Krom Schroder BCU 46 Series User manual

DK S N P GR
➔www.docuthek.com
D GB F NL I E
TR CZ PL RUS H
Cert. version 03.19
© 2019 Elster GmbH · Edition 05.19
Safety
Please read and keep in a safe place
Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the opera-
tor. This unit must be installed and commissioned
in accordance with the regulations and standards
in force. These instructions can also be found at
www.docuthek.com.
Explanation of symbols
• , 1 ,  , 3 ... = Action
▷= Instruction
Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
Safety instructions
Information that is relevant for safety is indicated in
the instructions as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.
Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
Contents
Operating instructions
D
GB
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GB-1
035158
Translation from the German
Burner control unit BCU46x,480
Burner control unit BCU46x,480..........1
Contents ..............................1
Safety.................................1
Checking the usage .....................
Installation ............................3
Replacing the power module/bus module/
parameter chip card ....................4
Cable selection and installation ...........5
Wiring ................................5
Connection diagram ....................7
Flame control ..........................12
Adjustment ...........................13
Commissioning........................14
Manual mode .........................15
Assistance in the event of malfunction ....16
Reading off the flame signal, fault
messages and parameters ..............5
Parameters and values .................5
Legend...............................9
Technical data ........................9
Safety instructions .....................30
Logistics .............................31
Accessories ..........................31
Certification ..........................3
Contact ..............................34
Safety
Contents

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Checking the usage
Burner control units BCU 460, 465 and480 are de-
signed to control, ignite and monitor gas burners in
intermittent or continuous operation. They replace
the local control cabinet. Air and gas flow monitoring
as an option.
The outputs for controlling the burners, e.g. for ac-
tuator and valves, are activated via the replaceable
power module LM400. All the parameters required
for operation are saved on the integrated parameter
chip card.
BCU 460, BCU 465
For directly ignited burners of unlimited capacity.
BCU 480
For pilot and main burners of unlimited capacity. Pilot
and main burners can be monitored independently.
LM..F0
Power module without air control interface.
LM..F1, LM..F3
Power module with air control interfaces to connect
an air valve (LM..F3) or actuator IC40 (LM..F1).
This function is only guaranteed when used within the
specified limits– see page29 (Technical data). Any
other use is considered as non-compliant.
Type code
Code Description
BCU 4 Series 4 burner control unit
60
65
80
Series 460
Series 465
Series 480
Q
W
Mains voltage: 120 V AC, 50/60 Hz
230 V AC, 50/60 Hz
1
2
3
8
Ignition transformer duty cycle: 100%
20%
100%
33%
P0
P1
P2
P3
P6
P7
Flange plate: none
standard
M32
industrial plug connector, 16-pin
Profibus
conduit
C0
C1
C2
No valve proving system
With TC and POC valve proving system
With POC valve proving system
D0
D1
D2
No high temperature operation
For high temperature operation
Flameless operation
0
1
2
3
Input functions: none
auxiliary gas
LDS
auxiliary gas and LDS
0
1
2
3
Pressure switches: none
air pressure switch
gas pressure switch
air and gas pressure switch
K0
K1
K2
No connection plugs
Connection plugs with screw terminals
Connection plugs with spring force
terminals
E0
E1
Energy supply: via safety interlocks
via L1
Code Description
LM Power module
400 For series 4
Q
W
Mains voltage: 120 V AC, 50/60 Hz
230 V AC, 50/60 Hz
F0
F1
F3
Air actuator: none
with IC40 interface
with air valve control
O0
O1
O2
Optional outputs: none
not fail-safe
fail-safe
E0
E1
Energy supply: via safety interlocks
via L1
K0
K1
K2
No connection plugs
Connection plugs with screw terminals
Connection plugs with spring force
terminals

GB-3
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Part designations
2
5
6
3
1
789
4
10
10
1LED display for program status and fault
messages
On/Off button
3Reset/Information button
4Connection for opto-adapter
5BCU type label
6Power module, replaceable
7Power module type label
8Parameter chip card, replaceable
9Bus module, replaceable
10 M5 screw terminal for burner ground
Type designation (A), identification number (B), con-
struction stage(C), year/week of manufacture(D),
device number(E), device ID(F), voltage(G), fre-
quency(H), ambient temperature in Celsius(I)/Fahr-
enheit(J), enclosure(K)– see type label.
Elster GmbH
Osnabrück, Made in Germany
C US
-
A
B
F
D EC
G
H
I
J
K
L
M
Installation
CAUTION
Please observe the following to ensure that the
BCU is not damaged:
– The device must not be installed in a public
place. It must be accessible to authorized
personnel only. Unauthorized personnel could
make changes which could cause the system
to become unsafe or dangerous.
– Dropping the device can cause permanent dam-
age. In this event, replace the entire device and
associated modules.
▷The following components are sealed: 1upper
housing section, power module, 3bus module,
4HMI. The BCU may only be installed and oper-
ated with undamaged seals.
1
4
2
3
▷Installation position: vertical (cable glands point-
ing downwards) or down flat.
8888
8888
8888
▷ Distance between BCU and burner: recom-
mended <1m (3.3ft), max.5m (16.4ft).
▷ Affix the sticker (with the program step/fault
message description) in the required language
(available as an accessory).

