BFI Automation 5012 User manual

Original Operating Instructions
Converter Module 5012
Type: 5012
Document No.: BA 5012 EN Rev2
BFI Automation Mindermann GmbH
Ruegenstr. 7
42579 Heiligenhaus / Germany
Telephone [phone]
Facsimile [phone]
http://www.bfi-automation.de

Content
i
1 General aspects 1-1
1.1 Introduction 1-1
1.2 Warning notes 1-2
1.3 Copyright protection 1-3
1.4 Disposal information 1-3
1.5 Warranty 1-4
1.6 Obligation of the operating company 1-5
1.7 Liability disclaimer 1-6
1.8 Declaration of conformity 1-7
1.9 Address of the manufacturer 1-8
2 Safety 2-1
2.1 Intended use 2-1
2.2 Requirements on persons 2-2
2.3 Safety instructions 2-3
2.4 Safety devices 2-4
2.4.1 Fundamental aspects 2-4
2.4.2 Safety devices on the compact flame controller 2-4
2.5 Safety instructions in case of maintenance and troubleshooting 2-5
2.5.1 Fundamental aspects 2-5
2.5.2 Electrical / electronic devices 2-6
2.5.3 Testing in keeping with the German Workplace Safety Ordinance (BetrSichV) 2-7
2.5.4 Safety test prior to initial operation 2-7
3 Technical data 3-1
3.1 General characteristic features 3-1
3.2 Factory settings of the converter 5012 3-1
3.3 Electrical system, Optical and Mechanical Data 3-2
3.4 Weight 3-3
3.5 Dimensions 3-3
3.6 Block diagram with connection table 3-3
4 Transport, Installation and Connection 4-1
4.1 Scope of delivery 4-1
4.2 Packaging 4-2
4.3 Forwarding instructions 4-2
4.4 Weight 4-2
4.5 Space requirement 4-2
4.6 Connection 4-3
4.6.1 Electrical connection 4-3
4.6.2 Network Configuration 4-4
4.7 Storage 4-6
5 Description 5-1
5.1 Functional description 5-1
5.2 Controls and displays 5-2
5.3 Frequency setting 5-3
5.4 6 DIP switch 5-4
5.4.1 Current output range 5-4
5.4.2 Current-Relay-Function (CRF) 5-4

Content
ii
5.4.3 Channel 2 (Ch.2) 5-4
5.4.4 BUS termination 5-4
5.4.5 BUS addressing 5-5
5.4.5.1 Adr. 5 5-5
5.4.5.2 Adr. 4 5-5
5.4.5.3 Address rotary switch 5-5
5.5 CFC-NET 5-6
5.5.1 Configuration 5-6
5.5.2 Single Mode 5-7
6 Commisioning 6-1
6.1 Connection of converter module 5012 6-1
6.2 Test of the converter module 5012 6-1
7 Care and Maintenance 7-1
8 Failures 8-1
9 Order data 9-1

General aspects
1-1
1 General aspects
1.1 Introduction
These operating instructions are a helpful guide for ensur-
ing the successful and safe operation of the converter
module 5012 . They contain important information on how
to operate the controller safely, correctly and efficiently.
Observing the operating instructions will help to prevent
hazards, reduce costs of repair and downtimes and in-
crease the reliability and life of the device.
All illustrations and drawings in these operating instruc-
tions are shown for illustration purposes and are not au-
thoritative detailed designs.
The operating instructions always have to be accessible
at the device. They have to be read and applied by each
person who is required to work with/on the device.
This work may involve, for example :
•operation
•troubleshooting during operation
•servicing
•maintenance (upkeep, inspection, repair) and/or
•transport
This should be confirmed by the operating company in
writing.

