krom schroeder BCU 570 Operating Instructions Manual

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057

D GB F NL I E

TR CZ PL RUS H

Operating instructions

Burner control unit BCU 570

Cert. version 02.18

Translation from the German

Contents

Burner control unit BCU 570..............

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

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

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

Installation ............................

Replacing the power module/parameter

chip card ..............................

Cable selection.........................4

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

Connection diagram ....................5

BCU 570 ..............................5

Flame control ...........................6

IC 20 connected to BCU570..F1............ 7

IC 20..E connected to BCU570..F1 .........8

IC 40 connected to BCU570..F1............9

RBW valve connected to BCU570..F2 ......10

Frequency converter connected to BCU570..

F2 .................................. 11

Adjustment ...........................

Commissioning........................

Manual mode .........................

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

Replacing the fuse ......................18

Reading off the flame signal, fault

messages and the parameters...........9

Parameters and values...................19

Legend...............................

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

Designed lifetime .......................22

Logistics .............................

Accessories ..........................

Contact ..............................4

Certification ..........................

DK S N P GR

➔ www.docuthek.com

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 0.5

The following chapters have been changed: – Installation – Connection diagram – Commissioning – Assistance in the event of malfunction – Certiﬁcation

GB-1

Checking the usage

Burner control unit BCU570 is designed to monitor and control modulating forced draught burners of unlimited capacity in intermittent or continuous operation.

The fail-safe outputs for controlling the burners, e.g.

for fan, actuator and valves, are activated via a replaceable power module. All the parameters required for operation are saved on the integrated parameter chip card.

Type code

Code Description BCU Burner control unit 570 Series 570

Q W C0 C1

F1 F2

RBW interface or frequency converter

K0 K1 K2

Part designations

No valve proving system

With valve proving system

Modulating capacity control:

three-point step, IC 20 and IC 40

in case of operation with gas

Mains voltage: 120 V AC, 50/60 Hz 230 V AC, 50/60 Hz

Ionization or UV control

Connection terminals:

none

screw terminals

spring force terminals

Input voltage– see type label.

BCU

 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, replaceable 7 Power module type label 8 Parameter chip card, replaceable

GB-2

Installation

4 5

CAUTION

Please observe the following to ensure that the burner control unit is not damaged:

– Dropping the device can cause permanent dam-

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

▷

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

▷ The BCU mounting is designed for horizontally

aligned 35×7.5mm DINrails.

▷

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

Replacing the power module/ parameter chip card

 Disconnect the system from the electrical power

supply.

 Disengage the BCU from the DINrail.

▷

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

6 Remove the old parameter chip card from the

BCU and insert the new one.

▷ All the parameter settings of the BCU are saved

on the parameter chip card.

7 Slide the power module back on. 8 Reconnect the connection terminals. 9 Mount the BCU on the DINrail again.

GB-3

Cable selection

▷ 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).

▷

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

▷

The control lines must be selected in accordance

with local/national regulations.

▷ Avoid external electrical interference.

Ionization cable, UVcable

▷ Cable lengths of 100m are acceptable if there

is no electromagnetic interference.

▷

The ﬂame signal is adversely affected by EMCin-

ﬂuences.

▷

Lay cables individually (with low capacitance) and, if possible, not in a metal conduit.

Wiring

▷

Do not reverse phaseL1 and neutral conductorN.

▷

Do not connect different phases of a three-phase current system to the inputs.

▷ 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 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 must not exceed a value of max. 6A for 1s– use an external motor protection or coupling 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 BCU’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 BCU.

▷

Observe the maximum duty cycle for the ignition transformer (see manufacturer’s instructions). Adjust the minimum pause time tBP (parameter62) correspondingly, if required.

▷

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19 (Parameters and values).

 Disconnect the system from the electrical power

supply.

 Before wiring the BCU, ensure that the yellow

parameter chip card has been inserted in the BCU – see page 3 (Replacing the power module/parameter chip card).

▷

Screw terminals or spring force terminals are available for the BCU– see page23 (Accessories).

 Wire as shown on the connection diagram– see

page5 (Connection diagram).

▷ Ensure a good PE (ground) wire connection to

the BCU and burners.

GB-4

Connection diagram

BCU 570

▷ Legend– see page21 (Legend).

3837

13 14 15 17 1811 12931 2

5AT

90°0°

0°90°

53 54 55 56 57 5849 50 51 52

3,15AT

P69

max.

PZH

Gas

min.