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Screwing on the BCU
From inside:
1 Open the cover of the BCU.
 Screw on the BCU with four screws, Ø4mm,
min. length 15mm.
Or
To the rear:
▷The unit remains closed.
1 Attach the BCU with four self-tapping screws.
163 mm
185 mm
7.28"
6.42"
▷Self-tapping screws (M6 x 20 mm) are supplied
with the unit.
▷Other mounting options are available as acces-
sories:
Mounting Order No.
Fastening set 74960422
External securing bars 74960414
Identification
▷
Each burner control unit can be labelled indi-
vidually.
1 Pull out the labelling plate at the top right of the
housing.
8888
 Label as required and slide back in.
Replacing the power module/bus
module/parameter chip card
CAUTION
Please observe the following to ensure that the
BCU is not damaged:
– Different power supply for the gas
valves. The following combinations of BCU
and LM are allowed:
BCU 4xx..E1 + LM..E1:
power supply via L1,
BCU 4xx..E0 + LM..E1:
power supply via terminal35,
power supply for air outputs via L1,
BCU 4xx..E0 + LM..E0:
power supply via terminal35.
1 Disconnect the unit from the electrical power
supply.
 Open the cover of the BCU.
3 Remove the connection plug from the power
and bus module.
▷Power module and bus module are secured in
the BCU by retaining lugs A. The retaining lugs
must be pushed away from the respective mod-
ule carefully so that the power or bus module
can be removed.
4 Remove the modules in the following order to
facilitate handling:
1. power module,
. bus module,
3. parameter chip card (PCC).
A
3.
2.
1.
▷Installation of the modules in reverse order.

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Cable selection and installation
▷Signal and control line for screw terminals max.
2.5mm2(min.AWG24, max.AWG12), for spring
force terminals max. 1.5mm
2
(min.AWG24,
max.AWG12).
▷ For the ionization and ignition cables, use un-
screened high-voltage cable:
FZLSi 1/7 up to 180°C,
Order No. 04250410, or
FZLK 1/7 up to 80°C,
Order No. 04250409.
▷ The control lines must be selected in accordance
with local/national regulations.
▷
External electrical interference must be avoided.
▷ Do not route BCU cables in the same cable
duct as frequency converter cables or cables
emitting strong fields.
Ionization cable, UVcable
▷Cable length:
for internal ignition max. 5 m (16.4 ft), for external
ignition (double-electrode operation or UV con-
trol) max. 50m (164ft); observe the requirements
of the ignition transformer.
▷ The flame signal is adversely affected by EMCin-
fluences.
▷ Lay cables individually (with low capacitance)
and, if possible, not in a metal conduit.
Profibus, Profinet, EtherNet/IP
▷
Use only cable and plug components which
comply with the appropriate fieldbus specifica-
tions.
▷ Profibus, Profinet and EtherNet/IP are unen-
crypted fieldbus protocols without authentica-
tion mechanisms.
▷Use shielded RJ45 plugs.
▷Cable length: max. 100m between 2subscrib-
ers.
▷ Profinet/Profibus installation guidelines, see
www.profibus.com.
▷ Ethernet installation guidelines, see
www.odva.org.
Wiring
CAUTION
Please observe the following to ensure that the
BCU is not damaged:
– Burner ground must be connected to the BCU
in order to avoid uncontrolled spark formation,
especially in the case of single-electrode opera-
tion.
– Different power supply for the gas
valves. The following combinations of BCU
and LM are allowed:
BCU 4xx..E1 + LM..E1:
power supply via L1,
BCU 4xx..E0 + LM..E1:
power supply via terminal35,
power supply for air outputs via L1,
BCU 4xx..E0 + LM..E0:
power supply via terminal35.
– For use in an ungrounded mains system or for
mains supply between phases, install an isolat-
ing transformer with single-side grounding.
▷
Do not reverse phaseL1 and neutral conduc-
torN.
▷
Do not connect different phases of a three-phase
current system to the inputs.
▷Check the following screw connections for the
correct tightening torque so as to ensure safe
grounding of housing, cover, (connection) flange
plate and electronics unit as well as a good PE
(ground) wire connection between the BCU and
burner:
2
1
3
4
1Cover screws: 2.4 Nm
PE terminals
3Flange plate screws: 2.4 Nm
4M5 screw terminal for burner ground: 1.8 Nm

GB-6
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▷ Use plastic cable glands/conduit couplings with
multiple cable grommet. These can be detached
with the plug-in connection terminals.
▷Do not supply voltage to the outputs.
▷ A short-circuit on the outputs causes one of the
replaceable fuses to trip.
▷Do not set the remote reset so that it operates
(automatically) in cycles.
▷Wire the safety circuit inputs via contacts (relay
contacts) only.
▷ The limiters in the safety interlock (e.g. safety
temperature limiter, emergency stop) must iso-
late terminal35, as well as the optional safety-
relevant inputs, e.g. at terminals 36 to 41, if these
are parameterized, from the voltage supply. If the
safety interlock is interrupted, the display shows
a blinking 51 as a warning signal and all of the
BCU’s gas valve outputs are disconnected from
the electrical power supply.
▷ Connected control elements must be equipped
with protective circuits in accordance with the
manufacturer’s instructions. The protective circuit
prevents high voltage peaks which can cause
malfunctioning of the BCU.
▷Install the ignition cable in the BCU in the desig-
nated cable duct1and feed it out of the BCU on
the shortest possible route via the cable gland.
2
1
▷ Observe the maximum duty cycle for the ignition
transformer (see manufacturer’s instructions).
Adjust the minimum pause timetBP (param-
eterA062) correspondingly, if required.
▷ All functions of the inputs at terminals 1 to 7
and 35to41, as well as of contacts 80to82,
85to87, 90to92 and 95to97, depend on
parameters I050toI074.
1 Disconnect the system from the electrical power
supply.
 Before wiring, ensure that the yellow parameter
chip card has been inserted in the BCU.
▷ Screw terminals or spring force terminals are
available for the BCU:
Screw terminals, Order No. 74924876,
spring force terminals, Order No. 74924877.
3 Wire as shown on the connection diagram, see
from page7 (Connection diagram).
4 After wiring, close the housing cover again and
tighten the cover screws to 2.4Nm.

