How it Works
Kromschroder
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FCU 505
Operating Instructions Manual
26 pgs3.67 Mb0
Technical Information
148 pgs7.72 Mb0
Table of contents
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Kromschroder FCU 500, FCU 505 Technical Information

Protective system controls FCU 500, FCU 505

Technical Information · GB
6 Edition 02. 17
• For monitoring and controlling central safety functions in multiple burner systems on industrial furnaces
• Valve proving system for a valve system leak tightness check (optional)
• Safety temperature monitor (STM) or safety temperature limiter (STL) (optional)
• Visualization and adaptation to the specific application via the PC programming and diagnostic software BCSoft to simplify logistics management

Contents

Protective system controls FCU 500, FCU 505 ......1
Contents ............................................2
1 Application ........................................5
1.1 Application examples ..............................8
1.1.1 ON/OFF rotary impulse control .......................8
1.1.2 Modulating burner control ..........................10
1.1.3 Safety limits (LDS) for modulating burner control ...11
1.1.4 Flame control using the temperature ...............12
1.1.5 Furnace and zone control ...........................13
2 Certification ......................................14
3 Function ..........................................15
3.1 Connection diagram ..............................15
3.1.1 FCU 500 .............................................15
3.1.2 FCU 505 .............................................16
3.1.3 Assignment of connection terminals ................17
3.2 Program sequence................................19
3.2.1 FCU 50 0..F0.........................................19
3.2.2 FCU 500..F1, FCU 50 0..F2..........................20
3.2.3 FCU 505..F1, FCU 505..F2 ...........................21
3.3 Animation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4 Temperature monitoring......................... 23
4.1 High temperature operation with safety
temperature monitor function (STM function) .......24
4.1.1 With integrated STM ................................ 24
4.1.2 With external STM ...................................25
4.1.3 With integrated and external STM .................. 25
4.2 Maximum temperature monitoring with (flue gas) safety temperature limiter (STL /FSTL
function) ..............................................26
4.2.1 With integrated STL/FSTL ..........................26
4.2.2 With external STL/FSTL ............................26
5 Air control ........................................27
5.1 Controlled air flow ................................28
5.2 Capacity control ..................................29
6 Furnace zone control .............................31
7 Valve proving system ............................ 33
7.1 Tightness control..................................34
7.1.1 Test instant...........................................35
7.1.2 One test volume bet ween 2 gas solenoid valves ....36
7.1.3 One test volume for system tightness...............39
7.1.4 Two test volumes for system tightness .............. 42
7.1.5 Large test volumes with reduced testing time ......46
7.2 Test period tP ..................................... 48
7.2.1 For one test volume Vp1 between 2 gas solenoid
valves ......................................................48
7.2.2 For one test volume V
7.2.3 For two test volumes for system tightness (V V
) ........................................................49
p2
7.2.4 Extended valve opening time 1 t
7.2.5 Measurement time t
for system tightness .......48
p1
..................50
...............................53
M
L1
p1
+
7.3 Proof of closure function ..........................57
8 BCSoft........................................... 58
9 Fieldbus communication via Ethernet . . . . . . . . . . . 59
9.1 FCU and bus module BCM ...................... 60
9.2 Configuration, planning ..........................61
9.2.1 Profinet/Device master data file (GSD)..............61
9.2.2 Modbus TCP..........................................61
9.2.3 Modules/Registers for process data................62
9.2.4 Device parameters and statistics . . . . . . . . . . . . . . . . . . . 68
10 Program step/status ........................... 69
11 Fault signalling ................................. 70
12 Parameters ......................................74
12.1 Scanning the parameters........................79
12.2 Safety limits .....................................79
12.2.1 Emergency stop....................................79
12.2.2 High gas pressure protection ......................80
12.2.3 Low gas pressure protection.......................80
12.2.4 Low air pressure protection.........................81
FCU 500, FCU 505 · Edition 02.17 2
= To be continued
▼
12.2.5 Safet y time during operation tSB ...................81
12.3 High temperature operation.....................82
12.3.1 Temperature monitoring mode ....................82
12.3.2 Thermocouple......................................83
12.3.3 Temperature difference limit value ................83
12.3.4 STM limit value (high temperature operation).....84
12.3.5 STL /FSTL limit value (system protection).........84
12.3.6 Temperature hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12.3.7 Pre-purge during high temperature operation ....86
12.4 Air control........................................87
12.4.1 Fan in the event of fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
12.4.2 Fan run-up time t
12.4.3 Fan ready for operation .............................87
12.4.4 Air monitoring during controlled air flow...........88
12.4.5 Pre-purge time t
12.4.6 Air flow monitoring during pre-purge ..............89
12.4.7 Post-purge time t
12.4.8 Air flow monitoring during post-purge.............90
12.4.9 Capacit y control.....................................91
12.4.10 Running time selection ..........................10 0
12.4.11 Running time ....................................100