PZL

Gas

Air

PDZ

P72

47 48

STL

STM/

5 7

P71 P73

Air

min.

PZL

P70

BCU 570

0,6 x I

GB-5

Flame control

13 14 15 17 18

3837

▷

In the case of UV control, use Elster UV sensors for intermittent operation (UVS 1, 5, 6, 10) or

ﬂame detectors for continuous operation (UVC 1).

Ionization/single-electrode operation:

▷ Parameter 04 = 0.

5 7

UV control:

UVS 1, 5, 6, 10

▷ Parameter 01 ≥ 5 µA. ▷ Parameter 04 = 1.

1 2

UVS

765

UVC 1

▷ Parameter 04 = 2.

4 3 2 1

765

11 129

9 12

UVC 1

GB-6

IC 0 connected to BCU570..F

▷ Parameter 40 = 1. ▷

Continuous control via three-point step controller.

3837

13 14 15 17 1811 129

BCU 570

47 48

0°

90°

MinMax

5AT

3,15AT

3.15AT

S11

S1S2

0°➔90°

53 54 55 56 57 5849 50 51 52

90°➔0°

0°➔90°

32116 674812 1115 13

S3 S4

90°➔0°

L1 N PE

IC 20

S10

GB-7

IC 0..E connected to BCU570..F

▷ Parameter 40 = 1. ▷

Continuous control via an analogue signal (directly connected to the control actuator).

3837

13 14 15 17 1811 129

47 48

BCU 570

OUT

20 19 18 321674812 11

123456

µC

0°

90°

131516

5AT

3,15AT

3.15AT

Min Max

90°➔0°

0°➔90°

53 54 55 56 57 5849 50 51 52

L1 N

IC 20..E

0°

90°

➔

517

0°

90°

S10

GB-8

IC 40 connected to BCU570..F

▷ Parameter 40 = 2. ▷ Set IC 40 to operating mode27, see operating

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

3837

13 14 15 17 1811 129

BCU 570

47 48

22 21 20

R..

5AT

3,15AT

3.15AT

90°➔0°

0°➔90°

53 54 55 56 57 5849 50 51 52

19 18 16 15 14 12 11 10 87 54 21

IC 40

L N

GB-9

RBW valve connected to BCU570..F

▷ Parameter 40 = 3.

Continuous control via three-point step controller

5 7

3837

13 14 15 17 1811 129

BCU 570

Continuous control via PLC

5 7

47 48

BCU 570

0°➔90°

RBW

5AT

3,15AT

3.15AT

90°➔0°

5AT

COM

AUTO

53 54 55 56 57 5849 50 51 52

R B W

L1 N

3837

13 14 15 17 1811 129

47 48

3,15AT

COM

53 54 55 56 57 5849 50 51 52

AUTO

OUT

PLC

+ F -

0°90°

RBW

L1 N

GB-10

Frequency converter connected to BCU570..F

▷ Parameter 40 = 4.

5 7

BCU 570

5AT

3.15AT

3,15AT

3837

13 14 15 17 1811 129

47 48

PLC

0–100%

Target = actual

COM

AUTO

53 54 55 56 57 5849 50 51 52

DI 3DI 2DI 1

PDZ PZL

GB-11

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 BCU, 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 23 (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:

Start-up position/standby

Delay

A Approaching minimum capacity

Fan OFF check

Fan run-up time

Approaching maximum capacity

Post-purge time air monitoring

Pre-purge

Approaching ignition capacity

Valve check Pre-ignition time tVZ

Safety time 1 t

Flame proving period 1t

Safety time 2 t

Flame proving period 2 t

Delay

Operation/controller enable

Over-run tN with air actuator in position for

SA1

FS1

SA2

FS2

maximum capacity

Post-purge

Controlled air ﬂow

Device Off

––

Remote control (with OCU)

U I

Data transfer (programming mode)

(blinking dots) Manual mode

0.0.

WARNING

Risk of explosion! Check the system for tightness before commissioning. Do not start the BCU 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 BCU by pressing the On/Off but-

ton.

▷ The display indicates ▷

If the display blinks (fault), reset the BCU by

pressing the Reset/Information button.

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

▷

The display indicates A. The air control valve

moves to the position for minimum capacity.

▷

The display indicates

. The switch-on delay

time (parameterP63) is active.

▷

The display indicates

. The fan run-up time

(parameterP30) is active.

▷ The display indicates

. The air control valve

moves to the position for maximum capacity.