LM 400..F0
PE
L
N
L1
N
PE
61 31
V2
60 30
V1
62 32
V3
N
28
L
58 37
TC
N
27
L
57 36 N
29
L
59 38
F3 3,15 A
O
I
F 3,15 A
UA-Sk
V1 V2 V3
82 81 80 95 96 97
51 21
BM
2322
85 86 87 92 91 90
54 24
N1
52 53
BM
55 25
N1
56 26
N1
F1
(BCU..E1)
1
N1
N1 N1 N1 N1 N1 N1
N1
pU
2
230 V
UVS
IZ
3
1246
5740 41
35 39
LDS
Start 1
F2 (BCU..E0)
HT
PE PE PE
PE
BCU 460
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Connection diagram
BCU 460/LM..F0
▷
The connection diagram shows BCU..E1 with
LM..E1.
▷Legend– see page29 (Legend).

LM 400..F3
PE
L
N
L1
N
PE
61 31
V2
60 30
V1
62 32
V3
N
28
L
58 37
TC
N
27
L
57 36 N
29
L
59 38
F3 3,15 A
O
I
UA-Sk
V1 V2 V3
82 81 80 95 96 97
51 21
BM
2322
85 86 87 92 91 90
54 24
N1
52 53
BM
55 25
N1
56 26
N1
1
N1
N1 N1 N1 N1 N1 N1
N1
pU
2
230 V
UVS
IZ
3
1246
5740 41
35 39
P
LDS
Start 1
AHT
PE PE PE PE
PE 65 34 66
vLuft
N1
67
BCU 460
F 3,15 A
F1
(BCU..E1)
F2 (BCU..E0)
Luft
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BCU 460/LM..F3
▷
The connection diagram shows BCU..E1 with
LM..E1.
▷Legend– see page29 (Legend).

LM 400..F3
PE
L
N
L1
N
PE
61 31
V2
60 30
V1
62 32
V3
N
28
L
58 37
TC
N
27
L
57 36 N
29
L
59 38
F3 3,15 A
O
I
UA-Sk
V1 V2 V3
82 81 80 95 96 97
51 21
BM
2322
85 86 87 92 91 90
54 24
N1
52 53
BM
55 25
N1
56 26
N1
1
N1
N1 N1 N1 N1 N1 N1
N1
pU
2
230 V
UVS
IZ
3
1246
5740 41
35 39
P
LDS
Start 1
AHT
PE PE PE PE
PE 65 34 66
vLuft
N1
67
DW 2DW 1
PE PE
menox
BCU 465
F 3,15 A
F1
(BCU..E1)
F2 (BCU..E0)
Luft
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BCU 465/LM..F3
▷
The connection diagram shows BCU..E1 with
LM..E1.
▷Legend– see page29 (Legend).

LM 400..F3
BCU 480
PE
L
N
L1
N
PE
61 31
V2
60 30
V1
62 32
V3
63 33
V4
N
28
L
58 37
TC
N
27
L
57 36 N
29
L
59 38
F3 3,15 A
O
I
UA-Sk
V1 V2 V3 V4
82 81 80 95 96 97
51 21
BM
2322
85 86 87 92 91 90
54 24
N1
52 53
BM
55 25
N1
56 26
N1
1
N1
N1 N1 N1 N1 N1 N1 N1
N1
pU
2
230 V
UVS
3
1246
5740 41
35 39
P
LDS
Start 1 Start 2
A
PE PE PE PE
PE 66
VLuft
67
PE
N1
65 34
Luft
HT
2
F 3,15 A
F1
(BCU..E1)
F2 (BCU..E0)
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BCU 480/LM..F3
▷
The connection diagram shows BCU..E1 with
LM..E1.
▷Legend– see page29 (Legend).

BCU..F1
PE
L
N
N
28
L
58 37
N
27
L
57 36 N 29
L
59 38
F3 3,15 A
O
I
F1 3,15 A
82 81 80 95 96 97
51 21
BM
2322
85 86 87 92 91 90
54 24
N1
52 53
BM 55 25
N1
56 26
N1
E1
1
N1
N1 N1 N1
N1
230 V
UVS
3
1246
5740 41
35 39
E0
PE
IC 40
PE
19 18 16 15 14 12 11 10 87 54 21
AAC
DDC
M
mA
L
N
22 21 20
R..
66 67
64 6540 41 56 26
N1
0°➔90°
90°
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IC 40 connected to BCU/LM..F1 (staged
control)
▷Parameter I020 = 2.
▷Set IC 40 to operating mode 11, see Actuator
IC40 operating instructions or technical informa-
tion bulletin at www.docuthek.com.