12.4.12 Controller enable signal delay time t
12.4.13 Minimum enable time ...........................101
12.4.14 Burner operating signal..........................101
12.4.15 Controller enable time limit......................102
12.4.16 Capacity control (bus) ...........................103
................................87
GV
.................................88
PV
...............................89
PN
.........101
RF
12.5 Valve check ....................................108
12.5.1 Valve proving system..............................108
12.5.2 Relief valve (VPS) .................................108
12.5.3 Tightness control test volume ....................109
12.5.4 Pressure reduction V
12.5.5 Opening time relief valve V3 ......................110
12.5.6 Measurement time V
12.5.7 Measurement time V
12.5.8 Valve opening time 1 t
12.5.9 Valve opening time 2 t
...........................110
p2
...........................110
p1
and Vp2 ..................110
p1
..........................112
L1
..........................112
L2
12.6 Behaviour during start-up .....................113
12.6.1 Minimum pause time tMP .........................113
12.6.2 Switch-on delay time t
12.6.3 Filling time before start-up .......................113
..........................113
E
12.7 Manual mode .................................. 114
12.7.1 Operating time in Manual mode ..................114
12.8 Functions of terminals 51, 65, 66, 67 and 68 . 115
12.8.1 Function of terminal 51 ...........................115
12.8.2 Function of terminal 65 ...........................116
12.8.3 Function of terminal 66 ...........................116
12.8.4 Function of terminal 67 ...........................117
12.8.5 Function of terminal 68 ...........................117
12.9 Password ......................................118
12.10 Fieldbus communication ....................118
13 Selection ......................................119
13.1 Type code ......................................119
14 Project planning information ..................120
14.1 Installation.....................................120
14.2 Commissioning ................................120
14.3 Electrical connection .......................... 121
14.3.1 OCU ...............................................121
14.3.2 Safety current inputs..............................122
14.4 High temperature operation...................123
14.4.1 Safety temperature monitor (STM) ...............123
14.4.2 Safety temperature limiter (STL)..................124
14.4.3 Temperature sensors (double thermocouples) . . .124
14.4.4 Thermocouples....................................124
14.4.5 PFH
and thermocouple........................................126
value for STM/STL temperature module
D
14.5 Safety interlock output ........................ 127
14.5.1 Safety interlock output in the case of higher
power requirement .......................................127
14.5.2 BCU with power supply for valves and ignition
transformer via safety interlocks.........................128
14.6 Actuators ......................................129
14.6.1 IC 20...............................................129
14.7 Air control ......................................129
14.8 Parameter chip card ...........................130
14.9 System leak tightness check ..................130
15 Accessories.................................... 131
FCU 500, FCU 505 · Edition 02.17 3
= To be continued
▼
15.1 BCSoft ..........................................131
15.1.1 Opto-adapter PCO 200 ...........................131
15.1.2 Bluetooth adapter PCO 300 ......................131
15.2 OCU.............................................131
15.3 Connection plug set ...........................132
15.4 Stickers for labelling ...........................132
15.5 “Changed parameters” stickers................132
16 OCU ...........................................133
16.1 Application.....................................133
16. 2 Function .......................................134
16.2.1 Manual mode......................................135
16.3 Electrical connection ..........................135
16.4 Installation.....................................136
16.5 Selection.......................................136
16.6 Technical data for OCU . . . . . . . . . . . . . . . . . . . . . . . . 136
17 BCM 500 ...................................... 137
17.1 Application ......................................137
17. 2 F unction ........................................137
17.3 Electrical connection ...........................137
17.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
17. 5 S e l e c t ion .......................................138
17.6 Technical data..................................138
18 Technical data .................................139
18.1 Electrical data .................................139
18.2 Mechanical data...............................140
18.3 Environment ...................................140
18.4 FCU..H1........................................140
18.5 Dimensions ....................................140
18.6 Safety-specific characteristic values...........141
18.7 Converting units ...............................142
19 Maintenance ..................................143
20 Legend ........................................144
21 Glossary.......................................145
21.1 Safety shut-down.............................. 145
21.2 Fault lock-out..................................145
21.3 Warning signal.................................145
21.4 Timeout ........................................146
21.5 Lifting .........................................146
21.6 Diagnostic coverage DC.......................146
21.7 Operating mode ...............................146
21.8 Safe failure fraction SFF........................147
21.9 Probability of dangerous failure PFH
21.10 Mean time to dangerous failure MTTF
........147
D
.....147
d
Feedback .........................................148
Contact...........................................148
FCU 500, FCU 505 · Edition 02.17 4
= To be continued
▼
Application
▼

