Pilz PSS SB FT, Basic license User Manual

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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.

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

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

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

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

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.

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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”.

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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

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

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

MBS Basics

Block design

Structure

Safety-related areas can be equipped with a multitude of safety devices such as (e.g. E-STOPs, safety gates, light barriers). These safety devices are used in various quantities and combinations, depending on the object requiring protection.

The Modular Block System (MBS) is made up of individual standard function blocks. A standard function block is geared towards the requirements of specific safety devices (e.g. monitoring an E-STOP button, safety gate monitoring).

A standard function block must be assigned to each safety device in order for it to be evaluated and monitored using the MBS. This procedure enables any combination of individual safety devices to be evaluated and monitored. The standard function blocks can be combined in any sequence within the user program (max. 600).

One exception to this are standard function blocks used to drive and monitor contactors or valves. For control engineering reasons, these should be called up at the end of the user program.

5-1Modular Block System: Burner Management

MBS Basics

Formal parameters and actual parameters

Parameters can be set on the MBS standard function blocks. Formal parameters are established in the block header. The user must assign a corresponding actual parameter to each formal parameter. When the standard function block is called up in the user program, the formal parameters will be replaced by the user-specific actual parameters.

Formal parameters

PSS WIN-PRO: Pilz IL

D Z

Further information is available in the PSS WIN-PRO “Progamming Manual”.

Actual parameters

PSS WIN-PRO: Pilz IL Input bit E

Output bit A Flag bit M

Input byte EB Output byte AB Flag byte MB Constant KB

Input word EW Output word AW Flag byte MW Constant KW

Data block DB Timer or counter

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Modular Block System: Burner Management

Administration data blocks DB015, DB016 and DB017

Data blocks DB015, DB016 and DB017 are permanently specified within the Modular Block System (MBS).

These data blocks are common administration blocks for fault and diagnostic data from the MBS standard function blocks and for block and parameter data that is required internally.

The administration data block DB015 must always be installed when using MBS standard function blocks. Administration data blocks DB016 and DB017 are installed when necessary. The administration data blocks must always be installed with their full length of 1024 data words and they must always have read/write status.

NOTICE

Data blocks DB015, DB016 and DB017 should only be used as MBS administration data blocks and not for other data.

Structure of the administration data blocks

The administration data blocks DB015, DB016 and DB017 have the same structure.

Each standard function block in the user program has 5 data words available in one of the administration data blocks. These data words are used to back up the temporary flags from the standard function block (see section entitled “Temporary flag range in MBS blocks”).

In each of the administration data blocks, the range DW0001 to DW1000 is divided into 5 blocks, each with 200 data words (see Fig. 5-1).

5-3Modular Block System: Burner Management

MBS Basics

DB017

DB016

DB015

DW0000

Block 1

200 data words

Block 2

200 data words

Block 3

200 data words

Block 4

200 data words

Block 5

200 data words

Block 6 Global parameters

DW 0001

DW 0200

DW 0201

DW 0400

DW 0401

DW 0600

DW 0601

DW 0800

DW 0801

DW 1000

DW 1001

DW 1023

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Fig. 5-1: Structure of the administration data blocks

Modular Block System: Burner Management

Blocks contained in the administration data blocks

Each standard function block occupies 1 data word per block (see Fig. 5-

2). This means a max. of 200 safety devices (e.g. E-STOP 1, E-STOP 2,

safety gate 1) can be managed per administration data block.

The PSS uses a standard function block’s SSNR to automatically generate the corresponding data words (see “Input parameter SSNR”).

DB017

DB016

DB015

DW0000

Block 1

Data word 1

Block 2

Block 3

Block 4

Block 5

Block 6 Global parameters

Data word 2

Data word 3

Data word 4

Data word 5

Fig. 5-2: Contents of the administration data blocks

Data words 1 to 5 of an MBS standard function block

5-5Modular Block System: Burner Management

MBS Basics

DW0000 (DB015)

1st data block (DB015/DB016/DB017):

DW 0001 ... DW0200 bits for hardware and operator errors

2nd data block ... 5. data block (DB015/DB016/DB017):

If parameters for a standard function block’s input parameter SSNR are not within the permitted range, DW0000 of DB015 will contain the incorrect SSNR parameter. The standard function block will not be enabled (output parameter ENBL= 0). If the SSNR=0, DW0000 of DB015 will contain the decimal value -1 or KH FFFF.

The significance of the individual bits can be found in the description for the relevant standard function block (see section entitled “Fault diagnostics”). If a data word contains the value 0, no error has been found

DW0201 ... DW1000

Data blocks 2 ... 5 are used for internal block data.

6th data block (DB015/DB016/DB017)

DW1001 ... DW1023

Data block 6 contains the global parameters (see section entitled “Global parameters”).

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Modular Block System: Burner Management

Input parameter SSNR

MBS standard function blocks have input and output parameters which can be adapted to suit the respective control configuration. The input parameter SSNR (safety subroutine number) is available on all MBS standard function blocks. It is required to manage the administration data blocks DB015, DB016 and DB017.

INFORMATION

MBS standard function blocks may differ in terms of the permitted value range for the SSNR. The following value ranges are possible for the SSNR:

• Value range of input parameter SSNR: 1 ... 200 (byte constant type: KB001 ... KB200)

• Value range of input parameter SSNR: 1 ... 600 (word constant type: KF000001 ... KF000600)

The valid value range for the SSNR of a standard function block is documented in the standard function block description.

The input parameter SSNR determines the administration data block plus the 5 data words assigned in the administration data block of the corresponding safety device (1 DW per block). The administration data blocks are assigned the following SSNR ranges:

• SSNR 001 ... 200: DB015

• SSNR 201 ... 400: DB016

• SSNR 401 ... 600: DB017

The one data word per block is generated automatically internally (SSNR + offset).

5-7Modular Block System: Burner Management

MBS Basics

NOTICE

• One MBS standard function block must be used for each safety device.

• Each standard function block should be assigned its own SSNR.

• Make sure that each SSNR is assigned once only.

• Document the assignment of the safety device to the respective SSNR of

Example

Safety device 2 (E-STOP button) is monitored using SB061. The value KB002 is assigned to input parameter SSNR of SB061.

If two SB calls have the same value for the SSNR, they will access the same data word in the administration data block. This can lead to malfunctions.

the standard function block.

The following DWs in DB015 are therefore assigned to safety device 2: Block 1: DW0002

Block 2: DW0202 Block 3: DW0402 Block 4: DW0602 Block 5: DW0802

The user program has read-only access to these data words.

5-8

Modular Block System: Burner Management

Fault diagnostics

Error types

On programmable safety systems from the PSS-range, a distinction is made between two types of errors. On the one hand there are errors which are detected and evaluated through the PSS operating system, and on the other there are errors which are detected and evaluated through the user program. The reaction to these two types of errors is different.

Where errors are detected through the operating system, the FS section of the PSS will switch to a STOP condition and all outputs will be switched off safely.

Where errors are detected through the user program, only the configured error reaction will occur. Errors that are detected via an MBS standard function block belong to this second type of error.

5-9Modular Block System: Burner Management

MBS Basics

Fault diagnostics using the administration data blocks

Data words DW0001 ... DW0200 of an administration data block contain the error messages from the individual MBS standard function blocks (see Fig 5-3). 1 data word is reserved for each standard function block used. The assignment is made using the SSNR.

SB061

KB001

KB005

KF000205

KF000427

SSNR

SB061

SSNR

SB065

SSNR

SB065

SSNR

ENBL

DB015

DW0000

DW0001

...

DW0005

...

DW0027

...

DW0200

...

DW1023

DB016

DW0000

DW0001

...

DW0005

...

DW0027

...

DW0200

...

DW1023

DB017

DW0000

DW0001

...

DW0005

...

DW0027

...

DW0200

...

DW1023

Fig. 5-3: Managing the MBS error messages using the administration data blocks (example)

5-10

Modular Block System: Burner Management

Temporary flag range in MBS blocks

Internally, MBS blocks use the flags in the range M 64.00 ... M69.31 as temporary flags.

NOTICE

We recommend the following:

• Do not use flags from the temporary flag range for your own applications. Malfunctions may occur if you use the temporary flag range M64.00 ... M69.31 for your own applications.