The display indicates

▷

. The pre-purge time

(parameterP34) is active.

▷

BCU..C1: the valve check runs in parallel to pre-purge. If the valve check lasts longer than pre-purge, the display indicates

▷

The display indicates

. The air control valve

moves to the position for ignition capacity.

▷ The display indicates 03,

ing a pilot and main burner,

and 05. When us-

and 07 are also

shown. Pre-ignition time, safety time and ﬂame proving period are running.

▷ The display indicates

. The controller enable

signal delay time is running.

▷ The display indicates

. The burner is in opera-

tion and the controller enable signal has been issued.

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), 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

BCU or in the event of a power failure.

▷

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

▷ Parameter 67 = 1: The BCU will terminate Man-

ual 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 BCU while holding the Reset/

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

GB-12

▷ 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 BCU now executes its program sequence until the display indicates

BCU 570..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 it reaches the position for maximum capacity.

▷ The display indicates ▷

Once the button has been released, the butterﬂy 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 it reaches the position for minimum capacity.

▷ The display indicates ▷ 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.

BCU 570..F with IC40, BCU570..F with RBW or frequency converter

▷

Following controller enable (status display it is possible to move between the positions for maximum and minimum capacity on a binary basis.

with blinking dots.

A.1.

with blinking dots.

A.0.

0.8.

), actuator

0.8.

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 BCU 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).

0 1

? The display blinks and indicates

! The BCU has detected an incorrect flame signal

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.

 • Exchange UV tube, OrderNo.: 04065304 – note

the Operating instructions for the UV sensor.

! Flame signal through conductive ceramic insula-

tion.

 • Increase value of parameter01 in order to adapt

the switch-off threshold of the flame amplifier.

0 4

? Start-up without ﬂame– 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.

GB-13

0 4 0 5

0 6 0 7

Start-up– ﬂame burning – nevertheless, the display blinks and indicates burner/burner or

! Flame failure on start-up.

• Read off the ﬂame signal.

If the ﬂame signal is lower than the switch-off

▷

threshold (parameter01), 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. ! Short-circuit or discontinuity on the ﬂame signal

cable.

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

• Remedy fault.

or

on the main burner.

on the pilot

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 BCU may only be reset manually under su-

pervision.

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

1 1

? The display blinks and indicates ! Too many restarts. More than 5restarts initiated

within the last 15minutes.

• Check burner setting.

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

0 8

? Operation– ﬂame burning– burner inter-

rupted– the display blinks and indicates

! Flame failure during operation or during delayed

controller enable.

• Read off the ﬂame signal, see page19 (Read-

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

▷

If the ﬂame signal is lower than the switch-off threshold for the ﬂame signal from burner 1 (parameter 01), 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. ! Short-circuit or discontinuity on the ﬂame signal

cable.

! Soiled UV sensor.

• Remedy fault.

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 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 position for ignition capacity.

GB-14

• Establish the cause of the fault to avoid repeat

2 2

? The display blinks and indicates ! Actuator 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..E connected to BCU570..F1).

! The unit has suffered an internal fault in the power

module.

• Replace the power module.

2 3

? 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

of the butterﬂy valve for max. capacity/ignition capacity/Closed 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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4 (Cable selection).

• 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BCU.

the BCSoft software.

• Reset the parameters to their original values using

GB-15

faults.

• Ensure that the cables have been installed prop-

erly– see page4 (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 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 3

? 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.

3 6

? The display blinks and indicates ! An internal device error occurred.

• Replace the power module.

• Remove the unit and return it to the manufacturer

for inspection.

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 for the valve

check has been set incorrectly.

• Check the inlet pressure.

• Set DGpu/2 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 Vp1)

using BCSoft.

• If the fault cannot be remedied by doing this,

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

4 1

5 3

? The display blinks and indicates ! One of the burner-side gas solenoid valves is

leaking.

• Check the burner-side solenoid valves. ! The gas pressure switch DGpu/2 for the valve

check has been set incorrectly.

• Check the inlet pressure.

• Set DGpu/2 to the correct inlet pressure.

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

• Change parameter56 (Measurement time V

using BCSoft.

• If the fault cannot be remedied by doing this,

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

p1)

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.

• 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.

5 2

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

min.time (timingcycle).