1 Application

FCU with plug-in connection terminals
Protective system control FCU 500 is designed to mon-
itor and control central safety functions, e.g. gas gas
max.
, air
, pre-purge, tightness test, high tempera-
min.
ture operation or start enable for burner control units, in multiple burner systems on industrial furnaces. In a fur­nace and zone control system, the FCU 500 assumes central functions. The FCU 505 is used to monitor local safety functions and to control the zone capacity. If the centrally checked safety requirements, e.g. pre-purge,
flow detector and pressure switch check, have been
met, the FCUs issue the start enable signal to the burn­er control units.
The FCU is optionally available with integrated safety
temperature monitor or safety temperature limiter, integrated tightness control and with an interface for
min.
,
controlling the capacity of actuators or a frequency converter interface.
The program status and device parameters can be read
directly from the unit. The FCU can be activated manu­ally using the integrated Manual mode for setting and diagnostic purposes.
Thanks to the optionally integrated valve proving sys-
tem, the valves can be checked for leaks by querying an external gas pressure switch or it can be checked whether the gas valve on the inlet side is closed.
Using the BCSoft program, the parameters, analysis and diagnostic information can be read from the FCU via the optionally available opto-adapter. All valid pa­rameters are saved on an integrated parameter chip card. The parameter chip card can be removed from the old unit and inserted into a new FCU to transfer the pa­rameters, for example when replacing the unit.
FCU 500, FCU 505 · Edition 02.17 5
Application
The monitored outputs for the actuator and valves are
accommodated in a plug-in power module. This can simply be replaced if necessary.
Once the plug-in power module has been removed, the param-
eter chip card and fuses are accessible.
The FCU can be installed on a DIN rail in the control
cabinet. Plug-in connection terminal strips on the FCU make it easier to install and remove.
The external operator-control unit OCU is available as
an option for the protective system controls. The OCU can be installed in the control cabinet door instead of standard control units. The program status, statistics, parameter values or fault messages can be read on the OCU. For burner adjustment, the operating points can be approached conveniently in Manual mode using the operator-control unit.
Thanks to the operator-control unit OCU, display functions and
operation of the FCU can be relocated to the control cabinet door.
The optional bus module BCM 500 makes it possible
to connect the FCU to a fieldbus interface in a Profinet or Modbus TCP network. Networking via the fieldbus enables multiple FCUs to be controlled and monitored by an automation system (e.g. PLC). The bus module is prepared for DIN rail installation. It is pushed on to the FCU from the side.
The address for the fieldbus communication is set using three
code switches.
FCU 500, FCU 505 · Edition 02.17 6
Application
Roller hearth kiln in the ceramics industry
Shaft melting furnace Smelting and holding furnace
FCU 500, FCU 505 · Edition 02.17 7
Application
PZL PZH PZ
DG DG DG
DG
min
49 15 131450
46
1
ϑ
2
3
FCU 500..F0
M
DG
max
µC
STM
DL
VAS
45
pu/2
P
>750°
47 4858
minDLPurge
PZL PDZ
DG DG
VAS
VAS
BCU 460..L
BCU 460..L
VCG
VR..L
VCG
VR..L

1.1 Application examples

1.1.1

ON/OFF ro tar y impul se contr ol

For processes which require a turn­down of more than 10:1 and/or those which require heavy circula-
M
TE
tion of the furnace atmosphere to ensure a uniform temperature, e.g. heat treatment furnaces operating at low and medium temperatures in the metallurgical industry.
With ON/OFF cyclic control, the capacity supplied to the process is controlled by means of a variable ratio of the operating time to the pause time. In this type of control, the burner output pulse frequency always maintains full momentum and results in maximum convection in the furnace chamber, even with regulated heating.
The pneumatic ratio control sys-
tem controls the gas pressure on the burner proportionally to the air pressure and thus maintains a con­stant air/gas ratio. At the same time, it acts as a low air pressure protec­tion device.
▼
FCU 500, FCU 505 · Edition 02.17 8
Application
PZL PZH PZ
VAS
BCU 460..L
The ignition and monitoring of the
individual burners is ensured by burner control unit BCU 460..L.
The centrally checked safety func-
tions such as pre-purge, tightness
M
test, flow detector and pressure switch check (gas air
) are provided by the FCU 500.
min.
min.
, gas
max.
,
45
P
>750°
VAS
pu/2
VAS
VCG
VR..L
BCU 460..L
DG DG DG
DG
46
1
ϑ
2
3
min
49 15 131450
DG
max
µC
FCU 500..F0
47 4858
STM
DL
minDLPurge
M
PZL PDZ
DG DG
FCU 500, FCU 505 · Edition 02.17 9
VCG
VR..L
TE
Application
PZL PZH PZ
DG DG DG
DG
min
49 15 131450
46
1
ϑ
2
3
FCU 500..F1
M
DG
µC
STM
DL
minDLPurge
VAS
max
45
P
>750°
TC
0°➔90°
53
90°➔0°
54 55
47 4858
PZL PDZ
DGDG
pu/2

