Kromschroeder BCU 56 Series User manual

DK S N P GR
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TR CZ PL RUS H
© 2018 Elster GmbH · Edition 07.18
Cert. version 07.18
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 ,  ,  ... = 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..
Changes to edition 0.18
The following chapters have been changed:
– Wiring
– Technical data
– Certification
Contents
Operating instructions
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Translation from the German
Burner control unit BCU56x,580
Burner control unit BCU56x,580..........1
Contents ..............................1
Safety.................................1
Checking the usage .....................
Installation ............................
Replacing the power module/parameter
chip card ..............................
Cable selection.........................4
Wiring ................................4
Connection diagram ....................5
Flame control ..........................13
Adjustment ...........................14
Commissioning........................14
Manual mode .........................15
Assistance in the event of malfunction ....16
Reading off the flame signal, fault
messages and the parameters...........
Parameters and values...................23
Legend...............................5
Technical data ........................6
Designed lifetime .......................26
Logistics .............................7
Accessories ..........................7
Certification ..........................8
Contact ..............................8
Safety
Contents

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Checking the usage
Burner control units BCU 560, 565 and580 are
designed to monitor and control gas burners in in-
termittent or continuous operation.
The outputs for controlling the burners, e.g. for fan,
actuator and valves, are activated via a replaceable
power module. All the parameters required for opera-
tion are saved on the integrated parameter chip card.
BCU 560, BCU 565
For directly ignited burners of unlimited capacity.
BCU 580
For pilot and main burners of unlimited capacity. Pilot
and main burners can be monitored independently.
BCU..F1, BCU..F, BCU..F
Burner control units with interfaces for air control
using an air valve or actuators IC20, IC40,RBW.
BCU 565..F1, BCU 565..F, BCU 565..F
With air flow monitoring as well as pre-ventilation
and post-ventilation to control and monitor a self-
recuperative burner.
This function is only guaranteed when used within the
specified limits – see page 26 (Technical data). Any
other use is considered as non-compliant.
Type code
Code Description
BCU Burner control unit
560
565
580
Series 560
Series 565
Series 580
Q
W
Mains voltage:
120VAC, 50/60 Hz
230VAC, 50/60 Hz
C0
C1
No valve proving system
With valve proving system
F0
F1
F2
F3
Capacity control:
none
with interface for actuator IC
with interface for RBW actuators
with air valve control
D0
D1
D2
With flame control
Operation on high temperature equipment
Operation with menox burner
K0
K1
K2
No connection plugs
Connection plugs with screw terminals
Connection plugs with spring force terminals
Part designations
3
5
2
6
8
1
7
4
1LED display for program status and fault
messages
Reset/Information button
On/Off button
4Type label
5Connection for opto-adapter
6Power module, replaceable
7Power module type label
8Parameter chip card, replaceable
Input voltage– see type label.
BCU

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Installation
CAUTION
Please observe the following to ensure that the
burner control unit is not damaged:
– Dropping the device can cause permanent dam-
age. In this event, replace the entire device and
associated modules before use.
▷
Installation position: vertically upright, horizontal
or tilted to the left or right.
▷The BCU mounting is designed for horizontally
aligned 35×7.5mm DINrails.
▷ If the DINrail is aligned vertically, end clamps are
required (e.g. Clipfix35 by Phoenix Contact) to
prevent the BCU from slipping.
▷ Install in a clean environment (e.g. a control
cabinet) with an enclosure ≥IP54, whereby no
condensation is permitted.
1
Replacing the power module/
parameter chip card
1 Disconnect the unit from the electrical power
supply.
2
 Disengage the BCU from the DINrail.
4 5
6 Remove the old parameter chip card from the
BCU and insert the new one.
▷All the parameter settings of the BCU are saved
on the parameter chip card.
7 Slide the power module back on.
8 Reconnect the connection terminals.
9 Mount the BCU on the DINrail again.