• Comply with the min. timing cycletz

[s] = (tVZ + 0.6 × t

min

Example: Pre-ignition time t Safety time 1 t tz

= (2 + 0.6 × 3) + 9 = 12.8 s

min

8 0

SA1

= 2 s

= 3s

8 38 1

8 6 8 78 5

9 4

9 9

8 9

9 8

? The display blinks and indicates

! 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4 (Cable selection).

• Ensure that the EMC regulations for the sys-

tem are satisﬁed– particularly for systems with frequency converters – see page 4 (Cable selection).

• Reset the unit by pressing the Reset/Information

button.

• 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.

9 5

min

) + 9

SA1

8 4

8 8

9 6

or

, .

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

• Check voltage supply to terminal3.

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

1second.

9 7

? 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.

GB-16

• 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.

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

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.

• Check the function of the differential pressure

switch. When the fan is switched off, the “no ﬂow” state (default position) of the differential pressure switch (terminal 48) is also monitored if air ﬂow monitoring has been activated.

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

has failed. The air monitor, depending on the parameter setting for input 47 or 48 (P15 and P35), 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.

2 3

• Check the air supply.

• Check the air pressure switch setpoint.

2 3

? The display blinks and indicates

! The signal for monitoring the max. gas pressure

(terminal50) has dropped out at program stepX (02to09).

• Check the wiring.

• Check the gas pressure.

or

? 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 BCU 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

5, 6, 7, 8

! The input signal for the air pressure switch has

dropped out during start-up/operation at program stepX (02to09). Failure of the air supply at program stepX



3, 4

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

PLC program.

GB-17

▷ Device name on delivery:

not-assigned-bcu-570-xxx (xxx = code switch setting on the BCU).

▷

The device name must at least consist of the

expression bcu-570-xxx.

• Check whether the code switch setting is identi-

cal 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.

? The display blinks and indicates

! The signal for monitoring the min. gas pressure

(terminal49) has dropped out at program stepX (00to09).

• Check the wiring.

• Check the gas pressure.

0, 1

or

Replacing the fuse

▷

The device fuses F1 and F2 can be removed

for inspection.

 Disconnect the system/BCU from the electrical

power supply.

 Disconnect the connection terminals from the

BCU.

▷ The connection cables may remain screwed to

the connection terminals.

 Disconnect the power module, see page3

(Replacing the power module/parameter chip card).

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 recon-

nect the connection terminals and restart the system/BCU, see also page 12 (Commissioning).

? The display blinks and indicates ! No “Position for 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.

? The display blinks and indicates ! No “Position for 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.

? The display blinks and indicates ! No “Position for ignition 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.

GB-18

• If the fault cannot be remedied by doing this,

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

Reading off the ﬂame signal, fault messages and the parameters

▷

During operation (display

), information about

the ﬂame signal intensity, the last 10fault mes-

? 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 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.

! The bus module is defective.

• Replace the bus module.

sages and the parameter values can be read off by repeatedly pressing the Reset/Informa-

tion button.

Display Information

F1 E0

E9 01

Flame signal intensity: burner 1

Last fault message to tenth to last fault message

Parameter 01 to parameter 99

• 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 (fault message, parameter value).

▷

Each time the button is released, the correspond-

? The display blinks and indicates

! Incorrect or defective parameter chip card (PCC).

• Only the intended parameter chip card is to be

used.

• Replace defective parameter chip card.

ing fault code or parameter value is displayed.

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

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

▷ If the button is pressed only brieﬂy, the display

indicates what parameter is currently being dis-

played.

▷

The normal program status is displayed again

? 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-

minal45) 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.

approx. 60seconds after the last time the but-

ton is pressed.

Parameters and values

Pa-

Name

ram-

Values

eter

Burner 1 ﬂame signal switch-off threshold

2 – 20 = µA

Flame control

0 = Ionization

1 = UVS 2 = UVD

Burner 1 start-up attempts

1 = 1 start-up attempt

? 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 (terminal45) if the valve is closed and no voltage is to be applied if the valve is open.

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

Restart

0 = No

1 = Burner 1 restart 4 = Max. 5 burner 1 restarts in 15minutes

Emergency stop

0 = Off

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

• Check that the proof of closure switch and valve

function perfectly, replace defective valves.