1.1.2 Modulating burner control

For processes that do not require heavy circulation in the furnace, e.g. aluminium smelting furnaces.
This system is suitable for process-
VAS
BCU 460..L
M
es in which infiltrated air may flow into the furnace through switched off burners. The capacity can be adjusted continuously by activating the air control valve (analogue or
VAS
VCG
3-point step signal). The pneumatic
ratio control system controls the gas pressure proportionally to the air pressure and thus maintains a constant air/gas ratio. At the same
BCU 460..L
time, it acts as a low air pressure protection device.
One burner control unit per burner is required for ignition and monitor-
VCG
M
ing.
The centrally checked safety func-
tions such as pre-purge, setting the
TE
valve to ignition position via a but­terfly valve control system, tight­ness test, flow detector and pres­sure switch check (gas air
) are provided by the FCU 500.
min.
min.
, gas
max.
,
FCU 500, FCU 505 · Edition 02.17 10
Application
PZL PZH PZ
DG DG DG
DG
min
49 15 131450
1
ϑ
2
3
FCU 500..F1
M
DG
µC
STM
DL
minDLPurge
VAS
max
45
P
57
16
>750°
TC
0°➔90°
53
90°➔0°
54
55
47 4858
PZL PDZ
DGDG
pu/2

1.1.3 Safety limits (LDS) for modulating burner control

The centrally checked safety func-
tions such as pre-purge, setting the valve to ignition position via a but-
VAS
BCU 560..F0
66
M
terfly valve control system, tight­ness test, flow detector and pres­sure switch check (gas air
) are provided by the FCU 500.
min.
min.
, gas
max.
,
The capacity can be adjusted con-
VAS
VCG
tinuously by activating the control element (analogue or 3-point step signal).
To ensure that the correct air vol-
ume is available for ignition (start
BCU 560..F0
66
fuel flow rate) when starting the burners, the FCU sends the burner start enable signal to the BCUs via the “LDS (limits during start-up)” output.
VCG
M
The circuit design of the safety
interlock and LDS outputs on the FCU and the corresponding in-
TE
puts on the BCUs ensures that the burners can only start if the safety interlocks and the LDS output have enabled burner start-up.
FCU 500, FCU 505 · Edition 02.17 11
Application

1.1.4 Flame control using the temperature

FCU 500..H1
HT
18
5-8
STM
HT
49
HT
49
BCU 56x..D
µC
5
BCU 56x..D
µC
5
M
In high temperature systems (temperature > 750°C), the flame may be controlled indirectly via the tempera­ture. As long as the temperature in the furnace chamber is below 750°C, the flame must be controlled by con­ventional methods.
If the temperature in the furnace chamber rises above the spontaneous ignition temperature of the gas/air mixture (> 750°C), the FCU signals to the burner control units via the fail-safe HT output that the furnace sys­tem is in High temperature mode (HT). When the HT in­put is activated, the burner control units switch to High temperature mode. They operate without evaluation of the flame signal and their internal flame control system is non-functional.
If the furnace temperature falls below the spontaneous ignition temperature (< 750°C), the FCU disconnects the HT output from the electrical power supply. There is no active signal at the HT inputs of the burner control units. The flame signals are monitored once again by the UV sensor or flame rod.
In the event of a fault in a temperature monitoring com­ponent (e.g. sensor discontinuity, sensor short-circuit) or in the event of a mains failure, the flame control task is transferred to the burner control units.
FCU 500, FCU 505 · Edition 02.17 12
Application
PZL PZH PZ
66
46
4
FCU 505..F1
+24V
L1
49 15 131450
1
2
3
FCU 500..F0
µC
4758 48
45
67
57
17
P
M
PZL PDZ