• If it is absolutely necessary to use this flag range, under no circumstances should you use the flags:

- in alarm OBs

- as input parameters for standard function blocks

- as output parameters for standard function blocks

- as global parameters

Output parameter ENBL

Many standard function blocks have an enable output ENBL. This output parameter indicates the enable status of a standard function block. The enable status results from the standard function block’s check of the inputs.

ENBL = 1: No error found,

the function is enabled

ENBL = 0: An error has been found,

the function is not enabled.

5-11Modular Block System: Burner Management

MBS Basics

Assignment of input and output parameters

Input and output parameters should be assigned in accordance with the details given in the operating manual.

WARNING!

If several unused output parameters are connected to the same flag, malfunctions may occur in the standard function blocks. If an unused output has to be assigned a flag, make sure the output is assigned to a flag that is not used anywhere else in the program.

Minimum scan time

Most of the timer functions required within the blocks are performed using cycle counters. This means that almost all the timers are available for use in applications.

INFORMATION

• If MBS blocks are used, a minimum scan time must always be entered in the configurator. Empirical values should be used.

• If the error message F-20/06 (error category/error number) appears on the CPU display, you must amend the minimum scan time appropriately. This error message indicates that the minimum scan time has been exceeded. The PSS must not be operated while this error message is present.

SB070 and SB071 automatically enter the minimum scan time in DW1022 of the administration data blocks. In this way it is automatically available to the MBS.

INFORMATION

Please note that the times are imprecise. The lack of precision on times is due to the cyclical processing of the user program. It is determined by the scan time of the respective user program. In general: The greater the ratio of time value to scan time, the greater accuracy you will have with the required times.

5-12

Modular Block System: Burner Management

Global parameters

Block 6 (DW1001 ... DW1023) of the administration data blocks contains global parameters. These are parameters that are valid for several blocks. For details of which global parameters a standard function block uses, please refer to the description of the individual standard function blocks.

The data words in block 6 must be initialised when the program is started (OB120) using SB070/SB071 (INIT_MBS). The abbreviations in brackets {... : ...} at the end of each data word correspond to the parameters in SB071. The times that are also specified within the brackets are empirical values, unless stated otherwise.

DW1001 Number of cycles in the contact synchronisation time between

DW1002 Number of cycles in the feedback loop’s reaction time to a

DW1003 Number of cycles in the contact switchover time between a N/

DW1004 Number of cycles in the contact switchover time between a N/

DW1005 Number of cycles in the machine clock time

DW1006 Number of cycles in the permitted ESPE reaction time

DW1007 Reserved DW1009 Reserved DW1010 Reserved DW1011 Reserved DW1012 Reserved DW1013 Reserved DW1014 Reserved

2 N/O contacts or 2 N/C contacts (e.g. E-STOP button, reset key, etc.) {CoSy : 50ms}

change in the PSS output connected to the main contactor {RFbL : 100ms}

O and N/C contact (pushbutton) {CS_B : 100 ms}

O and N/C contact (relay) {CS_R: 50 ms}

{MaCy : max. 30 s in accordance with EN 61496-1 section A.8.4, 06/98}

{ESPE : max. 150 ms in accordance with EN 61496-1 section

5.2.4, 06/98}

5-13Modular Block System: Burner Management

MBS Basics

DW1015 Counter for SSNR monitoring DW1016 Reserved DW1017 Reserved DW1018 Reserved DW1019 Reserved for administration DW1020 Reserved DW1021 Reserved for burner management DW1022 Min. scan time from DB002/DW0002 DW1023 Reserved

5-14

Modular Block System: Burner Management

Standard Function Blocks

SB149: Sequence control

Block header

Input parameters

•

SB149

STEP

X - RDY X - COND X - STEP B - W_BA

W - W_V

Z - W_T B - D_BA

W - D_V

Z - D_T

RDY

: Ready signal from the previous step

RDY

= 1: ready signal is present

COND

: Global input for step enabling conditions for next step

COND

= 1: all step enabling conditions fulfilled

NEXT - X

W_E - X

D_E - X

• STEP: Signals burner start-up for the duration of a cycle and deactivates the step

STEP

= 1: first cycle of burner start-up and deactivating the

step

STEP

= 0: no burner start-up detected This parameter must be assigned with the same operand used for the output parameter operator elements” and for the input parameter

STEP

from SB152 “Burner: Start and

STEP

SB157 “Ignition attempts” for the same burner.

•

W_BA

: Time base for step monitoring time (watchdog base)

Following values are valid: 0: 50 ms 1: 100 ms 2: 1 s 3: 10 s 4: 1 min

Modular Block System: Burner Management

6-1

Standard Function Blocks

•

W_V

: Time value (watchdog value) of step monitoring time as

multiplier for Permitted value range: - 32768 ... 32767 For W_V ≤ 0 to be valid: there is no step monitoring time, the output parameter W_E is permanently 0.

• W_T: Timer (watchdog timer) for step monitoring time

• D_BA: Time base for step time delay Following values are valid: 0: 50 ms 1: 100 ms 2: 1 s 3: 10 s 4: 1 min

•

D_V

: Time value of the time delay as multiplier for

Permitted vallue range: -32768 ... 32767 For

D_BA

the output parameter soon as a step is activated.

≤ 0 to be valid: there is no time delay,

W_BA

D_BA

D_E

changes immediately from 0 to 1 as

SB149

•

D_T

Output parameters

•

W_E

•

D_E

Function:

• Control of work cycles

• By adding together several SB149 blocks, a step sequence can be

• One PSS can control and monitor several work cycles (e.g. burner), in

: Timer for time delay

: Gives the status of the step

: Output parameter for step monitoring time

W_E

: Output parameter for the time delay

D_E

established

which each cycle is allocated a separate sequence

= 1: step is active

= 1: timer for the step monitoring time has elapsed.

= 1: timer for the time delay has elapsed.

6-2

Modular Block System: Burner Management

Error messages

• Each SB149 of this sequence waits for the ready signal from the previous step and for the step enabling conditions to be fulfilled, before it is active.

• Step monitoring time: a step provess can be monitored for a specific time

• Time delay: a function process can be limited to a certain time, or the process can be started after a specific time.

• Error messages in DB015

None

• Error messages on the CPU-display

Blocks required

E006: Parameter errors- the time base

W_BA

D_BA

does not lie within the permitted range 0 to 4. The incorrect value will be entered in DR0 (data byte right) of the administration data block DB015.

• DB002: Will be made available when the configurator is called up

• DB015: Administration data block DB015 must consist of its total length of 1024 data words and have Read/Write access (see section “Administration data blocks DB015, DB016 and DB017” in chapter 5).

• OB101: To call up SB149

• SB149: STEP

• SB255: To call up the operating system

Modular Block System: Burner Management

6-3

Standard Function Blocks

Programming guidelines

•

STEP

The operand for the input parameter assigned to the output parameter input parameter individual steps of the sequence to reset during burner start-up.

STEP

SB149

STEP

of SB157, if SB157 is used. This will enable the

of SB149 must also be

from SB152 and also to the

The operand for the parameter

STEP

has the value 1 for the duration of

a cycle when a positive edge of the ENBL of SB152 is detected.

If several burners are operated with one PSS, each burner must be assigned its own STEP operand. This enables the burners to be controlled and monitored independently.

Example:

SB157

IGNI_TRY

B - SSNR X - SyOK X - BIT0 X - BIT3 X - FLAs B - ITRY

M 70.00 .Burner 1 - X - STEP

W - T_V

Z- T

RDY - X

6-4

X - RDY X - COND

M 70.00 .Burner 1 - X - STEP

B - W_BA

W - W_V

Z - W_T B - D_BA

W - D_V

Z - D_T

SB149

STEP

NEXT - X

W_E - X

D_E - X

Modular Block System: Burner Management

SB152

BR_START

B - SSNR X - NEXT X - STRT X - STOP X - ERR X - GUAR X - AirP X - CHAI X - FLAs X - FTRY X - RUN B - D_C X - AuSt X - RSET

IGNI_TRY

B - SSNR X - SyOK X - BIT0 X - BIT3 X - FLAs B - ITRY

M 80.00 .Burner 2 - X - STEP

W - T_V

Z- T

ENBL - X

RDY - X

STEP - X - M 70.00 .Burner 1

SB157

RDY - X

M 80.00 .Burner 2 - X - STEP

Modular Block System: Burner Management

X - RDY X - COND

B - W_BA

W - W_V

Z - W_T B - D_BA

W - D_V

Z - D_T

SB149

STEP

NEXT - X

W_E - X

D_E - X

6-5

Standard Function Blocks

SB149

SB152

BR_START

•

RDY

and

The output parameter the input parameter

B - SSNR X - NEXT X - STRT X - STOP X - ERR X - GUAR X - AirP X - CHAI X - FLAs X - FTRY X - RUN B - D_C X - AuSt X - RSET

RDY

from the current step must be supplied to

of the following step. This ensures that when

ENBL - X

RDY - X

STEP - X - M 80.00 .Burner2

the next step is activated, the previous step is deactivated, thereby ensuring only one step is active at any given.

