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Contents
Introduction1-1
MBS Modular Block System1-2
Categories / requirement classes1-3
Overview of manual1-4
Definition of symbols1-5
Terminology1-6
Overview2-1
Software package2-1
Operation2-1
Range2-2
Safety3-1
Safety guidelines3-1
Use of qualified personnel3-1
Warranty and liability3-1
Application guidelines3-2
Standards3-3
Fault detection3-4
Feasibility test3-4
Fault prevention3-4
Intended Use4-1
Application4-1
System software4-1
Intended use of the standard function blocks4-2
SB149: Sequence control4-2
SB150: Flame monitoring4-2
SB151: Transient suppression4-2
SB152: Burner: start and operator elements4-3
SB153: Control and position monitoring of flaps4-3
1Modular Block System: Burner Management
Contents
SB154: Control and position monitoring of valves4-4
SB155: Pre-purge4-4
SB156: Tightness control4-4
SB157: Several ignition attempts4-4
SB158: Ignition4-5
SB159: Run4-5
SB160: Blower4-5
MBS Basics5-1
Block design5-1
Structure5-1
Formal parameters and actual parameters5-2
Administration data blocks DB015, DB016 and DB0175-3
Structure of the administration data blocks5-3
Blocks contained in the administration data blocks5-5
Input parameter SSNR5-7
Example5-8
Fault diagnostics5-9
Error types5-9
Fault diagnostics using the administration data blocks5-10
Temporary flag range in MBS blocks5-11
Output parameter ENBL5-11
Assignment of input and output parameters5-12
Minimum scan time5-12
Global parameters5-13
Setting / resetting the step without time delay and monitoring time 6-9
Setting/resetting the step with time delay but without monitoring
time6-11
Setting/resetting the step without time delay but with monitoring
time6-12
Setting/resetting the step with time delay and monitoring time6-13
Signal cycle with an uninterrupted burner start-up or uninterrupted
burner stop sequence6-19
Flame monitor error6-20
Spurious signals when monitoring for “flame not established”6-20
Spurious signals before and during monitoring for
“flame established”6-21
Spurious signals during monitoring for “flame established”6-21
Setting the ENBL output automatically when the signal is
recovered6-25
Setting the ENBL output after a reset when the signal is
recovered6-25
Spurious signal sequence at BASE input6-26
Spurious signal sequence at AuSt input6-26
Burner start-up without automatic start after a controlled
shutdown6-34
Failure of safety sequence, flame monitor sequence and general
faults6-34
Failure of monitor sequence6-35
Monitoring of air pressure6-36
Restart after flame failure or flame monitoring fault6-37
Automatic restart after air deficiency6-38
Spurious signals6-38
SB153: Control and position monitoring of flaps6-40
No automatic start after controlled shutdown6-44
Monitoring of end positions6-44
Missing acknowledgement6-45
Multiple drive commands6-46
Spurious fault signal reset6-46
Test to ensure safe monitoring time6-47
SB154: Control and position monitoring of valves6-48
Valve closed without power6-52
Reset spurious acknowledgements6-53
Spurious acknowledgement as valve opens6-53
SImultaneous OPEN and CLOSE commands6-54
Multiple recurring OPEN and CLOSE commands6-54
Signal cycle of uninterrupted tightness control on a plant with an
exhaust valve6-67
Signal cycle of uninterrupted tightness control on a plant without
an exhaust valve6-69
Loss of minimum pressure signal as valve VAV1 is incorrectly
seated6-70
Loss of maximum pressure signal as valve VAV3 or VAV4 is
incorrectly seated6-71
Enable and cancel tightness control via SyOK6-72
Spurious, undefined NEXT input combinations6-73
Counting ignition attempts where time is not exceeded6-80
Counting ignition attempts where time is exceeded6-81
Successful ignition after first attempt failed6-81
Spurious signals6-82
Automatic ignition cycle when no parameters are set for manual
ignition6-91
Automatic ignition cycle when parameters are set for manual
ignition6-93
Spurious signals at NEXT input6-94
Failure of SyOK in all NEXT steps6-95
Spurious signals at MANU and S_IG inputs6-95
Error analysis during manual ignition start-up6-96
Uninterrupted blower control6-111
Spurious, conflicting control signals6-111
Connections required between the SBs6-112
Sequence for calling SBs6-115
Link Blocks7-1
Check list7-1
Examples8-1
Application and parameters of individual blocks8-1
Managing enables8-2
Using step monitoring time W_E of SB1498-6
W_E as ignition ready time8-6
Using delay time D_E on SB1498-8
Executing a function during
D_E as pre-purge time8-8
Executing a function after D_E8-10
Delayed shutdown of blower8-10