1.1.5 Furnace and zone control

The FCU 500 (furnace FCU) performs central tasks
such as checking the safety interlocks, fan control, sys­tem leak tightness check and pre-purge.
It signals to the FCU 505 in the zones that the butterfly valves can be moved to the purge position. Signals are
1
µC
54 55
53
BCU
V1
V1
BCU
M
L1
BCU
+24V
BCU
V1
V1
66
46
1
4
FCU 505..F1
µC
54 55
53
M
sent to the butterfly valves by the FCU 505. The but­terfly valves move into position. A signal is sent to the FCU 505 via their safety interlock input that the central FCU 500 has issued the enable signal for the burners.
FCU 500, FCU 505 · Edition 02.17 13
Certification
2 Certification
Certificates – see Docuthek.
Certified pursuant to SIL
For systems up to SIL 3 pursuant to EN 61508.
Pursuant to EN ISO 138491:2006, Table 4, the FCU
can be used up to PL e.
EU certified pursuant to
– Gas Appliances Directive (2009/142/EC) in conjunc-
tion with EN 298, EN 1643
Meets the requirements of the
– Low Voltage Directive (2006/95/EC),
– EMC Directive (2004/108/EC).
FM approved
ANSI/CSA approved
American National Standards Institute/Canadian
Standards Association –ANSI Z21.20/CSA C22.2, No. 199 www.csagroup.org –Class number: 333501 (natural gas, propane), 333581 (natural gas, LPG).
Eurasian Customs Union
The product FCU 500 meets the technical specifica-
tions of the Eurasian Customs Union.
Factory Mutual Research Class: 7610 “Combustion Safe-
guards and Flame Sensing Systems”. Suitable for applica­tions pursuant to NFPA 86. www.approvalguide.com
FCU 500, FCU 505 · Edition 02.17 14
Function

3 Function

3.1 Connection diagram

3.1.1 FCU 500

Detailed connection diagrams for actuators and fre-
quency converters, see from page 91 (Capacity con­trol)
ϑ
PZL
PZL
Air
min
p
u
PZL
GZL
2
PZH
PZH
Gas
Air
PDZ
Gas
P72
P72
PDZ
min
PZL
PZL
max
Electrical connection, see page 120 (Project planning information)
Explanation of symbols, see page 144 (Legend)
1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68
62 61 5 6 7 8 11
44
STM/
STL
+ - + -
24V
DC
88
12
3,15AT
41 4216
17 18 57
13 14 1553
I
N
× 0.6
LDS
k11 k21
K2
K1
HT
P
V2
V1
V3
µC
FCU 505
FCU 500
5AT
54 55 56
58
M
0 V
N
L1
+24 V
0.6 × I
P69
P70
P70
P71
P71
P73
P73
N
FCU 500, FCU 505 · Edition 02.17 15
Function

3.1.2 FCU 505

Detailed connection diagrams for actuators and fre-
quency converters, see from page 91 (Capacity con­trol)
Electrical connection, see page 120 (Project planning
information)
Explanation of symbols, see page 144 (Legend)
L1
+24 V
PZH
PZH
0.6 × I
Gas
N
STM/
STL
ϑ
1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68
62 61 5 6 7 8 11
PZL
PZL
Air
Air
PDZ
Gas
P72
P72
PDZ
min
PZL
PZL
max
min
+ - + -
24V
DC
88
12
3,15AT
41 4216
17 18 57
13 14 1553
p
u
PZL
GZL
2
P69
P70
P70
P71
P71
P73
P73
µC
FCU 505
54 55 56
I
N
× 0.6
LDS
V1
k11 k21
K2
K1
HT
P
V2
M
V3
0 V
N
FCU 500, FCU 505 · Edition 02.17 16
Function

