Pilz PSS SB FT, Basic license User Manual

PSS Standard Function Blocks MBS Burner Management Version 4.0
Programmable control systems PSS
®
Operating Manual – No. 19532-EN-07
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made for internal purposes.
Suggestions and comments for improving this documentation will be gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®, SafetyEYE®,
®
SafetyNET p
, the spirit of safety® are registered and protected trademarks of
Pilz GmbH & Co. KG in some countries.
SD means Secure Digital.

Contents

Introduction 1-1
MBS Modular Block System 1-2 Categories / requirement classes 1-3 Overview of manual 1-4 Definition of symbols 1-5 Terminology 1-6
Overview 2-1
Software package 2-1
Operation 2-1
Range 2-2
Safety 3-1
Safety guidelines 3-1
Use of qualified personnel 3-1 Warranty and liability 3-1 Application guidelines 3-2 Standards 3-3
Fault detection 3-4
Feasibility test 3-4 Fault prevention 3-4
Intended Use 4-1
Application 4-1 System software 4-1 Intended use of the standard function blocks 4-2
SB149: Sequence control 4-2 SB150: Flame monitoring 4-2 SB151: Transient suppression 4-2 SB152: Burner: start and operator elements 4-3 SB153: Control and position monitoring of flaps 4-3
1Modular Block System: Burner Management
Contents
SB154: Control and position monitoring of valves 4-4 SB155: Pre-purge 4-4 SB156: Tightness control 4-4 SB157: Several ignition attempts 4-4 SB158: Ignition 4-5 SB159: Run 4-5 SB160: Blower 4-5
MBS Basics 5-1
Block design 5-1
Structure 5-1 Formal parameters and actual parameters 5-2
Administration data blocks DB015, DB016 and DB017 5-3
Structure of the administration data blocks 5-3 Blocks contained in the administration data blocks 5-5
Input parameter SSNR 5-7
Example 5-8
Fault diagnostics 5-9
Error types 5-9 Fault diagnostics using the administration data blocks 5-10
Temporary flag range in MBS blocks 5-11 Output parameter ENBL 5-11 Assignment of input and output parameters 5-12 Minimum scan time 5-12 Global parameters 5-13
Standard Function Blocks 6-1
SB149: Sequence control 6-1
Block header 6-1 Input parameters 6-1 Output parameters 6-2 Function: 6-2 Error messages 6-3 Blocks required 6-3
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Modular Block System: Burner Management
Programming guidelines 6-4 Timing diagrams 6-9
Setting / resetting the step without time delay and monitoring time 6-9 Setting/resetting the step with time delay but without monitoring time 6-11 Setting/resetting the step without time delay but with monitoring time 6-12 Setting/resetting the step with time delay and monitoring time 6-13
SB150: Flame monitoring 6-14
Block header 6-14 Input parameters 6-14 Output parameters 6-15 Function: 6-15 Error messages 6-15 Blocks required 6-16 Programming guidelines 6-17 Timing diagrams 6-19
Signal cycle with an uninterrupted burner start-up or uninterrupted burner stop sequence 6-19 Flame monitor error 6-20 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
SB151: Transient suppression 6-22
Block header 6-22 Input parameters 6-22 Output parameters 6-23 Function 6-23 Error messages 6-23 Blocks required 6-24 Programming guidelines 6-24 Timing diagrams 6-25
Setting the ENBL output automatically when the signal is recovered 6-25 Setting the ENBL output after a reset when the signal is recovered 6-25 Spurious signal sequence at BASE input 6-26 Spurious signal sequence at AuSt input 6-26
3Modular Block System: Burner Management
Contents
SB152: Burner: start and operator elements 6-28
Block header 6-28 Input parameters 6-28 Output parameters 6-30 Function 6-30 Error messages 6-31 Blocks required 6-32 Programming guidelines 6-33 Timing diagrams 6-34
Burner start-up without automatic start after a controlled shutdown 6-34 Failure of safety sequence, flame monitor sequence and general faults 6-34 Failure of monitor sequence 6-35 Monitoring of air pressure 6-36 Restart after flame failure or flame monitoring fault 6-37 Automatic restart after air deficiency 6-38 Spurious signals 6-38
SB153: Control and position monitoring of flaps 6-40
Block header 6-40 Input parameters 6-40 Output parameters 6-41 Function 6-41 Error messages 6-41 Blocks required 6-42 Programming guidelines 6-43 Timing diagrams 6-44
No automatic start after controlled shutdown 6-44 Monitoring of end positions 6-44 Missing acknowledgement 6-45 Multiple drive commands 6-46 Spurious fault signal reset 6-46 Test to ensure safe monitoring time 6-47
SB154: Control and position monitoring of valves 6-48
Block header 6-48 Input parameters 6-48 Output parameters 6-49 Function 6-49 Error messages 6-49 Blocks required 6-50 Programming guidelines 6-51
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Modular Block System: Burner Management
Timing diagrams 6-52
Valve closed without power 6-52 Reset spurious acknowledgements 6-53 Spurious acknowledgement as valve opens 6-53 SImultaneous OPEN and CLOSE commands 6-54 Multiple recurring OPEN and CLOSE commands 6-54
SB155: Pre-purge 6-56
Block header 6-56 Input parameters 6-56 Output parameters 6-56 Function 6-56 Error messages 6-57 Blocks required 6-57 Programming guidelines 6-58 Timing diagrams 6-58
Signal cycle with interrupted and uninterrupted pre-purge process 6-58 Spurious signal sequence at NEXT and RDY inputs 6-59
SB156: Tightness control 6-60
Block header 6-60 Input parameters 6-60 Output parameters 6-61 Function 6-61 Error messages 6-62 Blocks required 6-63 Programming guidelines 6-64 Timing diagrams 6-67