Building-up minimum air pressure8-12
Driving the air flaps8-14
Nesting of step sequences8-16
D_E8-8
7Modular Block System: Burner Management
Contents
Appendix9-1
Assignment table: Category « Requirement class9-1
Standard function blocks: current versions9-2
Changes to the standard function blocks9-3
SB 149: Sequence control9-3
SB151: Transient suppression9-4
SB152: Burner: start and operator elements9-4
SB 153: Control and position monitoring of flaps9-5
SB 154: Control and position monitoring of valves9-5
SB 155: Pre-purge9-6
SB156: Tightness control9-6
SB 157: Several ignition attempts9-6
Changes to the operating manual9-7
Changes from Version I to Version II9-7
Changes from Version II to Version III9-7
Changes from Version III to Version IV9-8
Changes in Version 059-8
Changes in Version 069-8
Changes in Version 079-8
8
Modular Block System: Burner Management
Introduction
This manual describes how to manage the standard function
blocks in the “MBS Burner Management” software package in accordance
with their intended use.
Standard function blocks in the “MBS Burner Management” software
package are part of the Pilz MBS Modular Block System. They can be
used in the failsafe section of a PSS-range programmable safety system.
To fully understand this manual you will need to be conversant with the
information found in the general documentation for the PSS-range (System
Manual, Installation Manual for the modular/compact PSS, PSS WIN-PRO
Programming Manual).
In particular you should refer to the following documents from the System
Manual:
• Safety Manual
• FS System Description
• Error List
To fully understand the bus-specific requirements and correlations for
SafetyBUS p applications you will need some knowledge of the design and
management of SafetyBUS p.
Knowledge of the safety regulations for the particular area of application is
assumed.
This installation manual is intended for instruction and should be retained
for future reference.
1-1Modular Block System: Burner Management
Introduction
MBS Modular Block System
Safety-related areas can be equipped with a multitude of safety devices
such as E-STOPs, safety gates, light barriers etc. Safety devices are
required in various quantities and combinations, depending on the object
requiring protection. The Pilz MBS Modular Block System was developed
to drive the various safety devices and to carry out process engineering
functions, The MBS is designed to help users save time and money.
The MBS consists of individual standard function blocks (SBs), which are
geared specifically towards the relevant safety device or process
engineering function. It allows standard function blocks to be used in any
combination. The standard function blocks can be combined in any
sequence (max. 600).
Standard function blocks are encoded by an authorised body so that they
cannot be modified. If encoded standard function blocks are used within a
user program, program testing may be restricted to the new parts of the
program, considerably reducing the test time.
1-2
Modular Block System: Burner Management
Categories / requirement classes
EN 954-1 divides safety devices into categories.
All standard function blocks are designed for the highest category
permitted for the safety device to be monitored. If safety devices with lower
categories are to be monitored, input parameters may be assigned
identical inputs (further information can be found in the description for the
relevant standard function block).
In process engineering, safety requirements must conform to DIN V 19250
(Fundamental Safety Aspects to be Considered for Measurement and
Control Equipment).
Requirement classes in accordance with DIN V 19250 may be referred to
the categories as per EN 954-1. The Appendix contains a table showing
the assignment of category and requirement class.
1-3Modular Block System: Burner Management
Introduction
Overview of manual
1 Introduction
The chapter you are reading provides an introduction to the Modular
Block System (MBS). It is designed to familiarise you with the
contents, structure and specific order of this manual and also contains
terminology definitions.
2 Overview
This chapter provides information on the most important features of
the software package and provides a brief overview of the application
range.
3 Safety
This chapter must be read as it contains important information on
safety regulations.
4 Intended Use
This chapter must be read as it contains information on intended use.
5 MBS Basics
This chapter explains the basic functions and safety requirements of
the MBS.
