Elster PFA Manual

6.2.1.6 Edition 03.11
Technical Information · GB
www.kromschroeder.com
• 19" module for easy transmission of activation signals and feedbacks from
burner control units via fieldbus cable
• Remote maintenance and diagnostics facilities
• Saves installation and wiring costs
• Units can be exchanged during bus mode operation thanks to industrial plug
connector system
• Bus interface remains in operation when PFA is switched off (standby mode)
• Certification for PROFIBUS DP
Field bus interface PFA
Module subrack BGT

PFA, BGT · Edition 03.11
2
t = To be continued
Contents
Field bus interface PFA
Module subrack BGT.............................. 1
Contents........................................2
1 Application.....................................3
1.1 Examples of application. . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 PFA 700 with PFU 760, staged On/Off burner control . . . . . .5
1.1.2 PFA 700 with PFU 760L, staged High/Low burner control . .5
1.1.3 PFA 710 with PFU 780, stage-controlled main burner with
alternating pilot burner..................................6
1.1.4 PFA 710 with PFU 780, stage-controlled main burner with
permanent pilot burner .................................6
2 Certification....................................7
2.1 EC type-tested and certified . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Approval for Russia.............................7
3 Function.......................................8
3.1 Safety-related control signals . . . . . . . . . . . . . . . . . . . . . 8
3.2 Air valve......................................8
3.3 BCSoft........................................9
3.4 Configuration, Master-Slave procedure . . . . . . . . . . . . 9
3.5 Addressing ...................................9
3.6 Network technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Configuration.................................10
3.7.1 Bus communication ...............................10
3.8 Program status ...............................12
3.9 Fault signalling ............................... 12
3.10 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.10.1 PFA 700 and BGT SA-9U/1DP700. . . . . . . . . . . . . . . . . . . . 13
3.10.2 PFA 710 and BGT SA-8U/1DP . . . . . . . . . . . . . . . . . . . . . . . 14
3.10.3 Flame control using an electrode . . . . . . . . . . . . . . . . . . . 15
3.10.4 Flame control with UV sensor UVS . . . . . . . . . . . . . . . . . . 15
3.10.5 Flame control with UV sensor for continuous operation
UVD 1 ...............................................15
4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Manual operation............................. 17
4.3.1 PFA 700 .........................................18
4.3.2 PFA 710 .........................................19
5 Selection .....................................20
5.1 PFA .........................................20
5.1.1 Selection table................................... 20
5.1.2 Type code ...................................... 20
5.2 BGT.........................................20
5.2.1 Selection table .................................. 20
5.2.2 Type code...................................... 20
6 Project planning information . . . . . . . . . . . . . . . . . . . . . 21
6.1 Installation ...................................21
6.2 Old-new PFA exchange . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Wiring.......................................22
6.3.1 Safety-related control signals . . . . . . . . . . . . . . . . . . . . . . 22
6.3.2 EMC........................................... 22
6.3.3 PROFIBUS plug connector . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 Manual operation.............................22
7 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 PROFIBUS plug connector . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Opto-adapter and BCSoft . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 “Changed parameters” stickers . . . . . . . . . . . . . . . . . . 23
8 Technical data.................................24
8.1 PFA 700, PFA 710 ..............................24
8.1.1 Operating controls ............................... 24
8.2 BGT.........................................25
8.2.1 Dimensions..................................... 25
9 Legend ......................................26
Feedback ......................................27
Contact........................................27

PFA, BGT · Edition 03.11
3 Application
1 Application
In module subrack BGT, up to nine burner control units can be
inserted together with the PFA700, while with the PFA710, the
maximum is eight burner control units.
The BGT is provided with a backplane with screw terminals for
simple, reliable wiring.
The conventional wide-spread systems used in industrial fur-
nace and kiln construction require bridging of large distances
for signal processing.
The field bus interface PFA is used in conjunction with the
pre-wired module subrack BGT for interworking of burner
control units PFU to industrial communication networks us-
ing PROFIBUS DP to control and monitor burners in industrial
furnaces and firing systems, e.g. in the iron and steel, glass
and ceramics, or plastics and chemical industries.
As a standardized fieldbus system, the PROFIBUS DP consider-
ably reduces development, installation and commissioning
costs compared to conventional wiring.
The use of a standard bus system offers massive benefits com-
pared to manufacturer-specific bespoke solutions. Time-tested
hardware components, standardized connection methods
and a series of tools of bus diagnostics and optimization are
available on the market from a whole range of manufacturers.
The widespread use of the system ensures that the planning
and service personnel are very familiar with how the system
operates and how to handle it and can therefore operate the
system efficiently.
PFA 700 with BGT SA-9U/1DP700
For interworking of up to nine burner control units PFU 760
for directly ignited burners to communication networks using
PROFIBUS DP. The PFA700 is plugged into the module subrack
with printed-circuit board and rear terminal strip, together with
the burner control units.
PFA 710 with BGT SA-8U/1DP710
For interworking of up to eight burner control units PFU780
for pilot and main burners to communication networks using
PROFIBUS DP. The PFA710 is plugged into the module subrack
with printed-circuit board and rear terminal strip, together with
the burner control units.

