Honeywell Krom Schroder BCU 580 Manual

6 Edition 11.15l
Industrial & Commercial Thermal
Technical Information · GB
• For monitoring and controlling modulating or staged burners for
multiple burner applications with a central air supply
• For directly ignited burners or burners ignited by a pilot burner in
intermittent or continuous operation
• Optionally with valve proving system
• PROFINET fieldbus connection using optional bus module
Burner control units BCU 580

BCU 580 · Edition 11.15l 2
▼= To be continued
Contents
Burner control units BCU 580 .......................1
Contents ............................................2
1 Application ........................................5
1.1 Examples of application ...........................9
1.1.1 Stage-controlled main burner with alternating
pilot burner ..................................................9
1.1.2 Stage-controlled main burner with permanent
pilot burner ................................................10
1.1.3 Two-stage-controlled main burner with
permanent pilot burner.....................................11
1.1.4 Modulating-controlled burner ...................... 12
1.1.5 Flame control using the temperature ...............13
1.1.6 PROFINET connection using bus module BCM .... 14
1.1.7 ON/OFF rotary impulse control .....................15
1.1.8 Modulating burner control ...........................17
2 Certification ......................................18
3 Function ......................................... 19
3.1 Connection diagram ..............................19
3.1.1 BCU 580..F1 with ionization control in single-
electrode operation .......................................19
3.1.2 BCU 580..F2.........................................20
3.1.3 BCU 580..F3..........................................21
3.1.4 Flame control........................................22
3.2 BCU 580 program sequence .....................23
4 Air control ....................................... 25
4.1 Capacity control ..................................26
4.1.1 BCU..F1/F2..........................................26
4.1.2 BCU..F3..............................................28
5 Valve proving system ............................ 29
5.1 Tightness test.....................................29
5.1.1 Test instant ..........................................30
5.1.2 Program sequence ...................................31
5.1.3 Test period tP........................................33
5.1.4 Opening time tL.....................................33
5.1.5 Measurement time tM...............................33
5.2 Proof of closure function .........................36
5.2.1 Program sequence ..................................36
6 BCSoft............................................37
7 Profinet .......................................... 38
7.1 BCU and bus module BCM ........................39
7.2 GSD file for PLC configuration . . . . . . . . . . . . . . . . . . . . 41
7.2.1 Modules for cyclic data exchange ................... 42
7.2.2 Indexes for acyclic communication .................48
8 Program step/status ............................ 49
9 Fault signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10 Parameters ..................................... 54
10.1 Scanning the parameters........................58
10.2 Flame control ....................................58
10.2.1 Switch-off threshold of the flame amplifier .......58
10.2.2 Flame control ......................................59
10.2.3 High temperature operation .......................60
10.3 Behaviour during start-up .......................63
10.3.1 Burner 1 start-up attempts ........................63
10.3.2 Burner 2 start-up attempts ........................64
10.3.3 Burner application .................................65
10.3.4 Safety time 1 tSA1..............................................68
10.3.5 Flame proving period 1 tFS1 .......................68
10.3.6 Safety time 2 tSA2..............................................69
10.3.7 Flame proving period 2 tFS2 .......................69
10.4 Behaviour during operation .....................70
10.4.1 Restart..............................................70
10.4.2 Minimum operating time tB.......................73
10.4.3 Pilot burner .........................................73
10.5 Safety limits .....................................74
10.5.1 Safety time during operation....................... 74
10.6 Air control ........................................75
10.6.1 Capacity control....................................75
10.6.2 Running time selection ............................84
10.6.3 Running time .......................................84
10.6.4 Low fire over-run ...................................85