6-6

• Activating a step

- To activate a step: the ready signal from the previous step must be present ( (

COND

RDY

= 1).

= 1) and all step enabling conditions must be fulfilled

- As soon as a step is active, the following occurs:

output parameter

the input parameter

parameter if

W_V

D_V

otherwise

> 0, step monitoring time

> 0, time delay

D_E

from the step is set to 1

RDY

of the current step and also the output

from the previous step are reset to 0

W_V

is started

D_V

is started,

is immediately set to 1

Modular Block System: Burner Management

• Deactivating a step

During burner start-up, the input parameter

STEP

is set for one cycle. The burner’s corresponding blocks evaluate this signal and reset the sequence.

• Starting the initial step in a sequence:

RDY

The input parameter

may not be assigned a communication flag (M100.00 - M104.31) nor an input. When using SB152 “Burner: Start and operator elements”, the output parameter

STEP

is set for the duration of a cycle, and the enable

is set. This parameter can be used to start the initial step.

Version 1: no conditions for the start of the initial step The operand for the parameter parameter to the input parameter

STEP

of SB149 and the same operand can also be assigned

RDY

The input for the step enabling conditions

STEP

can be assigned to the input

COND

can be permanently

assigned with RLO1 (M110.01). Example:

SB149

STEP

ENBL

M 70.08 .Step_1 - X - RDY M 110.01 .RLO1 - X - COND M 70.08 .Step_1 - X - STEP

Version 2: conditions for the start of the initial step are present The operand for the parameter input parameter

Example:

L M 70.08 .Step_1 S M 70.10 .RDY Step_1

Modular Block System: Burner Management

RDY

B - W_BA

W - W_V

Z - W_T B - D_BA

W - D_V

Z - D_T

STEP

NEXT - X

W_E - X

D_E - X

may not be assigned directly to the

6-7

Standard Function Blocks

SB149

STEP

M 70.10 .RDY Step_1 - X - RDY M 70.12 .COND Step_1 - X - COND M 70.08 .Step_1 - X - STEP

B - W_BA

W - W_V

Z - W_T

B - D_BA

W - D_V

Z - D_T

• Step monitoring time

W_E

If the step monitoring time has elapsed and the output parameter

NEXT - X

W_E - X

D_E - X

W_E

changes from 0 to 1, this alarm must be evaluated. The responsibility for this lies solely with the user.

An application example for step monitoring time can be found in Chapter 8.

• Time delay

D_E

There are two options for time delay:

- Time delay can be used to carry out a function for the duration of the

time delay, or

- To start a function after this time (

D_E

= 1).

An application example for time delay can be found in Chapter 8.

• Active steps in a sequence

To avoid a dangerous situation occurring in a process, the user must ensure that only one step is active in a sequence at any given time.

6-8

Modular Block System: Burner Management

Timing diagrams

Setting / resetting the step without time delay and monitoring time

The step is activated by a “1”-Signal at the waits for the step enabling condition at the If the conditions are present, the and at the same time the

When

= 1, the following step can be activated.

RDY

input. The block

COND

input.

output is set immediately,

RDY

input is reset.

The step enabling condition must be present at the input once only, so that the

output is set.

If the step enabling condition is met during the next step, then the previous step is reset.

COND

output from the

Modular Block System: Burner Management

6-9

Standard Function Blocks

With spurious signals:

SB149

If a step enabling condition is met at the cause the outputs to set too early.

Only if the step block was activated with outputs react to the step enabling condition.

Repeated “1”-Signals at the not cause malfunctions further on in the process.

COND

RDY

COND

input, it will not

= 1 do the

input do

6-10

The

RDY

output may not be set a second time after the step

block has been run through once.

Therefore, in the FS program it must be monitored that only one individual have a “0”-Signal. Should it be detected that more than one

output is active and all other

output has a “1”-Signal, an immediate fault lockout

Modular Block System: Burner Management

outputs

Setting/resetting the step with time delay but without monitoring time

Instead of the next step being activated immediately with the

output, it can be delayed

using the

D_E

output.

The time delay After the time has elapsed the

D_V

is started if the step enabling condition is met.

Spurious signals

Time delay

D_E

output is set.

Multiple-recurring step enabling conditions have no negative influence on the function. The time delay 0-1 edge at the

D_V

is started once only with the initial

COND

input.

Modular Block System: Burner Management

In each case: a “1”-Signal at the STEP-input resets the outputs NEXT and D_E.

6-11

Standard Function Blocks

Setting/resetting the step without time delay but with monitoring time

The step enabling condition needs to be present once only at the

output.

COND

SB149

input to set the

The monitoring time If the

-output is not reset before the monitoring time cycle, the set. This means that the step enabling condition from the following step was not met within the permitted time.

If the step enabling condition is met later during the next step, the and

D_E

output are reset simultaneously.

The

W_E

output can be processed further according to user requirements.

W_V

is started if all the step enabling conditions are met.

W_E

NEXT, W_E

Spurious signals:

Multiple-recurring step enabling conditions have no negative influence on the function. The monitoring time initial 0-1 edge at the

W_V

is started once only with the

COND

input.

output is

6-12

Monitoring time

In each case: a “1”-Signal at the STEP input resets the outputs NEXT, W_E and D_E.

Modular Block System: Burner Management

Setting/resetting the step with time delay and monitoring time

Spurious signals:

The monitoring time

D_E

are started if the step enabling

condition is met. Further processing of

is guided according to the technical requirements of the cycles.

Multiple-recurring, fulfilled step enabling conditions have no negative influence on the function. The monitoring time started once only with the initial 0-1 edge at the input.

W_V

and the time delay

W_E

and

D_E

and the time delay

outputs

D_V

are

COND

Modular Block System: Burner Management

In each case: a “1”-Signal at the STEP input resets the outputs NEXT, W_E and D_E.

6-13

Standard Function Blocks

SB150: Flame monitoring

Block header

Input parameters

•

SSNR

MONI

SB150

FLAME_M

B - SSNR X - MONI X - F_S1 X - F_S2 X - RUN

ENBL - X

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte constants KB 001 ... KB 200 (further information about the SSNR can be found in the sections “Administration data blocks DB015, DB016 and SB017” and “Input parameter

SSNR

” in chapter 5).

Value of DW0000/DB015 = 0: no error present

MONI

When When The output parameter

= 1: carries out flame monitoring:

RUN

= 1: monitoring for “ flame established”

RUN

= 0: monitoring for “flame not established”

FLAI

from SB158 “Ignition” must be supplied to this parameter when using SB150 for pilot flame monitoring, and the output parameter

FLAM

from SB159 “Run” must be supplied to this parameter when using SB150 for main flame monitoring.

6-14

•

F_S1

•

F_S2

•

RUN

: Flame signal (N/O contact)

F_S1

= 1: flame established

: Flame signal (N/C contact)

F_S2

= 1: flame not established

: The output parameter

RUN

from SB158 “Ignition” must be supplied to this parameter when using SB150 for pilot flame monitoring, so that information about the status of the pilot flame can be obtained. The output parameter

RUN

SB159 “Run” must be supplied to the input parameter from SB150 when using SB150 for main flame monitoring.

RUN

= 1: monitoring for “flame established”

Modular Block System: Burner Management

from

RUN

Output parameters

Function:

Error messages

ENBL

Pilot and main flame monitoring from burner start-up to operating position, through to burner switch-off.

Any fault that is detected will be stored statically in the corresponding error data word (SSNR) of DB015 (1st data block).

• Error messages in DB 015

: Enable flag bit

ENBL

(refer also to the Programming guidelines)

- Bit00: Burner in operating position but no flame established

- Bit01: Burner not in the operating position, but the flame is established

= 1: this function is fault-free

Remedy: Exit operating position ( and bring SB150 to the start position (

F_S2

Remedy: Bring SB150 to the start position ( 0,

= 1,

F_S2

RUN

= 1,

= 0).

