The display blinks and indicates ! The thermocouples are being operated outside

of the allowed temperature range.

• Use type K NiCr-Ni, type N NiCrSi-NiSi or typeS Pt10Rh-Pt Class 1 double thermocouples:

Thermocouple Temperature range (°C) Typ K NiCr-Ni -40 to 1000 Typ N NiCrSi-NiSi -40 to 1000 Typ S Pt10Rh-Pt 0 to 1600

7 2

? The display blinks and indicates ! The connected burner control units are not ready

for operation.

• Check voltage supply to terminal67.

• Check the setting of parameter72.

8 9

9 7

? The display blinks and indicates

96, 97, 98

! System fault– the FCU 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3 (Cable selection).

• Ensure that the EMC regulations for the system are satisﬁed– particularly for systems with frequency converters – see page 3 (Cable selection).

• Reset the unit.

• Disconnect the protective system control 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.

9 4 9 5 9 6

9 8 9 9

89, 94, 95

GB-18

? 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 (terminal47) when air monitoring is activated.

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

has failed. The air monitor has not switched after fan start-up.

• Check the air monitor wiring.

• Check the air pressure switch setpoint.

• Check the function of the fan.

? The display blinks and indicates ! The input signal (terminal48) for the air pressure

switch has dropped out during pre-purge.

• Check the air supply during the purging process.

• Check the electrical wiring of the air pressure

switch.

• Check voltage supply to terminal48.

• Check the air pressure switch setpoint.

? The display blinks and indicates ! The signal for monitoring the max. gas pressure

(terminal50) has dropped out at position stepX.

• Check the wiring.

• Check the gas pressure.

? The display blinks and indicates ! The signal for monitoring the min. gas pressure

(terminal49) has dropped out at position stepX.

• Check the wiring.

• Check the gas pressure.

? The display blinks and indicates ! No “Closed” signal from actuator.

• Check the butterﬂy valve for air 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.

1 0

? The display blinks and indicates ! The input signal for the air pressure switch has

dropped out during start-up/operation at position stepX.

! Failure of the air supply at position stepX.

• Check the air supply.

• Check the air pressure switch setpoint.

? The display blinks and indicates ! No “Open” signal from actuator.

• Check the butterﬂy valve for air 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.

GB-19

? The display blinks and indicates ! No “Ignition position” signal from actuator.

• Check the butterﬂy valve for air 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.

? 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 FCU.

• Use suppressed electrode adapters (1 kΩ).

• If the fault cannot be remedied by doing this,

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

! The bus module is defective.

• Replace the bus module.

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

• Only the parameter chip card provided is to be used.

• Replace defective parameter chip card.

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

during standby.

• Check the wiring.

▷

Mains voltage must be supplied to the FCU 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.

? The display blinks and indicates ! The FCU is receiving no information as to whether

the POC switch contact is still open.

• Check the wiring.

• During start-up, mains voltage must be supplied

to the FCU 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.

? The display blinks and indicates ! BCU waiting for connection to PLC.

• Check whether the PLC is switched on.

• Check the network wiring.

• Check the PLC programming.

• Check whether the correct device name and

IPaddress for the FCU have been entered in the PLCprogram.

? The display blinks and indicates ! An invalid address has been set on the bus mod-

ule.

• Adapt the bus module’s address with the code switches to the address allocated in the PLCprogram.

• Check whether the bus module’s address is in the permitted address range (001toFEF).

? 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 into the PLC.

? The display blinks and indicates ! The device name for the FCU is invalid in the

PLC program.

▷ Device name on delivery:

not-assigned-fcu-500-xxx

(xxx = code switch setting on the FCU).

The device name must at least consist of the

▷

expression fcu-500-xxx.

GB-20

• Check whether the code switch setting is identical to the entry(xxx) in the PLCprogram.

• Delete the expression “not-assigned-” in the PLC program or replace it with an individual name part (e.g. Furnacezone1-).

? The display blinks and indicates ! The PLC is set to Stop.

• Start the PLC.

Replacing the fuse

▷

The device fuses F1 and F2 can be removed

for inspection.

 Disconnect the system from the electrical power

supply.

 Disconnect the connection terminals from the

FCU.

▷ The connection cables may remain screwed to

the connection terminals.

 Disconnect the power module, see page5

(Safety interlock output in the case of higher power requirement).