3.1.3 Assignment of connection terminals

Terminal Type Designation Function
1
2 Controlled air flow
24 V DC input
3 Remote reset Input for ex ternal signal (button) to reset the unit after a fault lock-out
4 Operating signal
5, 6 and 7, 8
11, 12 V AC input Supply voltage
13 14 Gas valve V2 Connection of phase for gas valve V2
15 Gas valve V3 Connection of phase for gas valve V3
57 Safety interlocks (limits) Safety enable signal to the burner control units
16 Safety limits (limits during start-up)
17 Purge Signal to FCU 505 or burner control units to inform them that purge is in process 18 High temperature operation Enable signal from the FCU indicating that the furnace system is in High temperature mode 41 42 Operating signal Operation signalling output, 24 V DC, max. 0.1 A 44 24 V DC input Fan ready for operation Feedback signal from fan indicating readiness for operation, see Parameter 31
Double
thermocouple
Safety circuit output
24 V DC output
Start-up signal Signal applied: FCU start; no signal: FCU stop
Signal applied: fan is started to supply air to the combustion chamber for cooling, for example. Only functional in standby. The function is deactivated as soon as a signal is received at terminal 1 (FCU start).
Signal from the burner control units to inform the FCU that a sufficient number of burners is available for temperature control
Safety temperature monitor and/or safety temperature limiter
Gas valve V1 Connection of phase for gas valve V1
Fault Fault signalling output, 24 V DC, max. 0.1 A
Monitor the spontaneous ignition temperature of the gas/air mixture in High temperature mode and/or the maximum furnace or flue gas temperature using the integrated temperature module of the FCU..H1
Voltage to operate the FCU, 11 = phase (L1), 12 = neutral conductor (N)
To ensure that the correct air volume is available for ignition (start fuel flow rate) when starting the burners, the FCU sends the burner start enable signal to the burner control units via this output.
▼
FCU 500, FCU 505 · Edition 02.17 17
Function
Terminal Type Designation Function
45
46 Controller enable/emergency stop
47 Minimum air pressure
48 Minimum air flow
49 Minimum gas pressure Connection for pressure switch to monitor the minimum gas pres sure, see Parameter 13 50 Maximum gas pressure Connection for pressure switch to monitor the maximum gas pressure, see Parameter 12 51, 65,
66, 67, 68
52
53, 54, 55, 56
58 Fan
Safety circuit input
V AC output
Valve proving system
Programmable inputs
Feedback from actuator/frequency converter
Capacity control
Connection for the sensor of the valve proving system (tightness control pressure switch or POC switch for checking the closed position).
Connection for higher-level safety devices and interlocks (e.g. emergency stop, safety temperature monitor), see Parameter 10
Connection for pressure switch to monitor the minimum air pressure, see Parameter 15
Connection for a sensor to monitor the minimum air flow during pre-purge or post-purge, see Parameters 35, 38
The terminals can be assigned a function using parameters. To do so, logical AND gatings with terminals 46, 47, 48, 49 or 50 are possible.
Connection for the position feedback signal from the actuator/frequency converter
Connection for capacity control using an actuator or frequency converter, see Parameter 40 to 47
Connection for fan control. Alternatively, this output can be used to activate a valve to check the function of the air pres sure switch.
FCU 500, FCU 505 · Edition 02.17 18
Function

3.2 Program sequence

3.2.1 FCU 500..F0

Example of application, see page 8 (ON/OFF rotary
impulse control)
Switch on the FCU
▼
In the event of fault signal: reset
▼
00
H0
Switch-on delay time t
01
1
P1
08
Enable signal to burner control units for the burner start via the “safety
Start-up position/standby
▼
Start-up with ϑ signal
▼
running (parameter 63)
Safety interlocks check
Fan run-up time tGV running (parameter 30)
Pre-purge time tPV running (parameter 34)
Tightne ss test (if equipped with TC)
Gas enable via valves V1 and V2
E
▼
Pre-purge starts
▼
Air flow monitoring
▼
▼
interlock” output
▼
Operation
FCU 500, FCU 505 · Edition 02.17 19
Function

3.2.2 FCU 500..F1, FCU 500..F2

Example of application, see page 10 (Modulating
burner control)
Switch on the FCU
▼
In the event of fault signal: reset
▼
00
H0
01
A
P1
A
H7
H8
08
Switch-on delay time t
Actuator moves to the position for maximum capacity
1
Actuator moves to the position for ignition capacity
Enable signal to burner control units for the burner start via the
Controller enabler signal delay time t
Start-up position/standby
▼
Start-up with ϑ signal
▼
running (parameter 63)
Safety interlocks check
E
▼
Fan run-up time t
running (parameter 30)
GV
Pre-purge starts
▼
▼
Air flow monitoring
▼
Pre-purge time t
Tightne ss test (if equipped with TC)
running (parameter 34)
PV
▼
▼
Gas enable via valves V1 and V2
“safety interlock” output
▼
▼
Operation/controller enable
running
RF
FCU 500, FCU 505 · Edition 02.17 20
Function

3.2.3 FCU 505..F1, FCU 505..F2

Example of application, see page 13 (Furnace and zone control)
Switch on the FCU
▼
In the event of fault signal: reset
▼
00
H0
01
A
P1
H8
08
Switch-on delay time t
Actuator moves to the position for maximum capacity
A
Actuator moves to the position for ignition capacity
Controller enabler signal delay time t
Start-up position/standby
▼
Start-up with ϑ signal
▼
running (parameter 63)
Safety interlocks check
E
▼
Fan run-up time t
running (parameter 30)
GV
Pre-purge starts
▼
▼
FCU 500 pre-purge time t
Tightne ss test (if equipped with TC)
▼
▼
▼
Operation/controller enable
running
PV
running
RF
FCU 500, FCU 505 · Edition 02.17 21
Function