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Flame control
▷BCU 460, 465 = 1 flame amplifier
▷BCU 480 = 2 flame amplifiers
▷
In the case of UV control, use Elster UV sensors
for intermittent operation (UVS5,10) or flame
detectors for continuous operation (UVC1).
BCU 460, 465
Double-electrode operation:
▷
See from page 7 (Connection diagram),
BCU 460/LM..F0, BCU 460/LM..F3 and
BCU465/LM..F3.
Ionization/single-electrode operation:
▷Parameter I004 = 0.
5222 PE BM
Z
51 21
BM PE
N1
230 V
UVS
1
UV control:
UVS 5, 10
▷Parameter A001 ≥ 5 µA.
▷Parameter I004 = 1.
UVS
1
2
3
5222 PE BM
Z
51 21
BM PE
N1
230 V
UVS
1
UVC 1
▷Parameter I004 = 2.
UVC 1
4
3
2
1
54 24 PE
BM
22
Z
51 21
BM PE
N1
1
N1
BCU 480
Pilot burner = single-electrode operation/
main burner = ionization:
▷Pilot burner in single-electrode operation
▷Ionization control for main burner
▷Parameter I004 = 0.
LM 400..F3
BCU 480
PE
L
N
L1
N
PE
61 31
V2
60 30
V1
62 32
V3
63 33
V4
N
28
L
58 37
TC
N
27
L
57 36 N 29
L
59 38
F3 3,15 A
O
I
UA-Sk
V1 V2 V3 V4
82 81 80 95 96 97
51 21 BM
2322
85 86 87 92 91 90
54 24
N1
52 53
BM
55 25
N1
56 26
N1
1
N1
N1 N1 N1 N1 N1 N1 N1
N1
pU
2
230 V
UVS
3
124 6
5740 41
35 39
P
LDS
Start 1 Start 2
A
PE PE PE PE
PE
66
VLuft
67
PE
N1
65 34
Luft
HT
2
F 3,15 A
F1
(BCU..E1)
F2
(BCU..E0)
Pilot burner = single-electrode operation/
main burner = UVS:
▷Parameter A001 ≥ 5 µA.
▷Parameter I004 = 3.
LM 400..F3
BCU 480
UVS
1
2
3
5222 PE BM
23
51 21
BM PE
N1
230 V
UVS
1
N1
2
22 BM
23
51 21 BM PE
N1
12
UVC 1
4
3
2
1
54 24 PE
PEN1 N1
22 BM
23
51 21
BM PE
N1
12
UVC 1
4
3
2
1
54 24 PE
PEN1
UVS
1
2
3
5222 PE BM
23
51 21 BM PE
N1
230 V
UVS
12
Pilot burner = single-electrode operation/
main burner = UVC 1:
▷Parameter I004 = 4.
LM 400..F3
BCU 480
UVS
1
2
3
5222 PE BM
23
51 21
BM PE
N1
230 V
UVS
1
N1
2
22 BM
23
51 21 BM PE
N1
12
UVC 1
4
3
2
1
54 24 PE
PEN1
N1
22 BM
23
51 21
BM PE
N1
12
UVC 1
4
3
2
1
54 24 PE
PEN1
UVS
1
2
3
5222 PE BM
23
51 21 BM PE
N1
230 V
UVS
12

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Pilot burner = UVS/main burner = ionization:
▷Parameter A002 ≥ 5 µA.
▷Parameter I004 = 5.
UVS
1 2 3
5222 PE BM
23
51 21
BM PE
N1
230 V
UVS
12
Pilot burner = UVC/main burner = UVC:
▷Parameter I004 = 2.
N1
22 BM
23
51 21
BM PE
N1
12
UVC 1
4
3
2
1
54 24 PE
PEN1
UVC 1
4 3
2 1
Pilot burner = UVC/main burner = ionization:
▷Parameter I004 = 7.
N1
22 BM
23
51 21
BM PE
N1
12
54 24 PE
PEN1
UVC 1
4 3
2 1
Pilot burner = UVC/main burner = UVS:
▷Parameter A002 ≥ 5 µA.
▷Parameter I004 = 8.
N1
22 BM
23
51 21
BM PE
N1
12
54 24 PE PE
PEN1
UVC 1
4 3
2 1
UVS
1
2
3
52
230 V
UVS
Adjustment
In certain cases, it may be necessary to change the
parameters set at the factory. Using the separate
software package BCSoft and an opto-adapter, it
is possible to modify parameters on the BCU, such
as the safety time or the behaviour in the event of
a flame failure.
1 Set the parameters using BCSoft.
▷ For reasons of network security, it is not possible
to access the unit via the network using BCSoft.
▷ The software package and the opto-adapter are
available as accessories.
▷
Changed parameters are saved on the integrated
parameter chip card.
▷ The factory settings are secured with a program-
mable password. The default password is 1234.
We recommend changing the password upon
commissioning.
▷ Hardware parameters (e.g. type of flame con-
trol or type of air actuator) are set via interface
parameters I004 to I074.
▷Once parameters have been changed, a check
is automatically carried out to ensure that the
changes have been accepted and the display
shows V FY .
 Press the Reset/Information button on theBCU.
FU
▷ The first parameter value that was changed is
displayed.
3 Press the Reset/Information button again.
▷The next parameter value that was changed is
displayed.
▷Repeat this procedure until Yis displayed.