4 Remove the fuse holder (with ﬁne-wire fuse F1

orF2).

F1:T3,15A H

F2:T5A H

5 Check ﬁne-wire fuse F1 or F2 for correct func-

tioning.

6 Replace the ﬁne-wire fuse if defective.

▷

When replacing the fuse, use only the approved fuse type (F1:3.15A, slow-acting, H, F2: 5A, slow-acting,H; pursuant to ICE60127-2/5).

• First reconnect the power module, then reconnect the connection terminals and restart the system/FCU, see also page13 (Commissioning).

GB-21

Parameters and values

Scanning the parameters

• Press the Reset/Information button for 2s. The

display changes to parameter10.

• Release the button. The display stops at this parameter and indicates the related value.

• Press the button again for 2s. The display changes to the next parameter. All parameters can be recalled one after the other in this way.

▷ If the button is pressed only brieﬂy, the display

indicates what parameter is currently being displayed.

▷

The normal program status is displayed again

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

Parameter values

▷ For all FCU 500 unit variants

Pa-

Name

ram-

Values

eter

Emergency stop

0 = Off

1 = With safety shut-down 2 = With fault lock-out

High gas pressure protection

0 = Off

1 = With safety shut-down 2 = With fault lock-out

Low gas pressure protection

0 = Off

1 = With safety shut-down 2 = With fault lock-out

Low air pressure protection

0 = Off

1 = With safety shut-down 2 = With fault lock-out

Safety time during operation

0; 1; 2 = Time in seconds

Fan in the event of fault

0 = Off

1 = On

Fan run-up time tGV

0 – 6000 = Time in seconds

Fan ready for operation

0 = Off

1 = With safety shut-down 2 = With fault lock-out

Air ﬂow monitoring during controlled air ﬂow

0 = Off; maximum capacity

1 = On; maximum capacity 2 = Off; controller enable

Pre-purge time tPV

0 – 6000 = Time in seconds

Air ﬂow monitoring during pre-purge

0 = Off

1 = With safety shut-down 2 = With fault lock-out

Post-purge time tPN

0 – 6000 = Time in seconds

GB-22

Pa-

Name

ram-

Values

eter

Air ﬂow monitoring during post-purge

0 = On; maximum capacity

1 = Off; maximum capacity

2 = Off; ignition capacity 3 = Off; controller enable

Controller enable signal delay time tRF

0; 10; 20; 30 – 250 = Time in seconds

Minimum pause time tfp

0 – 3600 = Time in seconds

Switch-on delay time tE

0 – 250 = Time in seconds

Operating time in Manual mode

0 = Unlimited

1 = 5 minutes

Function of terminal 51

0 = Off

1 = IC 40/RBW max. capacity feedback

2 = AND with emergency stop (trm.46)

3 = AND with air min. (trm.47) 4 = AND with air ﬂow monitoring (trm.48) 5 = AND with gas min. (trm.49) 6 = AND with gas max. (trm.50)

Function of terminal 65

0 = Off

1 = Reduced DG test duration

2 = AND with emergency stop (trm.46)

3 = AND with air min. (trm.47) 4 = AND with air ﬂow monitoring (trm.48) 5 = AND with gas min. (trm.49) 6 = AND with gas max. (trm.50)

Function of terminal 66

0 = Off

1 = FCU as zone control unit

2 = External HT signal 3 = AND with emergency stop (trm.46)

4 = AND with air min. (trm.47) 5 = AND with air ﬂow monitoring (trm.48) 6 = AND with gas min. (trm.49)

7 = AND with gas max. (trm.50) Function of terminal 67

0 = Off

1 = BCU ready; safety shut-down

2 = BCU ready; fault lock-out 3 = AND with emergency stop (trm.46)

4 = AND with air min. (trm.47) 5 = AND with air ﬂow monitoring (trm.48) 6 = AND with gas min. (trm.49)

7 = AND with gas max. (trm.50) Function of terminal 68

0 = Off

1 = Contactor feedback

2 = AND with emergency stop (trm.46)

3 = AND with air min. (trm.47) 4 = AND with air ﬂow monitoring (trm.48) 5 = AND with gas min. (trm.49) 6 = AND with gas max. (trm.50)