RUN

= 0).

RUN

= 0),

MONI

= 1,

MONI

F_S1

= 1,

= 0,

F_S1

- Bit02: Burner in the operating position and both flame monitor

contacts ( Remedy: Exit operating position ( monitors' contacts and bring SB150 to the start position (

MONI

- Bit03: Burner in operating position and both flame monitor contacts

(

F_S1

Remedy: Exit operating position ( monitor contacts and bring SB150 to the start position ( = 1,

- Bit04: Burner not in the operating position and both flame monitor

contacts ( Remedy: Check flame monitor contacts and bring SB150 to the start position(

- Bit05: Burner not in the operating position and both flame monitor

contacts (

Remedy: Check flame monitor contacts and bring SB150 to

the start position (

= 1,

and

F_S1

F_S2

= 0,

F_S1

MONI

F_S1

and

F_S2

) have the value 1.

= 0,

F_S2

= 1,

) have the value 0

F_S2

and

MONI

= 1,

RUN

F_S2

) have the value 1

= 1,

F_S1

F_S2

) have the value 0

= 1,

F_S1

RUN

= 0).

= 0,

= 0), check flame

= 0).

= 0), check flame

F_S2

= 1,

RUN

= 0,

F_S2

= 1,

= 0).

RUN

MONI

= 0).

Modular Block System: Burner Management

6-15

Standard Function Blocks

- Bit07: Flame established but does not correspond to the expected status Remedy: Exit operating position ( to the start position (

- Bit08: Flame monitoring switched off Remedy: Switch on flame monitoring ( SB150 to the start position (

RUN

= 0).

• Error messagess on the CPU-display

E001: Parameter errors

The

SSNR

“Administration data blocks DB015, DB016 and DB017” in chapter 5).

does not lie within the limits 1 ... 200. The incorrect

is stated in DB015/DW0000 (see the section

MONI

= 1,

F_S1

MONI

RUN

= 0) and bring the SB150

= 0,

F_S2

= 1,

MONI

= 1,

= 1) and bring

F_S1

= 0,

F_S2

SB150

RUN

= 0).

= 1,

Blocks required

• DB002: Will be made available when the configurator is called up.

• DB015: Administration data block DB015 must consist of its total length of 1024 words and have Read/Write status (refer also to the section “Administration data blocks DB015, DB016 and DB017" in chapter 5).

• OB101: To call up SB(s)150 directly in OB101 or, for example, together in an FB.

• SB150: FLAME_M

• SB152: BR_START for evaluating the flame monitor global signal

FLAs.

• SB157: IGNI_TRY for evaluating the flame monitor global signal when carring out several ignition attempts.

FLAs

6-16

Modular Block System: Burner Management

• SB158: IGNITION for deciding about pilot flame monitoring.

• SB159: RUN for decision about monitoring the main flame.

• SB255: To call up the operating system.

Programming guidelines

•

ENBL

The enables for all SB150 blocks must be AND-connected in the application program after being called up. The result of this bit operation must be supplied to the input parameter and operator elements”.

The enables of the active SB150 blocks for pilot flame monitoring must be supplied and additionally AND-connected to the input parameter

FLAs

of SB157 “Ignition attempts”, if SB157 is used.

A programming example can be found in Chapter 8 under “Managing enables”.

• Main flame monitoring after an error

FLAs

of SB152 “Burner: Start

If the main flame is in the operating position and the plant is shutdown because an error occurs (e.g. monitor sequence broken), the flame monitor receives the command to check the flame for “flame established” in the next cycle. On some plants, the flame does not extinguish immediately after switch-off i.e. within a cycle. In these cases, a fault will result. To avoid this, a time negative edge at the plant enable ( this time, the flame monitor will not be evaluated (

D_V

can be started via step (SB149) when a

ENBL

of SB152) is detected. During

MONI

= 0). After this

time cycle SB159 “Run” assumes control of flame monitoring. Programming example: LN M74.00 .ENBL SB 152

U M73.01 .Auxiliary flag, negative edge ENBL = M73.02 .Pulse flag R M73.01 .Auxiliary flag, negative edge ENBL

L M74.00 .ENBL SB 152 S M73.01 .Auxiliary flag, negative edge ENBL

Modular Block System: Burner Management

6-17

Standard Function Blocks

SB159

RUN

SB150

SSNR NEXT SyOK

SB152

BR_START

SSNR NEXT STRT STOP ERR GUAR AirP CHAI FLAs FTRY RUN D_C AuSt RSET

ENBL

RDY

VAV3

REGL

RUN

FLAM

ENBL

RDY

STEP

Pulse

Time value for time delay

RDY COND STEP W_BA W_V W_T D_BA D_V D_T

SB149

STEP

W_E

D_E

S R Q

SB150

FLAME_M

SSNR MONI F_S1 F_S2 RUN

ENBL

Fig. 6-1: Main flame monitoring after a fault

6-18

Modular Block System: Burner Management

Timing diagrams

Signal cycle with an uninterrupted burner start-up or uninterrupted burner stop sequence

Monitoring for “Flame not established”

A “1”-Signal at the

F_S2

are monitored for “0” and “1” respectively, i.e. for “flame not established”. During the ignition process, the signals at SB 150 must change from detecting for “flame not established” to detecting for “flame established”. During this switching time the are not evaluated: they can have any status.

MONI

input and a “0”-Signal at the

Monitoring for “flame established”

A “1”-Signal at the Signal at the monitored for “1” and ”flame not established”.

RUN

input,

F_S1

and

F_S1

and

F_S2

must change, i.e.

F_S1/F_S2

MONI

RUN

-input means

If the

MONI

input is reset, monitoring is deactivated and the flame can be extinguished without the block generating an error message (

ENBL

-inputs

input and a “1”-

F_S1

F_S2

for “0”, i.e. for

= 0).

Modular Block System: Burner Management

6-19

Standard Function Blocks

Flame monitor error

Flame monitor fault when monitoring for “flame not established”.

SB150

After the Signals at Monitoring for “flame established” must be first run through without error, before switching to monitoring for “flame established” can be carried out.

ENBL

-output is reset, an enable is not set even with valid “1”-

F_S1

and

RUN.

Spurious signals when monitoring for “flame not established”

Spurious signals / signal combinations at

F_S1

and

F_S2

do have no effect on the block’s function.

If there is a “1”-Signal at the MONI input,

F_S2

monitoring is active and reacts immediately when the reset.

ENBL

F_S1/

output is

Only the permitted signal combination at

F_S2

can reactivate the

enable.

F_S1/

6-20

Invalid signals deactivate the enable. The enable signals processed in other program sections (flame monitor sequence, SB 152) will, via this program section, trigger the burner to shutdown. The enable signal will be issued again only if the inputs are

F_S1

= 0. With other signal combinations, the enable remains cancelled.

Modular Block System: Burner Management

F_S2

= 1 and

Spurious signals before and during monitoring for “flame established”

No spurious enable via interference signals possible.

Spurious signals during monitoring for “flame established”

Flame established, monitoring active.

Only the fault-free signals

F_S2

= 1,

F_S1

= 0 and the

MONI

input set the

output.

Shutdown due to flame failure. No spurious enable can be generated due to interference signals.

ENBL

Modular Block System: Burner Management

6-21

Standard Function Blocks

SB151: Transient suppression

Block header

Input parameters

•

SSNR

SB151

BridgedS

B - SSNR X- S1 X - BASE

W - T_V

Z- T X - AuSt X - RSET

ENBL - X

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte-constants KB001 ... KB200 (further infotmation about the

SSNR

can be found in the sections “Administration data blocks DB015, DB016 and DB017” and “Input parameter

SSNR

” in chapter 5).

Value of DW0000/DB015 = 0: no error present

•S1: N/C contact to be monitored (check with test pulse)

•

BASE

•

T_V

: Setting the time base

BASE T_V BASE

: Multiplier for

= M110.00 (RLO = 0): time base of 50 ms, multiplied by

gives a possible range of 50 ms to 27.3 min

= M110.01 (RLO = 1): time base of 100 ms, multiplied

T_V

gives a possible time range of 100 ms to 54,6 min

BASE

, to determine the length of time the enable signal should be delayed Permitted value range: 1 ... 32767

•T: Timer, which measures the set time

•

AuSt

: Automatic start (reset)

AuSt

= M110.01 (RLO =1): automatic start (without reset)

AuSt

= M110.00 (RLO =0): no automatic start

•

RSET

: Reset button (N/O)

6-22

Modular Block System: Burner Management

Output parameters

Function

Error messages

ENBL

: Enable flag bit

ENBL

= 1: the signal at the N/C contact S1 is fault-free

(refer also to Programming guidelines)

Spurious signals at the monitored input (e.g. a pressure monitor) cancels the enable after a set time.