General aspects
1-2
1.2 Warning notes
The following warning notes are used in these operating
instructions:
This warning level indicates an imminent hazardous situa-
tion.
If the hazardous situation is not prevented, this will result
in death or severe injury.
Follow the instructions that accompany this warning to
prevent the risk of death and severe personal injury.
This warning level indicates an potentially hazardous situ-
ation.
If the hazardous situation is not prevented, this may result
in death or severe injury.
Follow the instructions that accompany this warning to
prevent the potential risk of death and severe personal in-
jury.
This warning level indicates an potentially hazardous situ-
ation.
If the hazardous situation is not prevented, this may result
in slight or moderate injuries.
Follow the instructions that accompany this warning to
prevent the injury of persons.
This warning level indicates potential damage to property.
If this situation is not prevented, it may result in damage
to property.
Follow the instructions that accompany this warning to
prevent damage to property.
A notice indicates additional information that will make the
handling of the device easier.

General aspects
1-3
1.3 Copyright protection
These operating instructions have to be treated as confi-
dential. They may only be used by authorised staff. Ac-
cess by third parties may only be granted upon written
agreement of BFI Automation.
All documents are protected in keeping with the German
copyright law.
The disclosure and reproduction of documentation, in
whole or in part, as well as the exploitation and communi-
cation of its content shall not be permitted unless ex-
pressly stated otherwise. Offenders are liable for prosecu-
tion and the payment of damages.
We reserve all rights to exercise industrial property rights.
1.4 Disposal information
The flame detector is equipped with electrical and elec-
tronic components and must be disposed separate from
household waste. Follow the local and actual regulations
for waste disposal.

General aspects
1-4
1.5 Warranty
Read these operating instructions carefully and in full
before operating the converter module 5012 SD!
The manufacturer is not liable for damage or operating
malfunctions that result from the operating instructions not
being observed.
The operating company has to supplement the operating
instructions with operating instructions on the basis of na-
tional regulations on accident prevention and environmen-
tal protection, including information on supervision and
notification requirements with respect to special operating
circumstances, e.g. regarding organisation of work, work-
ing processes and staff deployed.
The recognised technical rules for safe and professional
working also have to be observed in addition to the oper-
ating instructions and the regulations on accident preven-
tion applicable to the country and place of use.
The warranty shall become void, for example, in the event
of:
•inappropriate use
•use of impermissible equipment
•incorrect connection
•prior works that are not part of the supplied product or
service
•non-use of original spares and accessories
•conversion, if this has not been harmonised with BFI
Automation
•non-performance of specified maintenance work
It is recommended that the operator of the device con-
cludes a service contract with BFI Automation. This guar-
antees that the device is regularly checked by our service
staff and ensures that any required wearing and spare
parts are available without long delivery periods.

General aspects
1-5
1.6 Obligation of the operating company
The converter module 5012 SD may cause hazards if it is
operated inappropriately or in an improper condition.
The operating company is under the obligation to operate
the machine in proper state only. The operating company
has to secure hazardous areas that exist between BFI de-
vices and the customer's own equipment.
The operating company has to appoint and instruct re-
sponsible staff:
•Only deploy trained or instructed staff.
•Clearly set out the responsibilities of the staff with re-
gard to operation, set-up, maintenance and repair.
•Regularly check that staff are safety conscious and
aware of hazards and are observing the operating in-
structions.
•Before starting work, staff who are assigned to work
with/on the device have to have read and understood
the operating instructions, in particular the chapter on
"Safety", as well as the relevant regulations.
•The operating instructions and relevant regulations
have to be stored in such a way that they are accessi-
ble to operating and maintenance staff.
•Set out who will have responsibility for device opera-
tion and ensure that this person has the authority to
overrule any unsafe instructions of third parties.
Generally valid legal and other binding regulations on ac-
cident prevention and environmental protection have to be
observed and instructed, in addition to the operating in-
structions.