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3 Press the Reset/Information button on theBCU
to confirm the new parameter settings.
Commissioning
▷ During operation, the 7-segment display shows
the program status:
00 Standby
H0 Delay
A Approaching minimum capacity
A0 Cooling
01 Fan run-up time
A1 Pre-ventilation
A Approaching maximum capacity
H1 Delay
P0 Pre-purge
P1 Pre-purge
A Approaching ignition capacity
Valve check
02 Safety time 1 tSA1
A2 Safety time 1 tSA1
03 Flame proving period 1 tFS1
A3 Flame proving period 1 tFS1
04 Burner 1 operation
A4 Burner 1 operation
05 Burner 2 waiting time
A5 Delay
H5 Delay time during burner 2 waiting time
06 Safety time 2 tSA2
A6 Safety time 2 tSA2
07
Flame proving period 2 tFS2
A7
Flame proving period 2 tFS2
08 Burner 2 operation
A8 Burner 2 operation
H8 Delay
–– Device Off
Data transfer (programming mode)
0.0.
(blinking dots) Manual mode
XX
Low NOxoperation in program stepXX
XX High temperature operation in program
stepXX
▷ Units with SafetyLink function (BCU with bus
module BCM..S1) may only be commissioned
using BCSoft. Further information can be found
in Technical Information bulletin BCU46x or
BCU480.
WARNING
Risk of explosion! Check the system for tightness
before commissioning.
Do not start the BCU until the parameter settings
and wiring are correct and the faultless processing
of all input and output signals complies with the
local standards.
1 Switch on the system.
▷The display shows –– .
 Switch on the BCU by pressing the On/Off but-
ton.
▷The display shows 00 .
▷ The display blinks and indicates
EXXX
. A reset-
table fault message is signalled. Reset the BCU
by pressing the Reset/Information button.
▷The display blinks without indicating “E”. A warn-
ing message is signalled. Once the fault has been
eliminated, the display stops blinking and the
BCU continues the program run.
BCU 460..F0
3 Apply the start-up signal to terminal1.
▷The display shows 01.
▷ The display shows
02
. The gas valves open and
the burner ignites. Safety time1 starts to elapse.
▷The display indicates 03 during flame proving
period1.
▷The display shows 04 . The burner is in opera-
tion.
BCU 46x..F1, BCU 46x..F3
▷If the air actuator is activated externally for cool-
ing in the start-up position, the display indicates
A0 .
3 Apply the start-up signal to terminal1.
▷The display indicates 01 or A1 if the air actua-
tor has been activated.
▷The display indicates 02 or A2 if the air actua-
tor has been opened. The gas valves open and
the burner ignites. Safety time1 starts to elapse.
▷ The display indicates
03
during flame prov-
ing period1 or A3 if the air actuator has been
opened.
▷The display indicates 04 or A4 if the air actua-
tor has been opened. The burner is in operation.
BCU 480..F1/F3
▷If the air actuator is activated externally for cool-
ing in the start-up position, the display indicates
A0 .
3 Apply the start-up signal to terminal1.
▷The display indicates 01 or A1 if the air actua-
tor has been opened.
▷The display indicates 02 or A2 if the air actua-
tor has been opened. The gas valves open, the
pilot burner (burner1) ignites and safety time1
starts to elapse.
▷
The display indicates
03
during flame prov-
ing period1 or A3 if the air actuator has been
opened.

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▷ The display indicates
04
or
A4
if the air ac -
tuator has been opened. The pilot burner is in
operation.
▷The display indicates 06 or A6 if the air actua-
tor has been opened. The main burner (burner2)
ignites and safety time2 starts to elapse.
▷ The display indicates
07
during flame prov-
ing period2 or A7 if the air actuator has been
opened.
▷ The display indicates
08
or
A8
if the air ac -
tuator has been opened. The main burner is
in operation. The controller enable signal has
been issued.
Manual mode
▷For adjustment of the burner control unit or for
fault-finding.
▷ In Manual mode, the BCU operates indepen-
dently of the status of the inputs for start-up
signal (terminal1), external air valve control
(terminal4) and remote reset (terminal2). The
function of the controller enable/emergency stop
input (terminal35) is retained.
▷Manual mode is terminated by switching off the
BCU or in the event of a power failure.
▷ Parameter A067 = 0: Manual mode unlimited
in time.
▷ Parameter A067 = 1: the BCU will terminate
Manual mode 5minutes after the last time the
Reset/Information button is pressed. It switches
to the start-up position/standby (display 00 ).
1 Switch on the BCU while holding the Reset/
Information button. Hold the Reset/Information
button until 4dots start to flash in the display.
....
▷ If the Reset/Information button is pressed briefly,
the current step in Manual mode is shown and
S.X.X.X. is displayed.
▷ If the Reset/Information button is pressed for
>1s, the BCU proceeds to the next program
step.
....S X
BCU 460/LM..F0
 Press the Reset/Information button for 1s.
▷The display shows S. . .2. (step2).
▷The BCU will start the first stage of the burner.
▷The display runs to . .0.2. or . .0.3. .
▷After 3 seconds in this position, the μA value for
the flame signal
XX.X
is displayed instead of the
program status.
3 Press the Reset/Information button for 1s.
▷The display shows S. . .3. (step3).
▷ The BCU will start the second stage of the burner.
▷The display runs to . .0.4..
▷
After 3 seconds in this position, the μA value
for the flame signal is displayed instead of the
program status.
BCU 46x/LM..F1/F3
 Press the Reset/Information button for 1s.
▷The display shows S. . .1. (step1).
▷The BCU will start to purge the burner.
▷The display shows . .P.0. .
WARNING
Risk of explosion! The pre-purge time is not includ-
ed in the program. Maintain state P.0. until the com-
bustion chamber has been adequately ventilated.
3 Press the Reset/Information button for 1s.
▷The display shows S. . .2(step2).
▷The BCU will start the first stage of the burner.
▷ The display runs to
. .0.2.
or
. .0.3.
(an Arather
than a 0appears if the air actuator is activated).
▷ After 3 seconds in this position, the μA value
for the flame signal is displayed instead of the
program status.
4 Press the Reset/Information button for 1s.
▷The display shows S. . .3. (step3).
▷ The BCU will start the second stage of the burner.
▷The display runs to . .0.4. ( . .A.4. ).
▷After 3 seconds in this position, the μA value for
the flame signal
XX.X
is displayed instead of the
program status.
Air actuator control:
The air actuator is activated externally
(parameter A048 = 0).
5 Press the Reset/Information button for 1s.
▷The display shows S. .4(step4).
▷The BCU will open the air actuator.
▷ Each time the button is pressed, the air actuator
is closed or opened again.
The air actuator opens under program control
(parameter 48 = 1, , 3, 4, 5 or 6).
▷ The air actuator opens under program control
with valves V1, V2, V3 or when it reaches the
operating position.
5 Press the Reset/Information button for 1s.
▷The display shows S. . .4(step4).
▷The BCU will start the shut-down procedure.
BCU 480
 Press the Reset/Information button for 1s.
▷The display shows S. . .1. (step1).
▷The BCU will start to purge the burner.
▷The display shows . .P.0. .