If the N/C contact functions without fault, SB151 sets the enable

ENBL

. If interference occurs, the enable is cancelled after a set time period. Short, fleeting interferences, for example, pressure swings after the valve has opened will have no effect on the enable.

Any fault that is detected will be stored statically in the corresponding error data word (SSNR) of DB015 (1st data block).

• Error messages in DB015

- Bit 09: Suppression time has elapsed, the signal is spurious Remedy: check contact S1 and if button

RSET

AuSt

= 0, press the reset

- Bit 14: Reset button

RSET

pressed continuously or pressed too soon.

Remedy: Release reset button and press again.

- Bit 15: Signal is fault-free, but the error which occurred was not reset (

RSET

Remedy: press the reset button

missing)

RSET

• Error Messages on the CPU-display

- E001: Parameter errors The

SSNR

incorrect

does not lie within the limits of 1 ... 200. The

SSNR

is stated in DB015/DW0000 (refer also to the section “Administration data blocks DB015, DB016 and DB017” in chapter 5).

- E007: Invalid time value for

T_V

Modular Block System: Burner Management

6-23

Standard Function Blocks

Blocks required

• DB002: Will be made available when the configurator is called up.

• DB015: Administration data block DB015 must consist of its total length of 1024 data words and have Read/Write status (refer also to the section “Administration data blocks DB015, DB016 and DB017” in chapter 5).

• OB101: To call up SB 151

• SB151: BridgedS

• SB152: BR_START for the error reaction

• SB255: To call up the operating system

Programming guidelines

ENBL

SB151

The enable before the global input input

CHAI

to use regarding error reactions.

ERR

: If an error occurs, a controlled shutdown is carried out when

CHAI

: If an error occurs, a safety shutdown is carried out.

A programming example can be found in Chapter 8 under “Managing enables”.

ENBL

of SB152 “Burner: Start and operator elements”. The decision

ERR

AuSt

from SB151 must be supplied to the AND-operation

ERR

or to the AND-operation before the global

CHAI

depends on the user and the respective standards

= 1 with restart.

6-24

Modular Block System: Burner Management

Timing diagrams

Setting the

ENBL

output automatically when the signal is recovered

A failure of S1 for a time less than the block set time means the

ENBL

output does not switch to "0". Only if S1 drops out for a longer period of time will the reset.

The

ENBL

output is set immediately without the

need for intervention.

ENBL

output

Setting the

ENBL

output after a reset when the signal is recovered

A failure of S1 for a length of time less than the block set time means the Only if S1 fails for a longer period of time will the reset.

ENBL

output does not switch to "0".

With signal recovery the is set only after a reset signal.

ENBL

output

ENBL

output

Modular Block System: Burner Management

6-25

Standard Function Blocks

SB151

Spurious signal sequence at

BASE

AuSt

input

According to the alloted time base, the set time is decreased ( counter value at the time base, giving the required time.

BASE

= 0) or increased (

T_V

BASE

= 1). The

-input is multiplied with the

input

6-26

Changing from “manual reset” ( reset” ( system start after a signal change at the re-assigning the parameter, down-loading a re-linked program and restarting the system.

AuSt

= 1) can only be achieved by a new

AuSt

= 0) to “automatic

AuSt

input, i.e.

Modular Block System: Burner Management

Notes

Modular Block System: Burner Management

6-27

Standard Function Blocks

SB152: Burner: start and operator elements

SB152

Block header

Input parameters

•

SSNR

SB152

BR_START

B - SSNR X - NEXT X - STRT X - STOP X - ERR X - GUAR X - AirP X - CHAI X - FLAs X - FTRY X - RUN B - D_C X - AuSt X - RSET

ENBL - X

RDY - X

STEP - X

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte-constants KB001 ... KB200 (further information about the

SSNR

can be found in the sections “Administration data blocks DB015, DB016 and DB017” and “Input parameter

SSNR

” in chapter 5).

Value of DW0000/DB015 = 0: no error detected.

6-28

•

STRT

•

STOP

•

ERR

= 1: Time for the step “Build-up minimum air pressure” has elapsed, air pressure monitoring is activated (air pressure monitor

AirP

) .

: Start input to switch on the burner

: Stop input to switch off the burner

: Global input of the error sequence

ERR

= 0: controlled shutdown when

safety shutdown when

ERR

= 1: the error sequence is inactive, which means no error

AuSt

= 0

= 1,

is present.

Modular Block System: Burner Management

•

GUAR

•

AirP

•

CHAI

•

FLAs

•

FTRY

•

RUN

: Global input of the monitor sequence

GUAR

shutdown when

GUAR

: Air pressure monitor

AirP AirP

: Global input of the safety sequence

CHAI CHAI

: Global input of the flame signals

FLAs FLAs

FTRY

flame error in operation (only possible if AuSt = 1)

FTRY

fault lock-out occurs.

: The output parameter

supplied to this parameter, so information about the operating status of the main flame can be obtained."

RUN

= 0: controlled shutdown when

AuSt

= 0

= 1: monitor sequence is inactive: no error is present

= 1: minimum air pressure is present = 0: air pressure is below the minimum

= 0: safety shutdown

= 1: the safety equence is inactive: no error is present

= 0: fault lock-out = 1: flame signlas are fault-free

= M110.01 (RLO =1): single attemptat a restart after a

= M110.00 (RLO =0): no option for automatic restart, a

RUN

from SB159 “Run” must be

= 1: operating position.

AuSt

= 1, safety

• D_C: Contains the number of cycles for the delayed enable of SB152 after the PSS has started-up. The delayed enable is required so that the flame monitors can reach a defined position without a fault lock-out occurring. Example: If the minimum scan time is 50 ms and the delayed

•

AuSt

•

RSET

enable 5 s, the parameter

: Automatic start (reset) when the PSS starts up

AuSt

= M110.01 (RLO =1): automatic start (without reset) is

required after a controlled shutdown

AuSt

= M110.00 (RLO =0): no automatic start required after a

controlled shutdown

: Reset button (N/O)

D_C

must be assigned KB100

Modular Block System: Burner Management

6-29

Standard Function Blocks

Output parameters

•

Function

ENBL

•

RDY

• STEP: signals burner stat-up for the duration of a cycle.

: Enable flag bit

ENBL

(see also Programming guidelines)

: Ready signal

RDY

correctly. The next step of the sequence is enabled.

STEP STEP

This parameter must be assigned with the operand also assigned to the input parameter “Ignition attempts” for the same burner.

= 1: this function is fault-free

= 1: the step “Build up minimum air pressure” ended

= 1: first cycle of burner start-up = 0: no burner start-up detected

STEP

SB152

of SB149 and SB157

• Monitoring the flames (pilot and main flames) from burner start-up to

operating position until burner switch-off (controlled or safety shutdown or fault lock-out)

• Restart after a controlled shutdown

• Allows a restart once only after a controlled shutdown, which has been

triggered because of a flame failure during operation.

• Monitoring the air pressure monitor, after the time has elapsed for

building-up minimum air pressure.

• Evaluating the reset, start and stop button

• Monitoring global signals from the error, monitor and safety sequences

• Carrying out a delayed start-up after the system has started so that the

safety, error, monitor and flame monitoring sequences can supply a positive acknowledgement signal for the global signal inputs.

6-30

Modular Block System: Burner Management

Error messages

Any fault that is detected will be stored statically in the corresponding error data word (SSNR) of DB015 (1st data block).