3.3 Animation

The interactive animation shows the function of the
protective system control FCU 500.
Click on the picture. The animation can be controlled using the control bar at the bottom of the window (as on a DVD player).
To play the animation, you will need Adobe Reader 9 or a
FCU 500, FCU 505 · Edition 02.17 22
newer version. If you do not have Adobe Reader on your system, you can download it from the Internet. Go to ww w.adobe.com, click on “Adobe Reader” at the bottom of the page and follow the instructions.
If the animation does not start to play, you can down­load it from the document library (www.docuthek.com) as an independent application.
Temperature monitoring

4 Temperature monitoring

The FCU..H1 is fitted with an integrated temperature
module.
This module can be used as a safety temperature moni-
tor (STM) to monitor the spontaneous ignition temper­ature of the gas/air mixture or as a safety temperature limiter (STL) to monitor the maximum furnace/flue gas temperature. Double thermocouples are connected to the temperature module to measure the temperature.
The functions STM and STL can also be combined. In
this case, the connected double thermocouple must re­liably detect whether the spontaneous ignition temper­ature (> 750°C) has been exceeded and also whether the maximum permitted furnace temperature has been exceeded.
The safety temperature monitor and safety temperature
limiter functions can be adjusted to the requirements of the system using parameters 20, 22, 23, 24 and 25, see page 82 (High temperature operation).
FCU 500, FCU 505 · Edition 02.17 23
Temperature monitoring
4.1 High temperature operation with safety
temperature monitor function (STM function)
As soon as the temperature in the furnace chamber
is above the spontaneous ignition temperature of the gas/air mixture (> 750°C), the FCU signals to the down­stream burner control units via the fail-safe HT output that the furnace system is in High temperature mode (HT). When the HT input is activated, the burner control units switch to High temperature mode. They operate without evaluating the flame signal and their internal
flame control is non-functional.
If the furnace temperature falls below the spontaneous ignition temperature (< 750°C), the FCU disconnects the HT output from the electrical power supply. As soon as the signal to the HT inputs of the burner control units is no longer present, the flame signals are once again monitored by a UV sensor or flame rod.
In the event of a fault in a temperature monitoring com­ponent (e.g. sensor discontinuity, sensor short-circuit) or in the event of a mains failure, the flame control task is transferred to the burner control units.
Either the temperature module integrated in the FCU.. H1 or an external safety temperature monitor (STM)
can be used for High temperature mode. Pre-purge can be disabled for both versions in High temperature mode, see page 86 (Pre-purge during high tempera­ture operation).

4.1.1 With integrated STM

The integrated temperature module (STM) can be used
for high temperature operation. Pre-purge can be disa­bled in High temperature mode, see page 86 (Pre­purge during high temperature operation).
FCU 50x..H1
HT
18
5-8
STM
HT
6
HT
6
BCU 4xx..D
µC
9
BCU 4xx..D
µC
9
M
FCU 500, FCU 505 · Edition 02.17 24
Temperature monitoring
M
BCU 4xx..D
µC
9
BCU 4xx..D
µC
9
HT
18
6
6
HT
HT

4.1.2 With external STM

An external safety temperature monitor (STM) can be
used for high temperature operation. Pre-purge can be disabled in High temperature mode, see page 86 (Pre-purge during high temperature operation).
FCU 50x..H0
FCU 50x..H1
HT
18
66
BCU 4xx..D
µC
HT
6
9
BCU 4xx..D
µC
HT
6
9
STM
M

4.1.3 With integrated and external STM

The integrated temperature module can also be used in
conjunction with an external safety temperature moni­tor (STM). The spontaneous ignition temperature can then be monitored at two different points in the furnace.
FCU 50x..H1
5-8
STM
66
STM
FCU 500, FCU 505 · Edition 02.17 25
Temperature monitoring
4.2 Maximum temperature monitoring with (flue gas) safety temperature limiter (STL/FSTL
function)
As soon as the maximum permitted temperature limit
is reached in the furnace or in the flue gas or an error occurs on the monitoring equipment within the permit­ted temperature range (e.g. sensor discontinuity, sensor short-circuit), the FCU will perform a fault lock-out. The safety interlock output will no longer be set.
The temperature module integrated in the FCU..H1 or
an external safety temperature limiter (STL) can be used for this function.