BCU 580 · Edition 11.15l 3
▼= To be continued
10.6.5 Controller enable signal delay time tRF ............86
10.6.6 Air actuator control.................................86
10.6.7 Air actuator can be activated externally on start-
up ..........................................................89
10.6.8 Air actuator in the event of fault....................89
10.6.9 Capacity control (bus) .............................90
10.7 Valve check ......................................95
10.7.1 Valve proving system ...............................95
10.7.2 Relief valve (VPS) ...................................96
10.7.3 Measurement time Vp1 .............................96
10.7.4 Valve opening time 1 tL1 ............................97
10.8 Behaviour during start-up .......................98
10.8.1 Minimum pause time tBP ..........................98
10.9 Manual mode ................................... 99
10.9.1 Operating time in Manual mode ...................99
10.10 Functions of terminals 50, 51, 65, 66, 67 and
68 ...................................................100
10.10.1 Function of terminal 50..........................100
10.10.2 Function of terminal 51..........................100
10.10.3 Function of terminal 65..........................100
10.10.4 Function of terminal 66..........................101
10.10.5 Function of terminal 67..........................101
10.10.6 Function of terminal 68..........................101
10.11 Password .....................................102
10.12 Fieldbus communication ....................102
11 Selection ......................................103
11.1 Type code ......................................103
12 Project planning information ..................104
12.1 Installation.....................................104
12.2 Commissioning ................................104
12.3 Electrical connection..........................105
12.3.1 OCU ...............................................105
12.3.2 Safety current inputs..............................106
12.3.3 UVD control .......................................107
12.4 Actuators ......................................108
12.4.1 IC 20 ...............................................108
12.5 Parameter chip card ...........................109
12.6 Protecting the pilot burner from overload .....109
12.7 Calculating the safety time tSA.......................110
12.8 Fifth or switchable gas valve on BCU..F3.......111
13 Accessories....................................112
13.1 BCSoft .........................................112
13.1.1 Opto-adapter PCO 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
13.1.2 Bluetooth adapter PCO 300 ......................112
13.2 OCU............................................112
13.3 Connection plug set ...........................113
13.4 Stickers for labelling ...........................113
13.5 “Changed parameters” stickers................113
14 OCU ...........................................114
14.1 Application.....................................114
14.2 Function .......................................115
14.2.1 Manual mode......................................116
14.3 Electrical connection ...........................117
14.4 Installation......................................117
14.5 Selection .......................................118
14.6 Technical data for OCU ........................118
15 BCM 500 ......................................119
15.1 Application.....................................119
15.2 Function .......................................119
15.3 Electrical connection..........................119
15.4 Installation.....................................120
15.5 Selection.......................................120
15.6 Technical data .................................120
16 Technical data ................................. 121
16.1 Electrical data ................................. 121
16.2 Mechanical data ...............................122
16.3 Environment ...................................122
16.4 Dimensions ....................................122
16.5 Safety-specific characteristic values..........123
16.6 Converting units ...............................124
Contents

BCU 580 · Edition 11.15l 4
▼= To be continued
17 Maintenance ..................................125
18 Legend ........................................126
19 Glossary ....................................... 127
19.1 Waiting time tW................................ 127
19.2 Ignition time tZ................................ 127
19.3 Safety interlocks ............................... 127
19.4 Safety time on start-up tSA1 ................... 127
19.5 Safety time during operation tSB ....................127
19.6 Safety shut-down..............................128
19.7 Fault lock-out ..................................128
19.8 Warning signal .................................128
19.9 Timeout ........................................128
19.10 Lifting ........................................129
19.11 Air valve.......................................129
19.12 Diagnostic coverage DC .....................129
19.13 Operating mode ..............................129
19.14 Safe failure fraction SFF .....................130
19.15 Probability of dangerous failure PFHD......130
19.16 Mean time to dangerous failure MTTFd.....130
Feedback ......................................... 131
Contact........................................... 131
Contents

BCU 580 · Edition 11.15l 5
Application
1 Application
Burner control unit with plug-in spring force connection termi-
nals
Burner control unit BCU 580 controls, ignites and
monitors gas burners in intermittent or continuous
operation. It can be used for gas burners of unlimited
capacity which are ignited by pilot burners. The burners
may be modulating-controlled or stage-controlled. Its
fast reaction to various process requirements makes
the BCU suitable for frequent cycling operation.
On industrial furnaces, it reduces the load on the
central furnace control by taking over tasks that relate
to the burner, for example it ensures that the burner
ignites in a safe condition when it is restarted.
The air control on the BCU..F1, F2 or F3 assists the
furnace control for cooling, purging and capacity
control tasks.
The burner control unit has an interface via which
an air valve or actuator (IC 20, IC 40 or RBW) can be
controlled for staged or modulating burner capacity
control.
The program status, the unit parameters and the level
of the flame signal can be read directly from the unit.
The burners or a connected control element can be
activated manually using the integrated Manual mode
for setting and diagnostic purposes.
Thanks to the optionally integrated valve proving sys-
tem, the valves can be checked for leaks by querying
an external gas pressure switch or it can be checked
whether the gas valve on the inlet side is closed.
▼