• Error messages in DB015

- Bit 00: Flame signal sequence interrupted: fault lock-out occurs Remedy: First press the reset button ( button (

STRT

)

RSET

) and then the start

- Bit 01: Safety sequence is interrupted: controlled shutdown occurs Remedy: First press the reset button ( button (

STRT

RSET

) a then the start

- Bit 02: Error sequence is interrupted: controlled shutdown occurs Remedy: If inactiveagain, otherwise press the reset button ( then press the start button (

AuSt

= 1, wait until the error sequence is

STRT

RSET)

and

- Bit 03: Monitor sequence is interrupted: controlled shutdown occurs

Remedy: If again, otherwise press the reset button ( start button (

AuSt

= 1, wait until the monitor sequence is inactive

STRT

RSET

) and then the

- Bit 04: Minimum air pressure at start-up was not achieved after step “Build up minimum air pressure”: safety shutdown occurs Remedy: First press the reset button ( button (

STRT

RSET

) and then the start

- Bit 05: Below minimum air pressure during operation: controlled shutdown occurs Remedy: If minimum air pressure, otherwise press the reset button ( and then the start button (

AuSt

= 1, wait for the air pressure monitor to signal

STRT

RSET

- Bit 06: Stop triggered by pressing the stop button Remedy: Press the start button (

STRT

- Bit 07: Flame signal sequence is interrupted: controlled shutdown occurs Remedy: If inactive again, otherwise press the reset button (

AuSt

= 1, wait for the flame signal sequence to be

RSET

) and

)

Modular Block System: Burner Management

6-31

Standard Function Blocks

SB152

then press the start button (

- Bit 08: Reset via Remedy: Press the reset button (

- Bit 09: Start button pressed ( value 1 Remedy: Check the stop button (

- Bit 10: Stop button pressed ( Remedy: Check start button

- Bit 11: Pressign start ( Remedy: Press the start button (

- Bit 12: Time delay for the plant enable after the PSS has started is running Remedy: Let the time delay run and following that, press the start button (

- Bit 13: An error is present. Evaluation of the reset or start button occurs only if the burner is no longer operating.

Remedy: Input parameter

reset this parameter if shutdown occurs.

RSET

STRT

is missing

STRT

STOP

) button is missing

STRT

), but

STRT

RUN

RSET

STOP

STRT

must be 0, i.e. SB159 must

)

has a constant

)

has a constant value 1

)

Blocks required

• Error messages on the CPU-display

E001: Parameter errors

The

SSNR

“Administration data blocks DB015, DB016 and DB017” in chapter 5).

• DB002: Will be made available when the configurator is called up

• DB015: Administration data block DB015 must consist of its total length of 1024 words and have Read/Write status (see also the section “Administration data blocks DB015, DB016 and DB017” in chapter 5).

• OB101: To call up SB152.

• SB152: BR_START

• SB255: To call up the operating system

does not lie within the limits 1 ... 200. The incorrect

is stated in the D015/DW0000 (see the section

6-32

Modular Block System: Burner Management

Programming guidelines

• Use the global inputs for the error sequence

sequence

GUAR

and the safety sequence

ERR,

CHAI

the monitor

An automatic restart due to an interrupted error sequence or monitor sequence is only possible, if the error sequence or monitor sequence is reset and

AuSt

= 1.

If the safety sequence is interrupted, the error must be removed and a manual reset carried out via the reset ( (

STRT

)! The block enable will only be issued if the safety sequence is

RSET

) and the start button

reset and no longer interrupted.

NOTICE The error reaction is the sole responsibility of the user. When selecting elements for error, monitor and safety sequences, all the safety-related aspects must be taken into account!

A programming example can be found in Chapter 8 under “Managing enables”.

• Linking the output parameter

ENBL

To ensure the valve seal if a shutdown occurs, the operand assigned to the

ENBL

must be assigned to the input parameters

SyOK

of SB156 “Tightness Control” (if available), of SB158 “Ignition” and SB159 “Run”. To control the ignition attempts, the operand assigned used for the must also be assigned to the input parameter

SyOK

of SB157 “Ignition

Attempts”

ENBL

• Linking the output parameter

The operand for the output parameter assigned to the input parameter parameter STEP of SB157, if SB157 is used. This will enable the individual steps of the sequence to reset during burner start-up.

The operand for the parameter a cycle when a positive edge of the ENBL of SB152 is detected.

If several burners are operated with one PSS, each burner must be assigned its own STEP operand. This enables the burners to be controlled and monitored separately (see example under the description of SB149).

Modular Block System: Burner Management

STEP

from SB152 must also be

of SB149 and also to the input

has the value 1 for the duration of

6-33

Standard Function Blocks

Timing diagrams

Burner start-up without automatic start after a controlled shutdown

The

ENBL

output is set with a start pulse,

provided all criteria are fulfilled (

GUAR, CHAI, FLAs

With each burner start-up, a pulse at the STEP output is created, with which all SB149 blocks and SB 157 are reset.

ERR

With a pulse at air pressure monitoring is activated

SB152

NEXT,

Failure of air pressure during burner operation (

ENBL

is reset.

Only after a reset signal can the be set again via a start pulse. No automatic restart is enabled.

RUN

=1 ):

If the monitor sequence is energised (

GUAR

= 0), the behaviour is identical

to that of air pressure monitoring.

ENBL

-output

Failure of safety sequence, flame monitor sequence and general faults

Failure of one of the followign criteria

• Safety sequence

• Flame monitor sequence

• Error sequence

6-34

CHAI

ERR

= 0,

= 0

FLAs

= 0,

Modular Block System: Burner Management

causes the output

ENBL

to be set to “0” and will only be set back to “1”, if:

• The failed criteria is once again fulfilled, i.e. at “1”.

• A reset followed, this means a pulse was issued to the

• And a start pulse was issued to the

STRT

input.

RSET

input

Please note: The short signals at the inputs are spurious signals. They are to be expected and will not trigger a fault.

Failure of monitor sequence

Modular Block System: Burner Management

6-35

Standard Function Blocks

Monitoring of air pressure

SB152 is designed for the safe monitoring of air pressure build-up, which should be carried out during burner start-up and continual air pressure monitoring while the burner is operating. If there is insufficient air SB152 resets the enable i.e.

ENBL

SB152

output.

After a start pulse, a delayed air pressure signal must appear at the

AirP

input. Until the air pressure is built up, the waiting time is determined via the ventilators and flaps. Continuous air pressure monitoring is activated via a pulse at the immediately if the air pressure is insufficient (

input. Afterwards, SB152 resets the

AirP

= 0).

ENBL

output

Please note: The short signals at the inputs are spurious signals. They are to be expected and will not trigger a fault.

When activating air pressure monitoring with NEXT = 1 and a “1”-Signal is not present at the AirP input, the ENBL output is reset.

6-36

The

ENBL

output is not set. It can only be started again after a reset.

Air pressure monitoring will only be activated after a pulse at the input. Before this, the signal at the input

AirP

can drop out, without burner

start-up needing to be interrupted.

Modular Block System: Burner Management

Restart after flame failure or flame monitoring fault

When

AuSt

= 1 and

FTRY

= 1 SB152 can begin an automatic restart once only after flame failure or flame monitor interference. Burner start-up will only be initiated if the safety sequence and the monitor sequence have not responded, no interference is present and the flame and the flame monitoring block does not signal a fault.

The

ENBL

output is set by a start pulse, provided all criteria are met (

GUAR, CHAI, FLAs

ERR

)

After air pressure has been built-up, monitoring is activated by a pulse at the

input. The activation. The

RDY

output is used as the step

enabling condition for the sequence.

RDY

output signals this

When

RUN

= 1, “Burner in operation” is signalled.

Modular Block System: Burner Management

Flame failure of flame monitor interference. The

ENBL

is reset After the interference is removed (

ENBL

FLAs

= 1), the

output is set again.

By a new, second flame failure or flame monitor fault, the

ENBL

output is not set again. Only after a reset and a start pulse is the

ENBL

set again.

6-37

Standard Function Blocks

Automatic restart after air deficiency

SB152

Spurious signals

When immediately if the input conditions are fulfilled after air pressure failure i.e. If correct air pressure is present again, monitoring can be activated with and then the next step can be carried out. With each burner start-up, a pulse is created at the reset.

AirP

AuSt

= 0

= 1 and

STEP

FTRY

= 1, SB152 sets its ENBL and STEP output

output with which all SB149 blocks and SB157 are

6-38

No irregularities with a safety sequence failure.

ENBL

= 1 only after a reset, a de-energised

monitor sequence and start pulse. geschlosse-

Modular Block System: Burner Management

No fault due to spurious signals at With a

ENBL

FTRY

and

AuSt

FLAs

drop out, the

is reset correctly.

Correct setting of the

RSET

and a follow-on

Correct reset of the

ENBL

-output.

ENBL

output after

STRT

signal.

Modular Block System: Burner Management

FTRY

= 0 there is no automatic restart

after a flame failure.