PFA, BGT · Edition 03.11
4 Application
Bogie hearth forging furnace in the metallurgical industry
Walking beam furnace with overhead firing
Intermittent shuttle kiln in the ceramics industry

PFA, BGT · Edition 03.11
5 Application
1.1 Examples of application
1.1.1 PFA 700 with PFU 760, staged On/Off burner control
DI
L1, N, PE
P
BUS
PFU 760 PFU 760 PFU 760 PFU 760 PFU 760 PFU 760 PFU 760 PFU 760 PFU 760
PFA 700
BUS
VR..R
VAG
TZI
UV
PLC
The burner can be started with reduced capacity.
A UV sensor monitors the flame signal from the burner. UV
sensor UVD 1 is used for continuous operation, UV sensor UVS
for intermittent operation.
1.1.2 PFA 700 with PFU 760L, staged High/Low burner
control
VR..R
TZI
GIK..B
VAS..N
DI
L1, N, PE
P
BUS
PFU 760L PFU 760L PFU 760L PFU 760L PFU 760L PFU 760L PFU 760L PFU 760L PFU 760L
PFA 700
BUS
PLC
The burner starts at low-fire rate. When the operating state is
reached, the PFU 760L advises the control unit. The PLC can
now pulse the air valve in order to control the burner capacity.

PFA, BGT · Edition 03.11
6 Application
1.1.3 PFA 710 with PFU 780, stage-controlled main burner
with alternating pilot burner
VR..L
VAG
t
1
2
ϑ1
ϑ2
UV
02–0402–04 06–08 06–08
VBY
TZI
2
1
DI
L1, N, PE
P
BUS
PFU 780 PFU 780 PFU 780 PFU 780 PFU 780 PFU 780 PFU 780 PFU 780
PFA 710
BUS
PLC
Control: main burner ON/OFF
The main burner can be started with reduced capacity after
the operating signal from the pilot burner has been detected.
The pilot burner is switched off automatically after the main
burner has started up. When the main burner is switched off,
the pilot burner automatically switches on again.
A UV sensor monitors the flame signal from pilot and main
burners. UV sensor UVD 1 is used for continuous operation,
UV sensor UVS for intermittent operation.
1.1.4 PFA 710 with PFU 780, stage-controlled main burner
with permanent pilot burner
VR..R
VAG
VBY
TZI
t
1
2
0402–04 06–08 06–08 04
2
1
ϑ1
ϑ2
DI
L1, N, PE
P
BUS
PFU 780 PFU 780 PFU 780 PFU 780 PFU 780 PFU 780 PFU 780 PFU 780
PFA 710
BUS
PLC
Control: main burner ON/OFF
The main burner can be started with reduced capacity after
the operating signal from the pilot burner has been detected.
Pilot and main burners can be operated simultaneously. Both
are ionization-controlled independently.
Control: main burner High/Low
The main burner starts at low-fire rate. When the operating
state is reached, the PFU780L advises the control unit. The
PLC can now pulse the air valve in order to control the capacity
of the main burner.

PFA, BGT · Edition 03.11
7
2 Certification
2.1 EC type-tested and certified
– Low Voltage Directive (2006/95/EC) in conjunction with EN
60730,
– Electromagnetic Compatibility Directive (2004/108/EC) in
conjunction with the relevant standards relating to radia-
tion.
2.2 Approval for Russia
Certified by Gosstandart pursuant to GOST-R.