6 Standard Function Blocks
This chapter explains the function of the package’s standard function
blocks.
7 Link Blocks
This chapter is designed to help you link the standard function blocks
into your project and to commission the safety functions.
8 Examples
This chapter is designed to give an overview of how the standard
function blocks may be applied and contains typical application
examples.
9 Appendix
The Appendix contains a table that explains the relationship between
categories and requirement classes, plus a list that documents the
current version status of the standard function blocks.
1-4
Modular Block System: Burner Management
Definition of symbols
Information in this manual that is of particular importance can be identified
as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that
poses an immediate threat of serious injury and death and indicates
preventive measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that
could lead to serious injury and death and indicates preventive
measures that can be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the unit(s) could be damaged and also
provides information on preventive measures that can be taken.
INFORMATION
This gives advice on applications and provides information on special
features, as well as highlighting areas within the text that are of particular
importance.
1-5Modular Block System: Burner Management
Introduction
Terminology
• The term “input” is frequently abbreviated to “I” (e.g. I-Parameter).
• The term “output” is frequently abbreviated to “O” (e.g. O-Parameter).
• The term “PSS” is always used when the description is valid for all
applicable PSS programmable safety systems. If the description only
relates to a specific PSS series, the specific name for that series will be
used (e.g. PSS 3000 or PSS SB 3056).
• In this manual, the Pilz system software “PSS WIN-PRO” is referred to as
the “programming device” or “PG”.
1-6
Modular Block System: Burner Management
Overview
Software package
The “MBS Burner Management” software package is part of the Pilz MBS
Modular Block System.
Standard function blocks in the “MBS Burner Management” software
package are used in the failsafe section of a PSS-range programmable
safety system.
The software package complies with the relevant standards and directives
for burners, steam boilers and thermoprocessing equipment.
The software package contains all the blocks necessary for burner control.
Operation
The individual standard function blocks perform individual functions such
as:
• Sequence control
• Flame monitoring
• Tightness control
• etc.
With these blocks the user can put the burner cycle together individually.
Details can be found in Chapter 6 of this manual, “Standard Function
Blocks”.
2-1Modular Block System: Burner Management
Overview
Range
The software package consists of:
• The files for the software package on CD and
• An operating manual:
PSS Standard Function Blocks, MBS Burner Management.
The software package on the CD contains the following blocks:
• SB149STEP
Sequence control
(approved safety block)
• SB152BR_START
Burner: start and operator elements
(approved safety block)
• SB153FLAP
Control and position monitoring of flaps
(approved safety block)
• SB154VALVE
Control and position monitoring of valves
(approved safety block)
• SB155PREPURGE
Pre-purge
(approved safety block)
• SB156TIGHT_C
Tightness control
(approved safety block)
• SB157IGNI_TRY
Several ignition attempts
(approved safety block)
2-2
Modular Block System: Burner Management
• SB158IGNITION
Ignition
(approved safety block)
• SB159RUN
Run
(approved safety block)
• SB160BLOWER
Blower
(approved safety block)
• SB071INIT_MBS
Initialisation of administration data blocks (DB015/DB016/DB017)
(approved safety block)
• SB255System block
SB255 is explained in the PSS System Description.
INFORMATION
Please refer to the Appendix, section entitled “Standard function blocks:
current versions”.
2-3Modular Block System: Burner Management
Overview
Notes
2-4
Modular Block System: Burner Management
Safety
Safety guidelines
These safety guidelines are an important part of this manual.
Failure to keep to these guidelines will render all warranty and liability
claims invalid:
• All health and safety / accident prevention regulations for the particular
area of application must be observed.
• Before using one or more of the standard function blocks in this software
package, it is necessary to perform a safety assessment in accordance
with the Machinery Directive.
Use of qualified personnel
The safety system may only be assembled, installed, programmed,
commissioned, operated, maintained and decomissioned by qualified
personnel. Qualified personnel are people who, because they are:
• Qualified electrical engineers and/or
• Have received training from qualified electrical engineers
are suitably experienced to operate devices, systems, plant and machinery
in accordance with the general standards and guidelines for safety
technology.