GB-19

Pa-

Name

ram-

Values

eter

High gas pressure protection

0 = Off

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

Low gas pressure protection

0 = Off

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

Low air pressure protection

0 = Off

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

Safety time during operation

0; 1; 2 = Time in seconds

Fan run-up time tGV

0 – 6000 = Time in seconds

Air monitoring during controlled air ﬂow

0 = Off; maximum capacity

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

Start-up with pre-purge

0 = On (see P34) 1 = Off; no air control

2 = Off; start from ignition position 3 = Off; start from closed/min. position 4 = Off; start from min. position

Pre-purge time tPV

0 – 6000 = Time in seconds

Air ﬂow monitoring during pre-purge

0 = Off

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

Post-purge time tPN

0 – 6000 = Time in seconds

Air ﬂow monitoring during post-purge

0 = On; maximum capacity 1 = Off; maximum capacity

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

Capacity control

0 = Off 1 = IC 20

2 = IC 40 3 = RBW 4 = Frequency converter

Low ﬁre over-run

0 = Off

1 = Up to minimum capacity

Controller enable signal delay timetRF

0 – 250 = Time in seconds

Minimum operating time tB

0 – 250

Minimum pause time tBP

3 – 3600 Switch-on delay time

0 – 250 = Time in seconds

Time in seconds

Operating time in Manual mode

0 = Unlimited

1 = 5 minutes

Pa-

Name

ram-

Values

eter

Function of terminal 51

0 = Off 8 = AND with emergency stop (trm.46) 9 = AND with air min. (trm.47)

10 =

AND with air ﬂow monitoring (trm.48)

11 = AND with gas max. (trm.50) 12 = AND with gas min. (trm.49) 13 = Max. capacity position feedback (IC40/

RBW) Function of terminal 65

0 = Off 8 = AND with emergency stop (trm.46) 9 = AND with air min. (trm.47)

10 =

AND with air ﬂow monitoring (trm.48)

11 = AND with gas max. (trm.50) 12 = AND with gas min. (trm.49)

Function of terminal 66

0 = Off 8 = AND with emergency stop (trm.46) 9 = AND with air min. (trm.47)

AND with air ﬂow monitoring (trm.48)

11 = AND with gas max. (trm.50) 12 = AND with gas min. (trm.49)

Function of terminal 67

0 = Off 8 = AND with emergency stop (trm.46) 9 = AND with air min. (trm.47)

10 =

AND with air ﬂow monitoring (trm.48)

11 = AND with gas max. (trm.50) 12 = AND with gas min. (trm.49)

Function of terminal 68

0 = Off 8 = AND with emergency stop (trm.46) 9 = AND with air min. (trm.47)

AND with air ﬂow monitoring (trm.48)

11 = AND with gas max. (trm.50) 12 = AND with gas min. (trm.49)

Capacity control (bus) 0 =

Off

1 =

MIN. to MAX. capacity; standby in position for MIN. capacity 2 =

MIN. to MAX. capacity; standby in CLOSED

position

3 =

IGNITION to MAX. capacity; standby in

CLOSED position

4 =

MIN. to MAX. capacity; standby in position for MIN. capacity; burner quick start 5 =

IGNITION to MAX. capacity; standby in position for MIN. capacity; burner quick start Password

0000 – 9999

Burner application

0 = Burner 1

1 = Burner 1 with pilot gas

2 = Burner 1 and burner 2 3 = Burner 1 and burner 2

with pilot gas

GB-20

Pa-

PZH

PZL

PDZ

Name

ram-

Values

eter

Pilot burner operation

0 = With shut-down

1 = Continuous operation

Fieldbus communication

0 = Off

1 = With address check

2 = No address check

Pre-ignition time

–

5 = Time in seconds

Safety time 1 t

2, 3, 5, 10 = Time in seconds

Flame proving period 1 t

–

20 = Time in seconds

Safety time 2 t

2, 3, 5, 10 = Time in seconds

Flame proving period 2 t

–

20 = Time in seconds

SA1

SA2

FS1

FS2

▷ Additional parameters for BCU570..F2

Pa-

Name

ram-

Values

eter

Running time selection 0 = Off; checking the positions for min./max. capacity 1 = On; for approaching the positions for min./ max. capacity

2 = On; for approaching the position for maximum

capacity 3 = On; for approaching the position for minimum capacity

Running time

0 – 250 = Running time in seconds, if

parameter41= 1, 2 or3

▷ Additional parameters for BCU570..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 and after shut-

down

4 = Proof of closure function

Relief valve

2 = V2

3 = V3 4 = V4

Measurement time Vp1

3 = Time in seconds

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

Valve opening time 1 tL1

2 – 25 = Time in seconds

Legend

pu/2

GZL

Ready for operation

Safety interlocks (limits)