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WARNING
Risk of explosion! The pre-purge time is not includ-
ed in the program. Maintain state P.0. until the com-
bustion chamber has been adequately ventilated.
3 Press the Reset/Information button for 1s.
▷The display shows S. . .2. (step2).
▷The BCU will start the pilot burner.
▷ The display runs to
. .0.4.
(an Arather than a 0
appears if the air actuator is activated).
▷After 3 seconds in this position, the μA value for
the flame signal
XX.X
is displayed instead of the
program status.
4 Press the Reset/Information button for 1s.
▷The display shows S. . .3. (step3).
▷ The BCU will start the first stage of the main
burner.
▷The display runs to . .0.8. .
▷After 3 seconds in this position, the μA value for
the flame signal
XX.X
is displayed instead of the
program status.
Air actuator control:
The air actuator is activated externally
(parameter A048 = 0).
5 Press the Reset/Information button for 1s.
▷The display shows S. . .4. (step4).
▷The BCU will open the air actuator.
▷The display shows . .A.4. .
▷ Each time the button is pressed, the air actuator
is closed or opened again.
▷Press the On/Off button to switch the unit off.
The air actuator opens under program control
(parameter 48 = 1, , 3, 4, 5 or 6).
▷
The air actuator opens under program control
with valves V1, V2, V3, V4 or when it reaches
the operating position.
▷ If the Reset/Information button is pressed for 1s,
the display shows
S. . .4.
(step4) and the BCU
starts the shut-down procedure.
Assistance in the event of
malfunction
DANGER
To avoid harm to persons and damage to the unit,
please observe the following:
–Electric shocks can be fatal! Before working
on possible live components, ensure the unit
is disconnected from the power supply.
–Fault-clearance must only be undertaken by
authorized trained personnel!
▷Faults may be cleared only using the measures
described below.
▷
If the BCU does not respond even though all
faults have been remedied: remove the unit and
return it to the manufacturer for inspection.
▷ In the event of a fault lock-out, the fault signalling
contact closes, the display blinks and shows
the current program step. The gas valves are
disconnected from the electrical power supply.
After a fault lock-out, the BCU must be reset
manually using the button on the front panel or
the remote reset input (terminal2).
The BCU cannot be reset by mains failure (non-
volatile fault lock-out). The fault signalling contact
does, however, open as soon as the mains volt-
age fails.
? Faults
! Cause
• Remedy
? The 7-segment display does not light up.
! Mains voltage is not applied.
• Check the wiring, apply mains voltage (see type
label).
0 1E A 1E
? The display blinks and indicates
E 01
or
E A1
.
! The BCU has detected an incorrect flame signal
without the burner having been ignited (extrane-
ous signal).
• Direct the UV sensor exactly at the burner to be
monitored.
! The UV tube in the UV sensor is defective (service
life ended) and issues a continuous flame signal.
• Replace the UV tube, see UV sensor operating
instructions.
! Flame signal through conductive ceramic insula-
tion.
• Increase value of parameterA001 in order to
adapt the switch-off threshold of the flame ampli-
fier for burner1.