Signal cycle of uninterrupted tightness control on a plant with an exhaust valve 6-67 Signal cycle of uninterrupted tightness control on a plant without an exhaust valve 6-69 Loss of minimum pressure signal as valve VAV1 is incorrectly seated 6-70 Loss of maximum pressure signal as valve VAV3 or VAV4 is incorrectly seated 6-71 Enable and cancel tightness control via SyOK 6-72 Spurious, undefined NEXT input combinations 6-73
5Modular Block System: Burner Management
Contents
SB157: Several ignition attempts 6-74
Block header 6-74 Input parameters 6-74 Output parameters 6-75 Function 6-75 Error messages 6-75 Blocks required 6-76 Programming guidelines 6-76 Timing diagrams 6-80
Counting ignition attempts where time is not exceeded 6-80 Counting ignition attempts where time is exceeded 6-81 Successful ignition after first attempt failed 6-81 Spurious signals 6-82
SB158: Ignition 6-84
Block header 6-84 Input parameters 6-84 Output parameters 6-85 Function 6-85 Error messages 6-85 Blocks required 6-86 Programming guidelines 6-87 Timing diagrams 6-91
Automatic ignition cycle when no parameters are set for manual ignition 6-91 Automatic ignition cycle when parameters are set for manual ignition 6-93 Spurious signals at NEXT input 6-94 Failure of SyOK in all NEXT steps 6-95 Spurious signals at MANU and S_IG inputs 6-95 Error analysis during manual ignition start-up 6-96
SB159: Run 6-98
Block header 6-98 Input parameters 6-98 Output parameters 6-98 Function 6-99 Error messages 6-99 Blocks required 6-100 Programming guidelines 6-101 Timing diagrams 6-104
Uninterrupted burner start-up or uninterrupted burner stop sequence 6-104
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Modular Block System: Burner Management
Failure of SyOK in all NEXT steps 6-106 Spurious signals at NEXT input 6-107
SB160: Blower 6-108
Block header 6-108 Input parameters 6-108 Output parameters 6-108 Function 6-109 Error messages 6-109 Blocks required 6-110 Programming guidelines 6-110 Timing diagrams 6-111
Uninterrupted blower control 6-111 Spurious, conflicting control signals 6-111
Connections required between the SBs 6-112 Sequence for calling SBs 6-115
Link Blocks 7-1
Check list 7-1
Examples 8-1
Application and parameters of individual blocks 8-1 Managing enables 8-2 Using step monitoring time W_E of SB149 8-6
W_E as ignition ready time 8-6
Using delay time D_E on SB149 8-8
Executing a function during
D_E as pre-purge time 8-8
Executing a function after D_E 8-10
Delayed shutdown of blower 8-10 Building-up minimum air pressure 8-12
Driving the air flaps 8-14 Nesting of step sequences 8-16
D_E 8-8
7Modular Block System: Burner Management
Contents
Appendix 9-1
Assignment table: Category « Requirement class 9-1 Standard function blocks: current versions 9-2 Changes to the standard function blocks 9-3
SB 149: Sequence control 9-3 SB151: Transient suppression 9-4 SB152: Burner: start and operator elements 9-4 SB 153: Control and position monitoring of flaps 9-5 SB 154: Control and position monitoring of valves 9-5 SB 155: Pre-purge 9-6 SB156: Tightness control 9-6 SB 157: Several ignition attempts 9-6
Changes to the operating manual 9-7
Changes from Version I to Version II 9-7 Changes from Version II to Version III 9-7 Changes from Version III to Version IV 9-8 Changes in Version 05 9-8 Changes in Version 06 9-8 Changes in Version 07 9-8
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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.
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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.
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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”.
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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:
• SB149 STEP Sequence control (approved safety block)
• SB150 FLAME_M Flame monitoring (approved safety block)
• SB151 BridgedS Transient suppression (approved safety block)
• SB152 BR_START Burner: start and operator elements (approved safety block)
• SB153 FLAP Control and position monitoring of flaps (approved safety block)
• SB154 VALVE Control and position monitoring of valves (approved safety block)
• SB155 PREPURGE Pre-purge (approved safety block)
• SB156 TIGHT_C Tightness control (approved safety block)
• SB157 IGNI_TRY Several ignition attempts (approved safety block)
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Modular Block System: Burner Management
• SB158 IGNITION Ignition (approved safety block)
• SB159 RUN Run (approved safety block)
• SB160 BLOWER Blower (approved safety block)
• SB071 INIT_MBS Initialisation of administration data blocks (DB015/DB016/DB017) (approved safety block)
• SB255 System 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
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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.
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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).
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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.
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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.
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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
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Modular Block System: Burner Management
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