High temperature operation

Gas valve

Air valve

Air/gas ratio control valve

Burner

Purge

Controlled air ﬂow

Burner operating signal

Start-up signal (BCU)

Emergency stop

Pressure switch for valve check (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

Valve check (tightness test)

Half of the inlet pressure

Outlet pressure

Valve with proof of closure switch

Input/Output, safety circuit

GB-21

Technical data

Electrical data

Mains voltage: BCU 570Q: 120 V AC, -15/+10%, 50/60 Hz, ±5%, BCU 570W: 230 V AC, -15/+10%, 50/60 Hz,

±5%,

for grounded or ungrounded mains. Flame control: with UV sensor or ionization sensor. For intermittent or continuous operation. Flame signal current: ionization control: 1 – 25 μA, UV control: 1 – 35 μA. Ionization cable, UV cable: max. 100m (164ft). Contact rating: valve outputs V1, V2, V3 and V4 (terminals 13, 14, 15,57) as well as actuator (terminals 53, 54 and55): max. 1A each, cosφ≥0.6, total current for the simultaneous activation of the valve outputs (terminals 13, 14, 15,57) and of the actuator (terminals 53, 54,55): max. 2.5A, fan (terminal58): max. 3 A (start-up current: 6A<1s), signalling contact for operating and fault signals: max. 1 A (external fuse required). Number of operating cycles: The fail-safe outputs (valve outputs V1, V2, V3 andV4) are monitored for correct functioning and are thus not subject to a max. number of operating cycles. Control actuator (terminals 53, 54 and 55): max. 250,000, signalling contact for operating signals: max. 250,000, signalling contact for fault signals: max. 10,000, 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: 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.

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,

rated current 10 A (8A UL),

to be observed in case of daisy chain.

Environment

Storage temperature: -20 to +60°C (-4 to +140°F). Ambient temperature:

-20 to +60°C (-4 to +140°F), no condensation permitted. 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):

20 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.

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22 (Technical data). 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.

GB-22

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

OCU

For installation in the control cabinet door. The program status or fault messages can be read on the OCU. In Manual mode, the OCU can be used to proceed through the sequence of operating steps.

Type Languages Order No. OCU 500-1 D, GB, F, NL, E, I 84327030 OCU 500-2 GB, DK, S, N, TR, P 84327031 OCU 500-3 GB, USA, E, P(BR), F 84327032 OCU 500-4 GB, RUS, PL, H, RO, CZ 84327033

BCU 570 Brenner 1

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

Connection terminal set

For wiring the BCU.

74923997 74923999

Plug-in, with screw terminal, Order No.: 74923997. Plug-in, with spring force terminal, 2connection options per terminal, Order No.: 74923999.

Certiﬁcation

Declaration of conformity

We, the manufacturer, hereby declare that the product BCU 570 complies with the requirements of the listed Directives and Standards.

Directives: – 2009/142/EC – GAD (valid until 20 April 2018) – 2014/30/EU – 2014/35/EU

Regulation: – (EU) 2016/426 – GAR (valid from 21 April 2018)

Standards: – EN 298:2012 – EN1643:2014 – EN 61508:2010, suitable for SIL 3 The relevant product corresponds to the tested type

sample. The production is subject to the surveillance proce-

dure pursuant to Directive 2009/142/EC AnnexII

paragraph3 (valid until 20 April 2018) and to Regu

lation (EU) 2016/426 Annex III paragraph 3 (valid from

21April 2018).

Elster GmbH

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

www.docuthek.com

GB-23

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.

FM approved

Factory Mutual (FM) Research Class:

7610 “Combustion Safeguards and Flame Sensing

Systems” Suitable for applications pursuant to NFPA 86.

ANSI/CSA approved

Canadian Standards Association – ANSI Z21.20 and CSA 22.2

UL listed

Underwriters Laboratories – UL 372 Standard for Limit Controls

Eurasian Customs Union

The product BCU 570 meets the technical speciﬁca-

tions of the Eurasian Customs Union.

Registered design

U.S. Patent No. D682,794

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

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-24

krom schroeder BCU 570 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Burner control unit BCU 570

Contents

Safety

Checking the usage

Installation

Replacing the power module/ parameter chip card

Cable selection

Wiring

Connection diagram

BCU 570

Flame control

Adjustment

Commissioning

Manual mode

Assistance in the event of malfunction

Replacing the fuse

Parameters and values

Legend

Technical data

Designed lifetime

Logistics

Accessories

Contact