Warranty and liability
All claims to warranty and liability will be rendered invalid if:
• Standard function blocks are used contrary to the purpose for which they
were intended
• Damage can be attributed to not having followed the guidelines in the
manual
• Operating personnel are not suitably qualified.
3-1Modular Block System: Burner Management
Safety
Application guidelines
• The instructions given in the “Safety Manual” and in the “Installation
Manual” must be followed.
• Please read the information in Chapter 4 concerning the proper
application of these blocks.
• The use of Pilz SBs does not detract from the fact that it is the
responsibility of the user to design appropriate safety systems for plant,
machinery and software.
• It is your responsibility to determine your application requirements by
carrying out a detailed risk analysis. This should take into account relevant standards and directives, etc.
WARNING!
Please note: To achieve the corresponding category or requirement class,
the whole system including all safety-related components (parts, devices,
user program etc.) must be included in the assessment. For this reason,
Pilz cannot accept liability for the correct classification into a category or
requirement class.
3-2
Modular Block System: Burner Management
Standards
To use the SBs correctly you will need to have a good knowledge of the
relevant standards and directives. The following gives an overview of the
most important standards:
• Safety of machinery – Basic terminology
• Electrical equipment
• Safety of machinery; safety-related parts of
control systems
• Fundamental safety aspects to be considered
for measurement and control equipment
• Electrical equipment for furnaces
• Automatic gas burner control systems for gas
burners and gas burning appliances with or
without fans
• Monobloc oil burners
• Forced draught oil burners
• Automatic forced draught burners for gaseous
fuels
• Valve proving systems for automatic shut-off
valves for gas burners and gas appliances
• Electrical equipment for furnaces
EN 292-1:1991-11 and
EN 292-2:1995-06
EN 60 204-1:1998-11
EN 954-1:1997-03
DIN V 19250:1994-05
EN 50 156-1:2004
EN 298:2003
EN 230:1990
EN 267:1999
EN 676:2003
EN 1643:2000
VDE 0116/
EN 50156:2004
• Industrial thermoprocessing equipment
• Water-tube boilers and auxiliary installations
• Shell boilers
• Directive for appliances burning gaseous fuels
• Pressure equipment directive
• Oil firing systems for boilers
• Gas firing systems for boilers
EN 746-2:1997
EN 12952-8:2003
EN 12953-7:2002
90/396/EEC
97/23/EC
TRD 411:1997
TRD 412:1998
Please note this is not an exhaustive list of safety standards and directives.
3-3Modular Block System: Burner Management
Safety
Fault detection
The detection of errors and defects is an important function of the PSS, in
addition to pure control tasks.
Further information on the fault detection concept can be found in the PSS
“System Description”.
WARNING!
It is particularly important to detect open circuits and shorts within the
safety circuits (e.g. two-hand control devices, E-STOP etc.).
It is the responsibility of the user to select and apply an appropriate fault
detection system.
Feasibility test
Fault prevention
Redundant input devices for safety functions must undergo a feasibility test
within the user program.
The plant must be stopped immediately if a feasibility error occurs. Similar
tests will also be required for other input devices.
If safety valves have feedback contacts, these must be evaluated
accordingly.
Not all potential faults can be detected and managed. Such faults must be
excluded by suitable wiring methods.
Additional information on how to exclude potential errors can be found in
the BIA Handbook (BG Institute for Occupational Safety, St Augustin) or in
the directive VDI 2854:1991-06 (safety requirements on automated
manufacturing systems).
3-4
Modular Block System: Burner Management
Intended Use
Application
The software package “MBS Burner Management” is designed for
use within the failsafe section of the PSS-range of programmable safety
systems. With this MBS package it is possible to control and monitor
various status conditions on furnaces.
INFORMATION
• Use of standard function blocks outside the specifications described here
will be deemed as improper use.
• MBS blocks must be run through as part of each cycle.
Please refer also to the table showing the required connections for the
standard function blocks, at the end of Chapter 6.
INFORMATION
Always use the current version of the standard function block.
Please ensure you refer to the Appendix, sections entitled “Standard
function blocks: current versions” and “Changes to the standard function
blocks”.
System software
The software package “MBS Burner Management” can be used with the
PSS WIN-PRO system software.
Further information is available in the PSS WIN-PRO “Progamming Manual”.