PFA, BGT · Edition 03.11
8
3 Function
DI
L1, N, PE
P
BUS
…
PFU PFU PFU PFU PFU PFU PFU PFU PFU
PFA
BUS
…
PFU PFU PFU PFU PFU PFU PFU PFU PFU
PFA
BUS
PROFIBUS-DP
PLC
The field bus interface PFA 700 integrates up to nine burner
control units PFU 760 into industrial communication networks
using PROFIBUS DP. The PFA 700 is plugged into the pre-wired
module subrack BGT SA-9U/1DP700, together with the burner
control units.
The field bus interface PFA 710 integrates up to eight burner
control units PFU 780 into industrial communication networks
using PROFIBUS DP. The PFA710 is plugged into the pre-wired
module subrack BGTSA-8U/1DP710, together with the burner
control units.
To the rear of the module subrack, there is a D-Sub socket for
connection to PROFIBUS DP and connection terminals in order
to send input and output signals to ignition transformers, gas
and air valves or UV sensors, for example, via the individual
burner control units PFU.
PROFIBUS DP
PROFIBUS is a manufacturer-independent, open fieldbus stand-
ard for diverse applications.
PROFIBUS DP is a bus variant for communication between
automation systems and distributed peripherals at the field
level, optimized for speed and low connection costs.
On PROFIBUS DP, the individual bus stations are connected
via a 2-core shielded cable as standard.
The bus system transfers the control signals for starting, re-
setting and for controlling the air valve to purge the furnace
or kiln or for cooling in start-up position and heating during
operation from the control system (PLC) to the PFA. In the op-
posite direction it sends information on the operating status.
3.1 Safety-related control signals
Control signals for the safety interlocks and digital input are
transferred independently of the bus communication by sepa-
rate cables.
3.2 Air valve
The air valves used to purge the furnace or kiln can either be
activated via the PROFIBUS or via a separate cable (to terminal
strip X10 of the BGT – at 24 V DC to terminal 12 or 13, or at
mains voltage to terminal 18).
It is possible to use the PROFIBUS to communicate that purging
is being carried out (by connecting mains voltage to terminal
17 of terminal strip X10 of the BGT).

PFA, BGT · Edition 03.11
9
3.3 BCSoft
The Windows software BCSoft allows extended access to
individual statistics, visualization of the process values and
the parameterization of the field bus interface via an optical
interface. Unit parameters can be adjusted to the specific
application.
3.4 Configuration, Master-Slave procedure
PROFIBUS DP is structured as a Master-Slave system. This al-
lows mono-master or multi-master systems to be implemented.
A distinction is made between three device types:
– DP Masters Class 1 (DPM1)
DPM1 devices are central controllers which exchange
data with the distributed stations (slaves) on the basis of a
defined cycle. This includes, for instance, the PLC, PC, CNC
or VME systems with which the PROFIBUS DP is operated.
– DP Masters Class 2 (DPM2)
DPM2 devices are programming, project planning or
operator-control devices. They are used for configuration
and commissioning of the system or for system operation
and visualization in ongoing operation.
– DP slaves
The devices which transmit input information from the
periphery to the master and which issue output informa-
tion from the master to the periphery are referred to as
“slaves”.
This also includes the PFA.
3.5 Addressing
A maximum of 126 units (masters and slaves) can be con-
nected to a PROFIBUS DP system. Each station is assigned an
individual PROFIBUS address which can be set between 0 and
126 using two code switches on the PFA board.
0
8
7
6
5
4
3
2
1
0
E
D
C
B
A
9
8
7
6
5
4
3
2
1
F
9
114 dec
Function

PFA, BGT · Edition 03.11
10
3.6 Network technology
All devices are connected in a bus structure (line). Up to 32
stations (masters or slaves) can be connected in a single seg-
ment. The beginning and end of each segment is fitted with
an active bus terminator. Both bus terminators must have a
permanent power supply to ensure error-free operation. The
power supply for the bus terminator is provided by the PFA. The
bus terminator can be connected in the bus connection plug.
If more than 32 stations are implemented or if there is a need
to expand the network area, repeaters (amplifiers) must be
used to link the individual bus segments.
3.7 Configuration
When planning a PROFIBUS DP system, unit-specific param-
eters of each station are to be taken into account.
To allow for simple and standardized planning, the parameters
of the PFA have been summarized in a so-called device master
data file (GSD). The file structure is standardized so that it can
be read by the planning devices of different manufacturers.
The GSD file is supplied on a CD with the PFA. The GSD file can
also be ordered at www.docuthek.com. The steps required to
copy the file are described in the instructions for the automa-
tion system.
3.7.1 Bus communication
Input/output bytes: The programmer can choose the data to
be transferred.
Input bytes
(PFA ▶ master)
Output bytes
(master ▶ PFA)
PFA 700 5 bytes 3 bytes
PFA 710 5 bytes 5 bytes
Baud rate: up to 1500 kbit/s.
The max. range per segment depends on the baud rate:
Baud rate [kbit/s] Range
[m] [ft]
93.75 1200 3937
187.5 1000 3280
500 400 1312
1500 200 656
The specified ranges may be increased by using repeaters.
No more than three repeaters should be connected in series.
The specified ranges relate to bus cable type A (two-core,
shielded and twisted), e.g.:
Siemens, Order No.: 6XV1830-0EH10, or
Lapp cable unitronic, Order No.: 2170-220T.
t