General aspects
1-6
1.7 Liability disclaimer
All technical information, data and guidance on device op-
eration that are contained within these operating instruc-
tions are, to the best of our knowledge, correct at the time
of printing, taking into account our present understanding
and experience.
We reserve the right to make technical changes with re-
spect to the further development of the compact flame
controller outlined in these operating instructions. No
claims can be made based on the specifications, illustra-
tions and descriptions of these operating instructions.
We shall not be liable for damage or operating malfunc-
tions that result from operating errors, inappropriate re-
pairs or the non-observance of the operating instructions.
We expressly state that only original spare parts and ac-
cessories approved by us may be used. This also applies
to the components of other manufacturers that have been
used.
The installation or use of non-approved spare and acces-
sory parts and any unauthorized retrofits and modifica-
tions are not permitted for safety reasons and exclude any
liability by BFI Automation for consequential damages.
BFI Automation is liable for possible errors or omissions
with the exclusion of additional claims entered into in the
framework of the warranty obligations conceded to in the
contract. Claims for damages, on whatever legal basis
they may be, shall be excluded.
Translations into foreign languages are carried out in
good faith. We cannot accept any liability for translation
errors; this also applies where the translation has been
carried out or has been commissioned by us. The original
text alone shall be binding.
Descriptions and illustrations do not necessarily depict the
delivered product or a possible spare parts order. Draw-
ings and graphics are not to scale.

General aspects
1-7
1.8 Declaration of conformity

General aspects
1-8
1.9 Address of the manufacturer
BFI Automation Mindermann GmbH
Ruegenstr. 7
42579 Heiligenhaus
Germany
Tel. [phone]
Fax. [phone]
E-mail: [email protected]
Internet: www.bfi-automation.de

Safety
2-1
2 Safety
2.1 Intended use
The converter box 5012 is intended for power supply and
functional enhancement of the BFI compact flame control-
ler CFC3000. It provides a powerful switching relays and
allows with its extra features and current outputs a precise
evaluation of the flame signal.
Danger when improperly used !
The device may cause hazards if it is not used as in-
tended and/or for any other purposes.
The device has to be used only for the purposes for which
it is intended.
The procedures described in the operating instructions
have to be observed.
The converter box 5012 must not be used for the supply
of BFI compact flame controller CFC3000 with built-in
heating. In this case, the plug-in power supply module
3002 is recommended.
The manufacturer/supplier shall not be liable for damage
resulting from use for non-intended purposes. The
user/operating company alone shall bear the risk.

Safety
2-2
2.2 Requirements on persons
Work on/with the device may only be performed by per-
sons authorized to do so based on their training and quali-
fication. Furthermore, such persons have to have been
commissioned by the operating company.
Do not allow any persons who are being apprenticed, ed-
ucated, instructed or on a general training programme to
work on the device without the constant supervision of an
experienced person.
Persons who are under the influence of drugs, alcohol or
medication that affects reactivity shall not be permitted to
carry out work on the device.
Connection, set-up, maintenance and repair work may
only be carried out by qualified specialist staff.
This device may cause hazards if it is operated inappro-
priately by untrained staff or if it is not used for its in-
tended purpose.
Generally valid legal and other binding regulations on ac-
cident prevention and environmental protection in addition
to basic health and safety requirements have to be ob-
served. The operating company has to instruct its staff ac-
cordingly.

Safety
2-3
2.3 Safety instructions
The following instructions on accident prevention have to
be observed when operating the converter module 5012.
Only operate the device if it is in a proper state !
•Do not remove or disable safety devices.
•Check for externally noticeable damage and defects
prior to using the device ! Immediately notify the appro-
priate authority/person of any changes that occur (in-
cluding changes in operating performance). If neces-
sary, stop and secure the device immediately.
•Allow only authorised specialist staff to carry out set-up
and/or maintenance work.
•Replace worn or defective parts.
•Use suitable maintenance tools only.
•After repair work, refit all safety devices and carry out
electrical and mechanical checks.
•Check the operating instructions for details of displays
as well as switch-on and switch-off procedures.
•Prior to switching on the device, make sure that no-one
can be endangered by the device!
•The operating company is responsible for ensuring that
the device is only operated in a proper state and that
account is taken of all the appropriate safety require-
ments and provisions.
•The operating instructions always have to be kept
close to the device and be readily at hand.
•Any non-compliance with the safety instructions out-
lined in these operating instructions may lead to dam-
age to property, personal injury or even death.