4-1Modular Block System: Burner Management
Intended Use
Intended use of the standard function blocks
SB149: Sequence control
SB149 is a standard function block designed to control operating cycles.
For this reason, several SB149 blocks can be arranged together to form a
sequence. Each SB149 in this sequence waits for the ready signal from the
previous step and for the step enabling conditions to be met, before it
becomes active.
A PSS can monitor and control several work cycles in which each cycle is
assigned a separate sequence.
NOTICE
During a sequence only one SB may be active. This requirement is only
met if output parameter
parameter
accordingly.
RDY
on the next step. Make sure the parameters are assigned
NEXT
from the current step is connected to input
SB150: Flame monitoring
SB150 is a standard function block for monitoring flames from the moment
the burner starts until the moment the burner stops. The block checks
whether the flame is present or absent, depending on the operating status.
SB151: Transient suppression
SB151 is a standard function block for monitoring a N/C contact, e.g. on a
pressure monitor. The N/C contact must be wired with a test pulse.
4-2
Modular Block System: Burner Management
SB152: Burner: start and operator elements
SB152 is used to control the burner start and monitor the burner.
Use SB152 to:
• Carry out a delayed start after the controller has started
• Carry out a restart after a controlled shutdown
• Evaluate the reset, start and stop button
• Monitor the air pressure monitor
• Monitor the flames (pilot and main flame)
• Monitor the global messages from the error, monitor and safety
sequences and to carry out a controlled shutdown or safety lockout.
If the safety sequence is interrupted, the error must always be rectified,
followed by a manual reset via the reset button (
(
STRT)
. The block enable
ENBL
sequence is no longer interrupted. .
NOTICE
Error reaction is the sole responsibility of the user. All safety-related
aspects must be taken into account when selecting the elements for the
error and safety sequences!
RSET)
and start button
will only be issued when the safety
SB153: Control and position monitoring of flaps
SB153 monitors the status of a flap. It opens and closes the flap after the
corresponding input prompt, monitors the direction of a positional change
and checks the reaction time.
The contact bounce time lasts for one cycle, if a change in position occurs.
4-3Modular Block System: Burner Management
Intended Use
SB154: Control and position monitoring of valves
SB154 monitors the status of a valve. It changes the valves' position after
the corresponding input prompt, monitors the direction of a positional
change and checks the reaction time.
The contact bounce time lasts for one cycle, if a change in position occurs.
SB155: Pre-purge
SB155 monitors the limit switch for the maximum position of the air
damper or the maximum air flow during the pre-purge time.
If the limit switch isn’t activated by the air damper during the pre-purge
time, or if the maximum air flow for pre-purge is not achieved, SB155
resets its enable.
SB156: Tightness control
SB156 checks the tightness (seal) of the safety valves, the main valves
and, if present, the exhaust valves.
Tightness monitoring must be called up separately. If an error occurs, the
enable is reset and a shutdown occurs.
SB157: Several ignition attempts
SB157 counts the number of ignition attempts. After a failed ignition, a
signal is issued for another attempt, after which the step sequence can
immediately start the initial ignition step.
SB157 also monitors the time between the ignition attempts and the
establishment of a flame.
4-4
Modular Block System: Burner Management
SB158: Ignition
SB159: Run
SB158 controls the ignition and monitors the process. The ignition steps
must be called up individually. If a fault occurs, the enable is reset and a
shutdown occurs.
To ensure a fault-free ignition process, the safety valve must not be driven
from SB158 and another safety block at the same time.
SB159 is used to set up the burner. These set-up steps must be called up
individually. If an error occurs, the enable is reset and a shutdown occurs.
Following a fault-free start-up SB159 issues a control enable.
To ensure a fault-free start-up process, the main valve must not be driven
from SB159 and another safety block at the same time.
SB160: Blower
SB160 is used to control a blower/fan on force draught burners.
The blower is switched on by pressing a button on the input parameter
STRT
the input parameter
NEXT
on SB160. The blower is switched off either by pressing a button on
STOP
on SB160 or by setting the input parameter
via the sequence block “Blower overrun time”.
When controlling fans the rising edge of the signals on the input
parameters has priority.
4-5Modular Block System: Burner Management
Intended Use
Notes
4-6
Modular Block System: Burner Management
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