Password

0000 – 9999

▷ Additional parameters for FCU..H1

Pa-

Name

ram-

Values

eter

Temperature monitoring mode

0 = Off 1 = STM function (high temperature operation)

2 = STL function 3 = STM and STL functions

Thermocouple

1 = Type K

2 = Type N 3 = Type S

Temperature difference limit value

10 – 100

Temperature in °C

STM limit value (high temperature operation)

650 – 1200 (temperature in °C)

STL/FSTL limit value (system protection)

200 – 1600 (temperature in °C)

Temperature hysteresis

10 – 100

Temperature in °C

Pre-purge in high temperature operation

0 = Off

1 = On

▷ Additional parameters for FCU..F1

Pa-

Name

ram-

Values

eter

Capacity control

0 = Off

1 = IC 20

2 = IC 40

Running time

0 – 250 = Time in seconds

Minimum enable time

0 – 250 = Time in seconds

Burner operating signal

0 = Off

1 = On; controller enable

Controller enable time limit

0 – 60

= Time in minutes

▷ Additional parameters for FCU..F2

Pa-

Name

ram-

Values

eter

Capacity control

0 = Off

3 = RBW 4 = Frequency converter

RBW running time selection

0 = Off; position check 1 = On; for min./max. capacity

2 = On; for max. capacity 3 = On; for min. capacity

RBW running time

0 – 250 = Running time in seconds, if

parameter41= 1, 2 or3 Minimum enable time

0 – 250 = Time in seconds

Burner operating signal

0 = Off

1 = On; controller enable

▷ Additional parameters for FCU..C1

Pa-

Name

ram-

Values

eter

Valve proving system

0 = Off 1 = Tightness test before start-up 2 = Tightness test after shut-down

3 = Tightness test before start-up & after

shut-down 4 = POC function Tightness control test volume

1 = Vp1 2 = Vp1; pressure reduction via V3

3 = Vp1 + Vp2; pressure reduction via V3 4 = Vp1 + Vp3; pressure reduction via V3 5 = Vp1 + Vp2 + Vp3; pressure reduction via V3

Pressure reduction of Vp2

0 = In standby

1 = Upon start-up

Relief valve V3 opening time tL3

0 – 6000

Venting time before Vp1test in seconds Measurement time Vp1

3 = Time in seconds

5 – 25 = (in 5 s steps) 30 – 3600 = (in 10 s steps)

Measurement time Vp1 + Vp2

3 = Time in seconds

5 – 25 = (in 5 s steps) 30 – 3600 = (in 10 s steps)

Valve opening time 1 tL1

2 – 25

Time for ﬁlling or pressure reduction in seconds Valve opening time 2 t

2 – 25 = Time for ﬁlling or pressure reduction in

seconds Filling time before start-up

0 – 25 = Time in seconds

▷ Additional parameters for FCU with BCM500

Pa-

Name

ram-

Values

eter

Capacity control (bus)

0 = Off 1 = MIN to MAX; STBY = MIN 2 = MIN to MAX; STBY = CLOSED

3 = IGNITION to MAX; STBY = CLOSED 4 = MIN to MAX; STBY = MIN; quick start 5 = IGNITION to MAX; STBY = MIN; quick start

Bus communication

0 = Off

1 = On; with address check 2 = On; no address check

GB-23

Legend

LDS

pu/2 pu/4

3pu/4

Ready for operation

Safety interlocks (limits)

High temperature operation

Safety limits during start-up

Gas valve

Air valve

Air/gas ratio control valve

Burner

Purge

Controlled air ﬂow

Burner operating signal

FCU start-up signal

Emergency stop

Pressure switch for tightness control (TC)

Pressure switch for maximum pressure

Pressure switch for minimum pressure

Differential pressure switch

Input signal depending on param-

eterxx

Control element with butterﬂy valve

Tightness control

Half of the inlet pressure

A quarter of the inlet pressure

Three-quarters of the inlet pressure

Outlet pressure

GZL

Valve with proof of closure switch

Input/Output, safety circuit

24VDC input and output

Technical data

Electrical data

Mains voltage: FCU..Q: 120 V AC, -15/+10%, 50/60 Hz, ± 5%, FCU..W: 230 V AC, -15/+10%, 50/60 Hz, ± 5%. Power consumption: at 230 V AC approx. 6 W/11 VA, plus approx.