Safety
2-4
2.4 Safety devices
2.4.1 Fundamental aspects
Check the safety equipment and locking devices on the
device for safe operational condition.
Only operate the device if all safety devices are present
and enabled. The operating company or operator of the
compact flame controller is responsible for the proper op-
eration of the device.
The device has been fitted with warning and danger signs
for the protection of operating staff. These signs have to
be observed. Damaged or illegible signs have to be re-
placed immediately.
2.4.2 Safety devices on the compact flame control-
ler
The converter module 5012 is equipped with the following
safety devices:
•IP50 housing (protection against accidental contact)
•Fuse for powerinput
•Fuse for relay output contacts
•Optional IP66-protection for variance in plastic housing

Safety
2-5
2.5 Safety instructions in case of maintenance
and troubleshooting
2.5.1 Fundamental aspects
•Deadlines set or indicated in the operating instructions
for repetitive checks / inspections shall have to be ob-
served !
•Appropriate workshop equipment is essential for per-
forming maintenance work.
•In conformity with the electrical regulations, work on
the electrical equipment of the system may only be car-
ried out by an electrical specialist or by trained staff un-
der the direction and supervision of an electrical spe-
cialist.
•The adjustment, maintenance and inspection activities
and deadlines stipulated by BFI Automation, including
information on the replacement of parts / assemblies,
have to be observed! These tasks may only be carried
out by authorised specialist staff.
•Operating staff have to be informed before mainte-
nance or other special work is carried out. A supervisor
has to be appointed.
•When working on the plug, the cable must be discon-
nected from the power supply.
•Screw connections which have been loosened during
maintenance and servicing work, have to be tightened.
•If maintenance and repairs require safety devices to be
dismantled, these devices have to be remounted and
checked as soon as the maintenance and repair work
has been completed.
•Operating and auxiliary materials as well as exchanged
parts have to be disposed of in a safe and eco-friendly
way.
•Spare parts supplied by BFI Automation or approved of
by BFI Automation only may be used.

Safety
2-6
2.5.2 Electrical / electronic devices
Danger to life caused by electrical current!
Contact with live wires or components presents a danger
to life !
Before working on electrical components, disconnect the
compact flame controller from the mains power supply!
In keeping with the electrical regulations, work on electri-
cal / electronic parts / components may only be carried
out by electrical specialists.
Important rules of conduct
•Check the device in regular intervals. Any defects or
faults ascertained have to be corrected immediately.
Switch off the machine until the defects have been cor-
rected.
•System components, on which inspection, mainte-
nance and repair work to be carried out, must - if re-
quired - be switched off. First check the de-energized
parts for voltage and adjacent, live parts isolate!
•If work is required on live parts, a second person has
to be assigned who can disconnect the power supply in
case of an emergency. Only use insulated tools !
•Fuses must not be repaired or bypassed. Only original
fuses with the specified current use!

Safety
2-7
2.5.3 Testing in keeping with the German Work-
place Safety Ordinance (BetrSichV)
In case of the coupling or installation of devices from vari-
ous manufacturers or suppliers, the operating company
has to carry out a precise test, prior to start-up, in keeping
with the German Workplace Safety Ordinance (BetrSichV)
in force and the applicable electrical regulations.
In case of queries, please get in touch with BFI Automa-
tion.
2.5.4 Safety test prior to initial operation
Danger of injury and material damage if improperly used!
Improper use of the converter module 5012 can lead to in-
jury or even death and to material damage!
In order to ensure correct operation, the compact flame
controller must be tested several times for all applications
by starting and stopping the burner several times. In all
cases the flame relay must switch off reliably in case if the
flame is not detected. Carry out these tests whilst several
neighbouring burners are started and stopped and differ-
ent boiler outputs are used. This is an indispensable pre-
requisite for a safe and correct operation of the device!

Safety
2-8