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0 2E
A 2E
? Start-up – no ignition spark – the display
blinks and indicates E 02 or E A2 .
! The ignition cable is too long.
• Shorten it to 1 m (max. 5 m).
! Gap between spark electrode and burner head
is too great.
• Adjust gap to max. 2mm.
! Ignition cable has no contact in the terminal boot.
• Screw the cable on firmly.
! Ignition cable has no contact in the ignition trans-
former.
• Check the connection.
! Ignition cable has short-circuited to ground.
• Check installation, clean the spark electrode.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
? Start-up without flame – no gas supply – the
display blinks and indicates E 02 or E A2 .
! A gas valve does not open.
• Check the gas pressure.
• Check voltage supply to the gas valve.
! There is still air in the pipe, e.g. after installation
work has been carried out or if the system has
not been in operation for a long period.
• “Purge” the pipeline and reset the BCU.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
0 2E 0 3E
A 6E
0 6E
A 2E
0 7E
A 3E A 7E
? Start-up– flame burning – nevertheless, the
display blinks and indicates E 02 orE 03 on
the pilot burner/burner (burner1) or E 06 or
E 07 on the main burner (burner).
! Flame failure on start-up.
• Read off the flame signal.
▷
If the flame signal is lower than the switch-off
threshold for the flame signal from burner1 (pa-
rameterA001) or burner2 (parameterA002), this
may be attributable to the following causes:
! The set value for the cut-off sensitivity is too high.
! Short-circuit on the flame rod as the result of
soot, dirt or moisture on the insulator.
! Flame rod not correctly positioned at the flame
edge.
! Terminal boot not properly connected to flame
rod.
! Gas/air ratio incorrect.
! Flame not contacting burner ground as the result
of excessively high gas or air pressure.
! Burner or BCU not (adequately) grounded.
! Short-circuit or discontinuity on the flame signal
cable.
! Soiled UV sensor.
! UV sensor wiring is defective.
• Remedy fault.
0 5E A 5E
? The display blinks and indicates
E 05
or
E A5
.
! The BCU has detected an incorrect flame sig-
nal without burner2 (main burner) having been
ignited (extraneous signal).
• Direct the UV sensor exactly at burner2 to be
monitored.
! The UV tube in the UV sensor is defective (service
life ended) and issues a continuous flame signal.
• Replace the UV tube, see UV sensor operating
instructions.
! Flame signal through conductive ceramic insula-
tion.
• Increase value of parameterA002 in order to
adapt the switch-off threshold of the flame ampli-
fier for burner2.
0 8E A 8E
? Operation – flame burning – burner inter-
rupted– the display blinks and indicates
E 08 orE A8 .
! Flame failure during operation or during delayed
controller enable.
• Read off the flame signal, see page25 (Read-
ing off the flame signal, fault messages and pa-
rameters).
▷ If the flame signal is lower than the switch-off
threshold for the flame signal from burner2 (pa-
rameterA002), this may be attributable to the
following causes:
! The set value for the cut-off sensitivity is too high.
! Short-circuit on the flame rod as the result of
soot, dirt or moisture on the insulator.
! Flame rod not correctly positioned at the flame
edge.
! Gas/air ratio incorrect.
! Flame not contacting burner ground as the result
of excessively high gas or air pressure.
! Burner or BCU not (adequately) grounded.

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! Short-circuit or discontinuity on the flame signal
cable.
! Soiled UV sensor.
• Remedy fault.
1 0E
? The display blinks and indicatesE 10 .
! Actuation of the remote reset input is faulty.
! Too many remote resets. More than 5resets
have been conducted within the last 15minutes,
either automatically or manually.
! Consecutive fault caused by a previous fault
whose actual cause has not been remedied.
• Pay attention to previous fault messages.
• Remedy cause.
▷The cause will not be remedied by performing a
reset every time a fault lock-out occurs.
• Check whether remote reset complies with
standards (EN746 allows resetting only under
supervision) and correct if necessary.
▷The BCU may only be reset manually under su-
pervision.
• Press the Reset/Information button on theBCU.
1 1E
? The display blinks and indicatesE 11 .
! Too many restarts for burner1. More than 5re-
starts initiated within the last 15minutes.
• Check burner settings.
▷ Ensure that the flame signal is above the switch-
off threshold during operation.
• Check the settings for capacity control during
operation.
• Press the Reset/Information button on theBCU.
1 2E
? The display blinks and indicatesE 12 .
! Too many restarts for burner2. More than 5re-
starts initiated within the last 15minutes.
• Check burner settings.
▷ Ensure that the flame signal is above the switch-
off threshold during operation.
• Check the settings for capacity control during
operation.
• Press the Reset/Information button on theBCU.
2 1E
? The display blinks and indicatesE 21 .
! Inputs 40 and 41 are activated simultaneously.
• Check input 41.
▷
Input 41 may only be activated if the valve is
open.
• Check input 40.
▷Input 40 may only be activated if the valve is in
the position for ignition capacity.
2 2E
? The display blinks and indicatesE 22 .
! The butterfly valve position is not constantly sig-
nalled back to theBCU.
• Check the wiring and ensure that the position for
max. capacity/ignition capacity of the butterfly
valve is constantly signalled back via terminals
41 and 42.
3 0E
? The display blinks and indicatesE 30 , E 31.
! Abnormal data change in the parameters set for
theBCU.
• Reset the parameters to their original values using
the BCSoft software.
• Establish the cause of the fault to avoid repeat
faults.
• Ensure that the cables have been installed prop-
erly– see page5 (Cable selection and instal-
lation).
• If the measures described above do not help,
remove the unit and return it to the manufacturer
for inspection.
3 2E
? The display blinks and indicatesE 32 .
! Supply voltage too low or too high.
• Operate the BCU in the specified mains voltage
range (mains voltage +10/-15%, 50/60Hz).
! An internal device error occurred.
• Remove the unit and return it to the manufacturer
for inspection.
3 3E
? The display blinks and indicatesE 33 .
! Faulty parameterization.
• Check parameter settings using BCSoft.
! An internal device error occurred.
• Remove the unit and return it to the manufacturer
for inspection.
3 1E