4.2.1 With integrated STL/FSTL

FCU 50x..H1
5-8
57
STL
BCU 4xx..D
5
BCU 4xx..D
BCU 4xx..D
5
9
9
9

4.2.2 With external STL/FSTL

FCU 50x..H0 FCU 50x..H1
57
46
BCU 4xx..D
STL
M
M
5
9
BCU 4xx..D
BCU 4xx..D
5
9
9
FCU 500, FCU 505 · Edition 02.17 26
Air control
M
PZL PZH PZ
PZL PDZ
TE
BCU 580..F3
FCU 500..F0
µC
P
DG DG DG
VAS
VAS
VAGVAS
VAS
VR..L
VR..L
DG DG
DG
minDGmax
49 15 131450
45
47 4858
>750°
pu/2
ϑ
1
46
2
3
DL
minDLPurge
BCU 580..F3
VAGVAS
VAS
M

5 Air control

Acting as the furnace protective system, the FCU 500
assumes the task of central air control on a furnace. It controls and monitors the required air volume for start­up, during operation and after the furnace has been shut down. The fan is activated by the FCU for this pur­pose. The static air pressure and the air volume for pre­purge can be monitored by pressure switches.
VAS
BCU 580..F3
49 15 131450
46
1
ϑ
2
3
FCU 500..F0
M
µC
P
>750°
47 4858
STM
DL
minDLPurge
PZL PDZ
DG DG
45
VR..L
BCU 580..F3
VR..L
The capacity control function provided by the FCU 500..
F1/F2 and FCU 505..F1/F2 allows an additional cen­tral actuator or a frequency-controlled fan to be con­trolled and monitored. While the furnace is starting up, the capacity control system controls and monitors the required air volumes for purging and for starting the burners. During operation, the FCU enables the exter­nal temperature control system for capacity control.
FCU 500, FCU 505 · Edition 02.17 27
Air control
ϑ
PZL
PZL
Air
min
p
u
PZL
GZL
2
P71
P71
P73
P73
L1
+24 V
PZH
PZH
0.6 × I
Gas
N
Air
PDZ
Gas
P69
P72
P72
PDZ
min
P70
P70
PZL
PZL
max
5.1 Controlled air flow
On FCU 500, actuation of the input at terminal 2 acti-
vates the controlled air flow function. The fan (termi­nal 58) is started in standby (with no start-up signal).
Air is fed to the combustion chamber, e.g. for cooling.
1 2 3 46 47 48 49 50 4 67 52 45 51 65 66 68
62 61 5 6 7 8 11
44
STM/
STL
+ - + -
24V DC
88
µC
FCU 505
FCU 500
5AT
12
3,15AT
41 4216
17 18 57
13 14 1553
54 55 56
58
I
N
× 0.6
LDS
k11 k21
K2
K1
HT
P
V3
V2
V1
M
The FCU starts the fan depending on the functions
defined using parameters, see also page 81 (Low air pressure protection), page 88 (Air monitoring during controlled air flow) and page 89 (Air flow monitoring during pre-purge).
The controlled air flow function is no longer performed
once the start-up signal has been received at terminal 1.
0 V
N
FCU 500, FCU 505 · Edition 02.17 28
Air control
CU
V1
CU
V1
µC
5455
53
1
6
(
)
V
M
1
7
▼

5.2 Capacity control

As soon as a start-up signal has been received by the FCU..F1/F2 (terminal 1), the fan of an FCU 500..F1/F2
is started via terminal 58 after the switch-on delay time has elapsed. The air volume for pre-purge is requested via the outputs for central capacity control (terminals 53 to 56). Air flow monitoring (terminal 48) starts. The pre-purge time starts if there is adequate air flow.
After the elapse of the pre-purge time, the air volume for ignition is requested. After the program has ended
(limits during start-up, pre-purge and also tightness test for FCU..C1), the gas enable signal is issued via the valve outputs V1 (terminal 13) and V2 (terminal 14) and the burner start enable signal is issued to the burner control units via the “safety interlock” output (termi­nal 57).
The correct air volume for ignition (start fuel flow rate)
must be available for each burner start, restart or start­up attempt. To this end, the FCU sends the burner start enable signal to the BCUs via the “LDS (limits during start-up)” output.
A corresponding circuit design between the FCU and
the BCUs ensures that the burners can only start if the safety interlocks and the LDS output are active.
7
BCU..F0
+24
4
FCU 500..F1
M
6
16
57
5
1
B
B
FCU 500, FCU 505 · Edition 02.17 29
Air control
CU
V
CU
V
µC
5455
53
1
6
(
)
V
M
After the burner operating signal from the burner con-
trol units has been received, the FCU enables the con­trol system for operation. For pertinent parameter set­tings, see page 101 (Burner operating signal).
7
BCU..F0
+24
+24V
4
4
FCU 500..F1
1
B
1
54 55
53
B
1
M
Depending on parameter 40, actuators IC 20 and IC 40,
an actuator with an RBW interface or a fan controlled by a frequency converter can be actuated via the out­puts for central capacity control, see page 91 (Ca­pacity control).
FCU 500, FCU 505 · Edition 02.17 30
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