0.15W/0.4VA per ACinput, at 120 V AC approx. 3 W/5.5 VA, plus approx.

0.08W/0.2VA per ACinput. Contact rating: control outputs LDS (terminal16), purge (terminal17), HT (terminal18), safety interlocks (terminal57): max. 0.5 A, cos ϕ = 1, gas valves V1 (terminal13), V2 (terminal14), V3 (terminal15): max. 1 A, cos ϕ = 1, air valve (terminals 53, 54 and55): max. 50 mA, cos ϕ = 1.

The total current for the simultaneous activation of

outputs V1, V2, V3, HT, purge, LDS, safety interlocks and air valve must not exceed 2.5A. 24 V DC signal for fault/operation: max. 0.1 A, fan: max. 3A (start-up current: 6A<1s). Number of operating cycles: FCU: 24 V DC signal for fault/operation: max. 10,000,000, On/Off button, Reset/Information button:

1000,

power module: control outputs LDS (terminal16), purge (terminal17), HT (terminal18), safety interlocks (terminal57), gas valves V1 (terminal 13), V2 (terminal14), V3 (terminal15), air valve (terminals 53, 54 and55), fan (terminal 58): max. 250,000. 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

Inherent current:

Signal “1” typ. < 2 mA

Rated value 24 V DC Signal “1” 24 V, ± 10% Signal “0” < 1 V

Inherent current:

Signal “1” typ. 5 mA

Fuses, replaceable, F1: T 3.15A H, F2: T 5A H, pursuant to IEC 60127-2/5.

Mechanical data

Weight: 0.7 kg. Dimensions (W × H × D): 102 × 115 × 112 mm.

GB-24

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, 12 A. 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, rated current 10 A (8A UL), to be observed in case of daisy chain.

Environment

Ambient temperature:

-20 to +60°C (-4 to +140°F), no condensation permitted. Storage temperature: -20 to +60°C (-4 to +140°F). Enclosure: IP 20 pursuant to IEC 529. Installation location: min. IP 54 (for installation in a control cabinet).

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 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.

Bluetooth adapter PCO 00

Including BCSoft CD-ROM, Order No.: 74960617.

Stickers for labelling

FCU 500 Zone 2

For printing with laser printers, plotters or engraving machines, 27 × 18mm or 28 × 17.5mm. Colour: silver.

Connection plug set

For wiring the FCU.

Logistics

Transport

Protect the unit from external forces (blows, shocks, vibration). On receipt of the product, check that the delivery is complete, see page2 (Part designations). Report any transport damage immediately.

Storage

Store the product in a dry and clean place. Storage temperature: see page24 (Technical data). Storage time: 6months in the original packaging 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.

74923998 74924000

Plug-in, with screw terminal, Order No.: 74923998. Plug-in, with spring force terminal, 2connection options per terminal, Order No.: 74924000.

GB-25

Certiﬁcation

Declaration of conformity

We, the manufacturer, hereby declare that the product FCU500 complies with the essential requirements of the following Directives and Standards:

Directives: – 2006/95/EC – 2004/108/EC

Standards: – EN 298

– EN 1643 – EN 14597 – EN 60584 – EN 60730 – EN 61508, Parts 1 – 7 for Safety Integrity Level

SIL3

The production is subject to a Quality System pursu-

ant to DIN EN ISO 9001.

Elster GmbH

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

www.docuthek.com

Eurasian Customs Union

The products FCU 500 meet the technical speciﬁca-

tions of the Eurasian Customs Union (the Russian Federation, Belarus, Kazakhstan).

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

Elster GmbH Postfach 28 09, D-49018 Osnabrück Strotheweg 1, D-49504 Lotte (Büren)

T +49 541 1214-0

F +49 541 1214-370

in the interests of progress. info@kromschroeder.com, www.kromschroeder.com

GB-26

Krom Schroder FCU 505, FCU 500 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Protective system control FCU 500 Furnace zone control FCU 505

Contents

Safety

Checking the usage

Installation

Replacing the protective system/ furnace zone control

Cable selection

Wiring

Connection diagram

FCU 500

FCU 505

Adjustment

Commissioning

Manual mode

Assistance in the event of malfunction

Replacing the fuse

Parameters and values

Legend

Technical data

Designed lifetime

Accessories

Logistics

Contact