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43E
? The display blinks and indicatesE 34 .
! Faulty actuation of the air valve.
! Voltage is applied to the air valve outputs
(65–67).
• Check the wiring and ensure that the voltage
outputs and inputs have the same polarity and
are not reversed.
! Fuse F3 defective.
• Replace fuse F3.
! An internal device error occurred.
• Replace the power module.
• Remove the unit and return it to the manufacturer
for inspection.
53E
? The display blinks and indicatesE 35 .
! Bus module and control unit are incompatible.
• Check the bus system and PLC for compatibility.
! Bus module does not support the selected func-
tion.
• Check the setting of parameterA075.
3 6E
? The display blinks and indicatesE 36 .
! Voltage is applied to the device outputs.
• Check the wiring and ensure that the voltage
outputs and inputs have the same polarity and
are not reversed.
! Fuses defective.
• Replace the fuses.
! An internal device error occurred.
• Replace the power module.
• Remove the unit and return it to the manufacturer
for inspection.
4 0E
? The display blinks and indicatesE 40 .
! The gas solenoid valve V1 is leaking.
• Check the gas solenoid valve V1.
! The gas pressure switch DGp
u
/2 for the tightness
test has been set incorrectly.
• Check the inlet pressure.
• Set DGpu/2 to the correct inlet pressure.
• Check the wiring.
! The test pressure between V1 andV2 has not
decreased.
• Check the installation.
! The test period is too long.
• Check parameterA056 (Measurement timeV
p1
)
and change using BCSoft.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
4 1E
? The display blinks and indicatesE 41 .
! The downstream gas solenoid valve (V2, V3 or
V4) is leaking.
• Check the downstream solenoid valve.
! The gas pressure switch DGp
u
/2 for the tightness
test has been set incorrectly.
• Check the inlet pressure.
• Set DGpu/2 to the correct pressure.
• Check the wiring.
! The test period is too long.
• Check parameterA056 (Measurement timeV
p1
)
and change using BCSoft.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
4 4E
? The display blinks and indicatesE 44 .
! Faulty pressure switch signal.
• Check the wiring and setting of the pressure
switch/gas valve.
5 1
? The display blinks and indicates 51 .
! Interruption of signal at the “Safety interlock/
Controller enable/Emergency stop” input (ter-
minal35).
• Check voltage supply to terminal35.
5 2
? The display blinks and indicates 52 .
! The BCU is permanently reset by remote reset.
• Check remote reset activation (default termi-
nal=2 or bus).
• To reset the unit, only apply voltage to the remote
reset terminal for approx. 1second.

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5 3
? The display blinks and indicates 53 .
! The time between two starts is less than the
min.time (timingcycle).
• Comply with max. number of start-ups (n) per
minute:
tSA Device type Max.
number
[s] Ignition transformer ID number [n/min.]
3BCU..Q1
34340581
BCU..W1
34340585
6
5 6
10 3
3BCU..Q2
34340582
BCU..W2
34340586
3
5 2
10 1
3BCU..Q3
34340583
BCU..W3
34340587
6
5 4
10 2
3BCU..Q8
34340584
BCU..W8
34340588
4
5 3
10 2
5 4
? The display blinks and indicates 54 .
! Faulty feedback signal of the control element
position for ignition capacity.
• Check wiring from central actuator to BCU (ter-
minal39).
• Check whether parameter I072=13 (LDS ignition
position check) and A089=2.
5 7E
? The display blinks and indicatesE 57 .
! Faulty actuation of the input for high tempera-
ture operation. The BCU is prompted to go into
menox mode, even though there is no signal for
high temperature operation (>750°C).
• Check the wiring.
8 0E
? The display blinks and indicatesE 80 .
! Burner 1 flame amplifier is defective.
• Remove the unit and return it to the manufacturer
for inspection.
8 5E
? The display blinks and indicatesE 85 .
! Burner 2 flame amplifier is defective.
• Remove the unit and return it to the manufacturer
for inspection.
8 9E
9 9E
9 5E
9 7E
9 6E
9 8E
9 4E
? The display indicates
E 89
,
E 94
,
E 95
,
E 96
,
E 97 , E 98 or E 99 .
! System fault – the BCU has performed a safety
shut-down. The cause may be a unit defect or
abnormal EMC influence.
• Ensure that the ignition cable has been installed
properly– see page 5 (Cable selection and
installation).
• Ensure that the EMC regulations for the sys-
tem are satisfied– particularly for systems with
frequency converters – see page 5 (Cable
selection and installation).
• Reset the unit.
• Disconnect the burner control unit from the mains
supply and then switch it on again.
• Check mains voltage and frequency.
• If the measures described above do not help, the
unit has probably suffered a hardware defect–
remove the unit and return it to the manufacturer
for inspection.
9 1E
? The display blinks and indicatesE 91 .
! Flame amplifier is defective.
• Check the wiring.
! Fuses defective.
• Replace the fuses.
• If the measure described above does not help,
the unit has probably suffered a hardware de-
fect– remove the unit and return it to the manu-
facturer for inspection.
9 2E
? The display blinks and indicatesE 92 .
! DC voltage is supplied to the inputs.
! The signal inputs and L are supplied with different
phases of a three-phase current system.
• Check the wiring and ensure that the device and
the inputs are supplied with the same phase.
9 4E
? The display blinks and indicatesE 94 .
! The inputs are supplied with different phases of
a three-phase current system.