BCU 580 · Edition 11.15l 6
Application
Using the BCSoft program, the parameters, analysis
and diagnostic information can be read from a BCU
via the optionally available opto-adapter. All valid
parameters are saved on an integrated parameter chip
card. The parameter chip card can be removed from
the old unit and inserted into a new BCU to transfer the
parameters, for example when replacing the unit.
The monitored outputs for the actuator and valves are
accommodated in a plug-in power module. This can
simply be replaced if necessary.
Once the plug-in power module has been removed, the param-
eter chip card and fuses are accessible.
The BCU can be installed on a DIN rail in the control
cabinet. Plug-in connection terminal strips on the BCU
make it easier to install and remove.
Thanks to the operator-control unit OCU, display functions and
operation of the BCU can be relocated to the control cabinet
door.
▼

BCU 580 · Edition 11.15l 7
Application
The external operator-control unit OCU is available as
an option for the burner control units. The OCU can be
installed in the control cabinet door instead of standard
control units. The program status, flame signal or
fault messages can be read on the OCU. For burner
adjustment, the operating points can be approached
conveniently in Manual mode using the operator-
control unit.
The address for the fieldbus communication is set using three
code switches.
The optional bus module BCM 500 makes it possible to
connect the BCU to a PROFINET network via a fieldbus
interface. Networking via the fieldbus enables multiple
BCUs to be controlled and monitored by an automation
system (e.g. PLC). The bus module is prepared for DIN
rail installation. It is pushed on to the BCU from the side.

BCU 580 · Edition 11.15l 8
Application
Bogie hearth forging furnace in the met-
allurgical industry
Intermittent shuttle kiln in the ceramics
industry
Walking beam furnace with overhead
firing

BCU 580 · Edition 11.15l 9
Application
1.1 Examples of application
1.1.1 Stage-controlled main burner
with alternating pilot burner
Control:
Main burner ON/OFF or High/Low
The main burner can be started with
reduced capacity after the operat-
ing 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. This reduces the main
burner start-up time.
The UV sensor monitors the flame
signal from pilot and main burners.
The BCU provides the cooling and
purging processes.
BCU 580..C0F3
µC
VAS VAS 1 VAG
TZI/TGI
VR..L
V1 V2
V4
10
UVS
38371817 1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
4
ϑ2
9
13
14
57
5
41
42
43
ϑ1
1
2
t
1
2
02–0402–04 06–08 06–08
ϑ1
ϑ2
PLC

BCU 580 · Edition 11.15l 10
Application
1.1.2 Stage-controlledmainburnerwith
permanent pilot burner
Control:
Main burner ON/OFF or High/Low
The main burner can be started with
reduced capacity after the operat-
ing signal from the pilot burner has
been detected. Pilot and main burn-
ers can be operated simultaneously.
This reduces the time required by
the main burner for starting up.
The BCU provides the cooling and
purging processes.
BCU 580..C0F3
µC
VAS VAS 1 VAG
TZI/TGI
VR..L
V1 V2
V4
10
38371817 1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
ϑ1
9
13
14
57
8
5
4
41
42
43
1
2
ϑ2
t
1
2
04 0402–04 06–08 06–08
ϑ1
ϑ2
PLC

BCU 580 · Edition 11.15l 11
Application
1.1.3 Two-stage-controlledmainburner
with permanent pilot burner
Control:
Main burner ON/OFF with ignition
via bypass
The main burner can be started
with minimum capacity after the
operating signal from the pilot
burner has been detected. When
the operating state is reached, the
BCU issues the Enable signal for
the maximum burner capacity. Pilot
and main burners can be operated
simultaneously. This reduces the
time required by the main burner for
starting up.
The BCU provides the cooling and
purging processes.
TZI/TGI
VAS
VAS 1
VAG
IC 40 + BVA
V1 V2
V3
V4
VAS 1
4
10
12
7
16
12
M
µC
BCU 580..C0F2
µC
38371817 1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
ϑ1
9
13
14
15
57
85
53 55 51 52
4
41
42
43
1
2
ϑ2
t
1
2
04 0402–04 06–08 06–08
ϑ1
ϑ2
PLC