START

pulse.

is only after a reset and a start

6-39

Standard Function Blocks

SB153: Control and position monitoring of flaps

Block header

Input parameters

•

SSNR

SB153

FLAP

B - SSNR X- C! X- O! X - DirO X - DirC

W - T_V

Z- T

X - RSET

ENBL - X

OPEN - X

CLOS - X

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte-constants KB001 ... KB200 (further information about the

SSNR

can be found in the sections “Administration data blocks DB015, DB016 and DB017” and “Input parameter

SSNR

” in chapter 5).

Value of DW0000/DB015 = 0: no error is present

•C!: Limit switch (N/O contact “flap closed”)

= 1: the flap is closed and operated via the limit switch

= 0: limit switch not operated

•O!: Limit switch (N/O contact “flap open”)

= 1: the flap is opened and operated via the limit switch

= 0: limit switch not operated

•

DirO

: Drive direction

positive edge from

DirO

: flap should be opened (output

= 1, until the limit switch O! is achieved)

•

DirC

: Drive direction

positive edge from

DirC

: flap should be closed (output

= 1)

•

T_V

: Switch time for the position change,

Permitted value range: 1 ... 32767, multiplying the value with the fixed time base of 50 ms gives a time range from 50 ms ... 27.3 min.

OPEN

CLOS

6-40

Modular Block System: Burner Management

•T: Timer which measures the time

•

RSET

Output parameters

•

ENBL

•

OPEN:OPEN

•

CLOS

Function

• Monitoring the flap status (open/closed), the direction of the change in position and the reaction time due to a change in position

• Opening and closing a flap after a received request

• The contact-bounce time due to a change in position is one cycle.

: reset button (N/O)

: Enable flag bit

ENBL

= 1: this function is fault-free

= 1: open flap

OPEN CLOS

CLOS

= 0: no drive direction “open”

= 1: close flap = 0: no drive direction “close”

T_V

Error messages

Any fault that is detected will be stored statically in the corresponding error data word (SSNR) of DB015 (1st data block).

• Error messages in DB015

- Bit 00: Status of contact C! does not correspond to the previous drive

direction. Remedy: Check the limit switch and the switch time

T_V

and reset the error. If neither limit switch is operated, the drive direction must be re-selected.

- Bit 01: Status of contact O! does not correspond with the previous drive direction. Remedy: Check the limit switch and switch time

T_V

and reset the error. If neither limit switch is operated, the drive direction must be re-selected.

Modular Block System: Burner Management

6-41

Standard Function Blocks

- Bit 02: Switch time for the change in position is exceeded. Remedy: check the switch time the error.

SB153

T_V

for the contact(s) and reset

- Bit 03:

- Bit 04: Feasibility check: neither limit switch operated.

- Bit 05: Feasibility check: both limit switches operated.

- Bit 06: Reset button not operated

- Bit 07: A new drive direction selected

• Error messages on the CPU-display

- E001: Parameter errors

DirO

and

DirC

driven simultaneously Remedy: Only drive in one direction and reset the error. If neither limit switch is operated, the drive direction must be reselected.

Remedy: Check contacts and reset the error. Subsequently if neither limit switch is operated, the drive direction must be reselected.

Remedy: check contacts and reset error.

Remedy: Press reset button

Remedy: Create a positve edge at

The

SSNR

“Administration data blocks DB015, DB016 and DB017 in chapter 5).

does not lie withn the limits 1 ... 200. The incorrect

is stated in DB015/DW0000 (refer also to the section

DirC

DirO

Blocks required

6-42

- E007: Invalid time value for

• DB002: Will be made available when the configurator is called up

• DB015: Administration data block DB015 must consist of its totla length of 1024 data words and have Read/Write status (see the section “Administration data blocks DB015, DB016 and DB017” in chapter 5).

• OB101: To call up SB153

T_V

Modular Block System: Burner Management

• SB152: BR_START for error reaction

• SB153: FLAP

• SB255: To call up the operating system

Programming guidelines

•

ENBL

The

ENBL

global input SB152 “Burner: Start and operator elements”. The decision to use or

CHAI

error reaction.

ERR

: If an error is present, a controlled shutdown occurs when

CHAI

: If an error is present a safety shutdown occurs

A programming example can be found in Chapter 8 under “Managing enables.

of SB153 must be supplied to the AND-operation before the

ERR

or to the AND-operation before the global input

CHAI

ERR

depends on the user and the respective standards regarding

AuSt

= 1 with restart

• Driving the air dampers

During burner start-up the air dampers must be driven by SB153. After a control enable, position monitoring is no longer required and the air damper motors can be drive directly without SB153. A programming example can be found in the section “driving the Air Dampers” in Chapter 8.

•

DirO

and

DirC

Driving one flap: the drive must be driven in one direction only i.e. and

DirC

must not be driven simultaneously.

DirO

Modular Block System: Burner Management

6-43

Standard Function Blocks

Timing diagrams

No automatic start after controlled shutdown

OPEN

-output is set when

ENBL

must be "1".

= 1: the flap leaves the CLOSED position. After the control time, the flap reaches the OPEN position. The acknowledgment

DirO

The

input can also be reset by the user.

DirO

= 1 resets the

= 1

OPEN

SB153

output.

When

After the control time the flap reaches the CLOSED position. The acknowledgement The

Monitoring of end positions

The present. Despite a reset and The

DirC

= 1 the

= 1: the flap leaves the OPEN position.

DirC

input can also be reset by the user.

ENBL

signal is cancelled, if both final position acknowledgements are

ENBL

signal is cancelled, if

output sets and the,

= 1 resets the

DirO/DirC

O!/C!

signals, no outputs are reset.

are present simultaneously.

ENBL

output.

must be “1”.

6-44

If the with

O!/C!

acknowledgements are valid again, they can be reset and

DirO/DirC

the outputs can be activated again.

Modular Block System: Burner Management

Missing acknowledgement

Behaviour of the flaps in the case of missing or unrequested end position acknowledgements (single attempt).

The

OPEN

with the is present, i.e. a fault is registered. The

OPEN

ENBL

via parameters.

ENBL

output, if a “1” signal at the

output after the position monitoring time, which is set

output is activated once only, together

DirC

DirO

input

output is reset at the same time as the

If the control time monitoring has responded once, a new control command

RSET

pulse. If the control time has been exceeded and, subsequently, a required acknowledgement issued, this must still be reset before further control commands are handled.

OPEN/CLOSE

can be issued after a

Modular Block System: Burner Management

Control time

The short signals at the inputs are spurious signals. They are to be expected and will not trigger a fault.

6-45

Standard Function Blocks

Multiple drive commands

Repeated drive commands, although the final position has already been reached.

No drive commands with invalid input signals (both inputs “1”)

ENBL

output is reset.

SB153

Spurious fault signal reset

The outputs will be active again only after an enable reset and a new control command edge.

After a fault signal (

OPEN/CLOSE

at the

DirO/DirC

output is set when there is a 0-1 edge

input and

ENBL

= 0) the corresponding

RSET

pulse.

6-46

Modular Block System: Burner Management

Test to ensure safe monitoring time

A new 0-1 edge at the not reset the control time monitoring. There are no new pulses for the monitoring time.

DirO/DirC

input does

Modular Block System: Burner Management

6-47

Standard Function Blocks

SB154: Control and position monitoring of valves

Block header

Input parameters

•

SSNR

SB154

VALVE

B - SSNR X - Pos1 X - Pos2 X - Dir1 X - Dir2

W - T_V

Z- T

X - RSET

ENBL - X

VAV - X

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte-constants KB001 ... KB200 (further information about the

SSNR

can be found in the sections “Administration data blocks DB015, DB016 and DB017” and “Input Parameter

SSNR

” in chapter 5). Value of DW0000/DB015 = 0: no error present

6-48

•

Pos1

•

Pos2

•

Dir1

•

Dir2

•

T_V

: Limit switch (N/O contact “start position reached?”)

Pos1

= 1: valve in the “start position”

Pos1

= 0: valve not in the “start position”

: Limit switch (N/O contact “operating position reached?”)

Pos2

= 1: valve in “operating position”

Pos2

= 0: valve not in the “operating position”

: Drive direction

positive edge from

Dir1

: valve will take up the start position

: Drive direction

positive edge from

Dir2

: valve will take up the operating

position

: Switch time for a change in position

Permitted value range: 1 ... 32767, multiplying the value with the fixed time base of 50 ms gives a time range from 50 ms ... 27.3 min.