BCU 580 · Edition 11.15l 12
Application
1.1.4 Modulating-controlled burner
Control:
Main burner continuous
The butterfly valve for air is moved
to the position for minimum capac-
ity in order to start the main burner.
The main burner is started with
minimum capacity after the operat-
ing signal from the pilot burner has
been detected. The control system
controls the burner capacity via the
butterfly valve for air after the oper-
ating state has been signalled. Pilot
and main burners can be operated
simultaneously. This reduces the
time required by the main burner for
starting up.
V1
IC 20 + BVA
BCU 580..C0F1
µC
38371817 1 2 3
FCU 500
Process control (PCC)
46
49
50
P
HT
A
ϑ1
13
14
57
TZI/TGI
9
8
5
VAS VAS 1 VAG
V2
V4
M
52 53 54 55 56
4
41
42
43
1
2
ϑ2
t
1
2
04 0402–04 06–08 06–08
ϑ1
ϑ2
PLC

BCU 580 · Edition 11.15l 13
Application
1.1.5 Flame control using the temperature
FCU 500..H1
M
HT
18
HT
HT
BCU 580..D
49
58
µC
BCU 580..D
49
58
µC
5-8
STM
In high temperature systems (temperature > 750°C),
the flame may be controlled indirectly via the tempera-
ture.
As long as the temperature in the furnace chamber is
below 750°C, the flame must be controlled by conven-
tional methods.
If the temperature in the furnace chamber rises above
the spontaneous ignition temperature of the gas/air
mixture (> 750°C), the FCU signals to the downstream
burner control units via the fail-safe HT output that
the furnace system is in High temperature mode (HT).
When the HT input is activated, the burner control units
switch to High temperature mode. They operate with-
out evaluating the flame signal and their internal flame
control is non-functional.
If the furnace temperature falls below the spontaneous
ignition temperature (< 750°C), the FCU disconnects
the HT output from the electrical power supply. As soon
as the signal to the HT inputs of the burner control
units is no longer present, the flame signals are once
again monitored by a UV sensor or ionization electrode.
In the event of a fault in a temperature monitoring com-
ponent (e.g. sensor discontinuity, sensor short-circuit)
or in the event of a mains failure, the flame control task
is transferred to the burner control units.

BCU 580 · Edition 11.15l 14
Application
1.1.6 PROFINET connection using bus module BCM
BCU 580
BCM
BCU 580
BCM
BCU 580
BCM
PROFINET
2
1
2
1
2
1
BUS
FCU P
HT
PLC
The bus system transfers the control signals from the
automation system (PLC) to the BCU/BCM for starting,
resetting, controlling the air valve, purging the furnace
or for cooling and heating during operation. In the op-
posite direction, it sends operating status, the level of
the flame signal and the current program status.
Control signals that are relevant for safety, such as the
safety interlocks, purge and HT input, are transferred
independently of the bus communication by separate
cables.

BCU 580 · Edition 11.15l 15
Application
1.1.7 ON/OFFrotaryimpulsecontrol
For processes which require a turn-
down of more than 10:1 and/or
those which require heavy circula-
tion of the furnace atmosphere to
ensure a uniform temperature, e.g.
heat treatment furnaces operating
at low and medium temperatures in
the metallurgical industry.
With ON/OFF cyclic control, the
capacity supplied to the process is
controlled by means of a variable
ratio of the operating time to the
pause time. In this type of control,
the burner output pulse frequency
always maintains full momentum
and results in maximum convection
in the furnace chamber, even with
regulated heating.
The pneumatic ratio control sys-
tem controls the gas pressure on
the burner proportionally to the air
pressure and thus maintains a con-
stant air/gas ratio. At the same time,
it acts as a low air pressure protec-
tion device.
M
PZL PZH PZ
PZL PDZ
TE
BCU 580..F3
FCU 500..F0
µC P
DG DG DG
VAS VAS
VAS
VAGVAS
VAS
VR..L
VR..L
DG DG
DGmin DG max
49 15 131450
45
47 4858
>750°
pu/2
ϑ1
46
2
3
DLmin DL Purge
BCU 580..F3
VAGVAS
VAS
M
STM
▼

BCU 580 · Edition 11.15l 16
Application
The ignition and monitoring of the
pilot/main burners is ensured by
burner control units BCU 580.
The centrally checked safety func-
tions such as pre-purge, tightness
test, flow detector and pressure
switch check (gasmin., gasmax.,
airmin.) are provided by the FCU 500.
M
PZL PZH PZ
PZL PDZ
TE
BCU 580..F3
FCU 500..F0
µC P
DG DG DG
VAS VAS
VAS
VAGVAS
VAS
VR..L
VR..L
DG DG
DGmin DG max
49 15 131450
45
47 4858
>750°
pu/2
ϑ1
46
2
3
DLmin DL Purge
BCU 580..F3
VAGVAS
VAS
M
STM