Modular Block System: Burner Management

•T: Timer which measures the time

•

RSET

Output parameters

•

ENBL

•

VAV

Function

• Monitoring valve status (open/closed), the direction of a change in position and the reaction time to a change in position

• Change in valve position after a request (start position, operating position)

• The contact bounce time due to a change in position is one cycle.

: Reset button (N/O)

: Enable flag bit

ENBL

= 1: this function is fault-free

(refer also to the Programming guidelines)

: Driving the valve

VAV

= 0: bring the valve to its start position

VAV

= 1: bring the valve to its operating position

T_V

Error messages

Any fault that is detected will be stored statically in the corresponding error data word (SSNR) of DB015 (1st data block).

• Error messages in DB 015

- Bit 00: Status of the contact

Pos1

does not correspond with the previous drive direction. Remedy: Check the contact and the switch time the error in the start position ( operated,

Dir2

= 0) .

- Bit 01: Status of the contact

Pos2

Pos1

operated,

does not correspond with the

T_V

Pos2

and reset

not

previous drive direction. Remedy: Check the contact and switch time error in the start position (

Dir2

= 0).

Pos1

operated,

T_V

Pos2

and reset the

not operated

- Bit 02: Switch time for a change in position has been exceeded Remedy: Check the switch time reset the error in the start position ( operated,

Dir2

= 0).

T_V

for the contact(s) and the

Pos1

operated,

Pos2

not

Modular Block System: Burner Management

6-49

Standard Function Blocks

SB154

- Bit 03:

- Bit 04: Feasibility check: neither limit switch operated

- Bit 05: Feasibility check: both limit switches operated

- Bit 06: Reset button not operated

- Bit 07: Valve start position is missing

• Error messages on the CPU-display

- E 001: Parameter errors

Dir1

and

Dir2

driven simultaneously Remedy: Only drive in one direction and reset the error in the start position (

Remedy: Check contacts and reset the error in the start position (

Pos1

Remedy: Check contacts and reset the error in the start position (

Pos1

Remedy: Press reset button

Remedy: Check contacts and reset the error in the start position (

Pos1

The

SSNR

“Administration data blocks DB015, DB016 and DB017” in chapter 5).

operated,

SSNR

is stated in DB015/DW0000 (refer also to the section

Pos1

does not lie within the limits 1 ... 200. The incorrect

operated,

Pos2

not operated,

Dir2

= 0).

Dir2

= 0).

Blocks required

6-50

- E007: Invalid time value for

• DB002: Will be made available when the configurator is called up

• OB101: To call up SB154

• SB152: BR_START for the error reaction

• SB154: VALVE

• SB255: To call up the operating system

T_V

Modular Block System: Burner Management

Programming guidelines

•

ENBL

The enable before the global input input

CHAI

decision to use

ENBL

of SB154 must be supplied to the AND-operation

ERR

or to the AND-operation before the global

of SB152 “Burner: Start and operator elements”. The

ERR

CHAI

depends on the user and the respective

standards regarding error reaction.

ERR

: If an error is present, a controlled shutdown occurs when

AuSt

= 1 with restart.

CHAI

: If an error is present, a safety shutdown occurs.

A programming example can be found in Chapter 8 under “Managing enables”.

•

Dir1

and

Dir2

Driving one flap: the drive must be driven in one direction only i.e. and

Dir2

must not be driven simultaneously.

Dir1

Modular Block System: Burner Management

6-51

Standard Function Blocks

Timing diagrams

Valve closed without power

It is established which valve position is active on de-energising. An inverted operating mode can be achieved by changing inputs

Dir2

, but the block's function mode remains unchanged.

Dir1

= 1 drives the block and the state can, depending on the type of the valve, be the closed or the open valve position. It is the responsibility of the user to take the type of valve into consideration and make changes accordingly. To avoid any misunderstanding, the illustrations and descriptions for the I/Os in the following function diagrams are defined as such:

VAV

output to a safe state. This safe

SB154

Dir1

and

• Dir1

• Dir2

• Pos1

• Pos2

• VAV

= 1: drive command for the valve to close = 1: drive command for the valve to open

= 1: acknowledgement feedback: valve closed = 1: acknowledgement feedback: valve open

= 1: valve open

A pulse at Dir2 sets the VAV output, and the valve opens. A pulse at the Dir1 resets the VAV output, and the valve closes (closed without power). The acknowledgements from Pos1/Pos2 follow the OPEN/CLOSE commands, but are delayed.

6-52

Modular Block System: Burner Management

Reset spurious acknowledgements

After a fault lock-out due to an incorrect acknowledgement, a reset can only occur (with a positive edge at valve is closed (

Spurious acknowledgement as valve opens

Pos1

=1).

RSET

), if the

The valve positions OPEN/CLOSE are polled to the feedback inputs The inputs are polled for validity and the control time OPEN →CLOSE and CLOSE→ OPEN is monitored. If faults occur, the closed immediately and additionally

Modular Block System: Burner Management

Pos1

and

Pos2

VAV

output, together with the valve are

ENBL

= 0 is set.

If the “1”-Signal remains off for a time shorter than the block's set time, the Only after a “1” signal is off for a longer period will the

ENBL

output be reset.

ENBL

output is not set to "0".

6-53

Standard Function Blocks

SImultaneous OPEN and CLOSE commands

A “close valve” command at the Dir1 input resets the VAV output immediately. The present state of the acknowledgements at Pos1 and Pos2 has no influence on the function.

SB154

With simultaneous OPEN/CLOSE commands, the VAV output is reset.

Multiple recurring OPEN and CLOSE commands

Although the selected state has been achieved, multiple OPEN/CLOSE commands have no effect on the outputs.

6-54

Modular Block System: Burner Management

Notes

Modular Block System: Burner Management

6-55

Standard Function Blocks

SB155: Pre-purge

Block header

Input parameters

•

SSNR

NEXT COND

SB155

PREPURGE

B - SSNR X - NEXT X - COND

ENBL - X

RDY - X

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte-constants KB 001 ... KB 200 (further information about the

SSNR

can be found in the sections “Administration data blocks DB015, DB016 and DB017” and the “Input Parameter

SSNR

” in chapter 5).

Value of DW0000/DB015 = 0: no error present

= 1: activate “pre-purge” step

: Limit switch for maximum position of the air damper or monitor

maximum air flow

COND

= 1: Limit switch is operated

Output parameters

•

ENBL

•

RDY

Function

Monitoring the limit switches for the maximum position of the air damper or the maximum air flow during the pre-purge time.

6-56

: Enable flag bit

ENBL

= 1: this function is fault-free

(refer also to Programming guidelines)

: Ready signal

RDY

= 1: “Pre-purge” is active

Modular Block System: Burner Management

Pilz PSS SB FT, Basic license User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

MBS Modular Block System

Categories / requirement classes

Overview of manual

Definition of symbols

Terminology

Overview

Software package

Operation

Range

Safety

Safety guidelines

Use of qualified personnel

Warranty and liability

Application guidelines

Standards

Fault detection

Feasibility test

Fault prevention

Intended Use

Application

System software

Intended use of the standard function blocks

SB149: Sequence control

SB150: Flame monitoring

SB151: Transient suppression

SB152: Burner: start and operator elements

SB153: Control and position monitoring of flaps

SB154: Control and position monitoring of valves

SB155: Pre-purge

SB156: Tightness control

SB157: Several ignition attempts

SB158: Ignition

SB159: Run

SB160: Blower

MBS Basics

Block design

Structure

Formal parameters and actual parameters

Administration data blocks DB015, DB016 and DB017

Structure of the administration data blocks

Blocks contained in the administration data blocks

Input parameter SSNR

Example

Fault diagnostics

Error types

Fault diagnostics using the administration data blocks

Temporary flag range in MBS blocks

Output parameter ENBL

Assignment of input and output parameters

Minimum scan time

Global parameters

Standard Function Blocks

SB149: Sequence control

Block header

Input parameters

Output parameters

Error messages

Blocks required

Programming guidelines

Timing diagrams

Setting / resetting the step without time delay and monitoring time

Setting/resetting the step with time delay but without monitoring time

Setting/resetting the step without time delay but with monitoring time

Setting/resetting the step with time delay and monitoring time

SB150: Flame monitoring

Block header

Input parameters

Output parameters

Error messages

Blocks required

Programming guidelines

Timing diagrams

Signal cycle with an uninterrupted burner start-up or uninterrupted burner stop sequence

Flame monitor error