BCU 580 · Edition 11.15l 17
Application
1.1.8 Modulating burner control
For processes that do not require
heavy circulation in the furnace, e.g.
aluminium smelting furnaces.
This system is suitable for process-
es in which infiltrated air may flow
into the furnace through switched
off burners. The capacity can be
adjusted continuously by activating
the air control valve (analogue or
3-point step signal).
The pneumatic ratio control sys-
tem controls the gas pressure on
the burner proportionally to the air
pressure and thus maintains a con-
stant air/gas ratio. At the same time,
it acts as a low air pressure protec-
tion device.
The ignition and monitoring of the
pilot/main burners is ensured by
burner control units BCU 580.
The centrally checked safety func-
tions such as pre-purge, tightness
test, flow detector and pressure
switch check (gasmin., gasmax.,
airmin.) are provided by the FCU 500.
M
PZL PZH PZ
PZL PDZ
TE
BCU 580..F3
DG DG DG
VAS VAS
VAS
VAGVAS
VAS
VR..L
VR..L
DG DG
DGmin DG max
pu/2
DLmin DL Purge
BCU 580..F3
VAGVAS
VAS
M
FCU 500..F1
µC
P
49 15 131450
53
45
47 4858
M
TC
90°➔0°
0°➔90°
54
55
>750°
ϑ1
2
3
46
STM

BCU 580 · Edition 11.15l 18
Certification
2 Certification
Certified to SIL and PL
For systems up to SIL 3 pursuant to EN 61508 and PL
e pursuant to ISO 13849
EU certified pursuant to
– Gas Appliances Directive (2009/142/EC)
Meets the requirements of the
– Low Voltage Directive (2006/95/EC),
– EMC Directive (2004/108/EC)
FM approved
Factory Mutual Research Class: 7400 Process Control
Valves. Designed for applications pursuant to NFPA 85
and NFPA 86. www.approvalguide.com
ANSI/CSA approved
American National Standards Institute/Canadian
Standards Association–ANSI Z21.20/CSA C22.2 No.
199
www.csagroup.org–Class number: 333501 and
333581.
Eurasian Customs Union
The product BCU 580 meets the technical specifica-
tions of the Eurasian Customs Union.

BCU 580 · Edition 11.15l 19
Function
3 Function
3.1 Connection diagram
3.1.1 BCU 580..F1 with ionization control in single-
electrode operation
Alternative flame control, see page 22 (Flame con-
trol).
Detailed connection diagrams for actuators and fre-
quency converters, see from page 75 (Capacity con-
trol)
Electrical connection, see page 104 (Project planning
information)
Explanation of symbols, see page 126 (Legend)
N
BCU 580..F1
µC
88
c
c
0 V+24 V
24V
DC
9 11 121062 61
230V
1 2 3 4
L1
ϑ1
P70
ϑ2
P70
P70P69
P73
P72P72
HT
pu
2GZL
PZL
P71
4645 65 66 67 6849 50 51 52
5 6 7 8
17 18 37 38
max. 1 A;
24 V DC,
250 V AC
3,15AT
4241 43
13 14 15 57
V1
V2
V3
V4
A
53 54 55 56
mA
(P40 = 2/3) => 51
P
2
1
I
Airmin
Air
0.6 × IN

BCU 580 · Edition 11.15l 20
Function
3.1.2 BCU 580..F2
Alternative flame control, see page 22 (Flame con-
trol).
Detailed connection diagrams for actuators and fre-
quency converters, see from page 75 (Capacity con-
trol)
Electrical connection, see page 104 (Project planning
information)
Explanation of symbols, see page 126 (Legend)
N
BCU 580..F2
µC
88
c
c
0 V+24 V
24V
DC
9 11 121062 61
230V
mA
53 54 55 56
COM
HI
LO
AUTO
1 2 3 4
L1
ϑ1
P70
ϑ2
(P69 = 13)
P70
P73
P72P72
HT
pu
2GZL
PZL
P71
4645 65 66 67 6849 50 51 52
5 6 7 8
A
17 18 37 38
max. 1 A;
24 V DC,
250 V AC
3,15AT
4241 43
13 14 15 57
V1
V2
V3
V4
PP
17 18 37 38
max. 1 A;
24 V DC,
250 V AC
3,15AT
4241 43
13 14 15 57
V1
V2
V3
V4
2
1
I
Airmin
Air
0.6 × IN