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Cable selection
▷Signal and control line for screw terminals max.
2.5mm2(min.AWG24, max.AWG12), for spring
force terminals max. 1.5mm2(min.AWG24,
max.AWG12).
▷ Do not route BCU cables in the same cable duct
as frequency converter cables or cables emitting
strong fields.
▷ The control lines must be selected in accordance
with local/national regulations.
▷ External electrical interference must be avoided.
Ionization cable, UVcable
▷Cable lengths of 100m are acceptable if there
is no electromagnetic interference.
▷ The flame signal is adversely affected by EMCin-
fluences.
▷ Lay cables individually (with low capacitance)
and, if possible, not in a metal conduit.
Wiring
▷ Do not reverse phaseL1 and neutral conduc-
torN.
▷ Do not connect different phases of a three-phase
current system to the inputs.
▷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 46, as well as the optional safety-
relevant inputs at terminals 65 to 68 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 control 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.
▷ Observe the maximum duty cycle for the ignition
transformer (see manufacturer’s instructions). Ad-
just the minimum pause timetBP (parameter62)
correspondingly, if required.
▷ Functions of terminals 51, 65, 66, 67 and 68 are
dependent on parameter values:
Terminal Dependent on parameter
51 69
65 70
66 71
67 72
68 73
See page23 (Parameters and values).
1 Disconnect the system from the electrical power
supply.
 Before wiring, ensure that the yellow parameter
chip card has been inserted in the BCU– see
page 3 (Replacing the power module/pa-
rameter chip card).
▷ Screw terminals or spring force terminals are
available for the BCU– see page27 (Acces-
sories).
 Wire as shown on the connection diagram– see
page5 (Connection diagram) onwards.
▷Ensure a good PE (ground) wire connection to
the BCU and burners.
▷ To safeguard the safety current inputs (terminals
45 to52 and 65to68), the fuse must be de-
signed so that the sensor with the lowest switch-
ing capacity is protected.

BCU 560..F0
L1
V1 V2 V3
45
65
46
66 68
49 50 51
N
0,6 x IN
67
13 14 15 17 1811 1231 2 5 7
P69
P72
P70
P71 P73
3837
pu
2
PZ
GZL
61 62
+24 V
41 42
0 V
A
ϑ
9
+24 V DC
F1:T3,15AT
FS
HT
c
IZ
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Connection diagram
BCU 560..F0
▷Legend– see page25 (Legend).

BCU 560..F3
L1
V1 V2 V3
45
65
46
66 68
53 5449 50 51 52
N
0,6 x IN
67
13 14 15 17 181110 1231 2 5 7
P69
P72
P70
P71 P73
3837
pu
2
PZ
GZL
A
ϑ
9
+24 V DC
F2:T2AH F1:T3,15AH
FS
FS
61 62
+24 V
41 42
0 V
P
HT
c
IZ
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BCU 560..F
▷Legend– see page25 (Legend).

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BCU 565..F
▷Legend– see page25 (Legend).
BCU 565..F3
L1
V1 V2 V3
45
65
46
66
47 48
68
53 5449 50 51 52
N
0,6 x IN
67
13 14 15 17 181110 129
5 7
P72
P70
P71 P73
3837
pu
2
PZ
GZL
61 62
+24 V
41 44
0 V
42
A
ϑ
9
+24 V DC
P69
P
HT
31 2
F2:T2AH F1:T3,15AH
FS
FS
PZL
c
IZ
Airmin

BCU 580..F3
A
L1
V1 V2 V3
45
65
46
66 68
53 54 5749 50 51 52
N
0,6 x IN
67
13 14 15 17 181110 129831 2 5 7
P72
P70
P71 P73
3837
V4
pu
2
PZ
GZL
4
ϑ2
ϑ1
9
+24 V DC
F2:T2AH F1:T3,15AH
FS
P69
P
HT
61
+24 V
41
0 V
42
62
43
FS
1 2
c
c
12
I
IZ
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BCU 580..F
▷Legend– see page25 (Legend).

PE
L1
N
32116 674812 1115 13
S3 S4
S11 S10
0° 90°
M
IC 20
PE
S1S2
90°➔0° 0°➔90°
S1
Min Max
BCU..F1
45
65
46
66
47 48
68
53 54 55 56 5749 50 51 52
67
13 14 15 17 181110 12
31 2 5
7
3837
90°➔0° 0°➔90°
9
+24 V DC
F2:T2AH
F1:T3,15AH
FS FS
61 62
+24 V
41 44
0 V
42
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IC 0 connected to BCU..F1
▷Parameter 40 = 1.
▷ Continuous control via three-point step controller.

20 19 18 321674812 11
S3 S4
S10
OUT
0°
➔90°
0° 90°
90°
➔
0°
IC 20..E
S1
S2
517
++
IN
OK
RR
PE
A
D
A
D
R
123456
ON
µC
131516
M
PE
L1
N
S1
Min Max
45
65
46
66
47 48
68
53 54 55 56 5749 50 51 52
67
13 14 15 17 181110 12
31 2 5
7
3837
90°➔0° 0°➔90°
9
+24 V DC
F2:T2AH
F1:T3,15AH
FS FS
BCU..F1
61 62
+24 V
41 44
0 V
42
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IC 0..E connected to BCU..F1
▷Parameter 40 = 1.
▷ Continuous control via an analogue signal (di-
rectly connected to the control actuator).

IC 40
PE
19 18 16 15 14 12 11 10 87 54 21
AAC
DDC
M
mA
L
N
22 21 20
R..
45
65
46
66
47 48
68
53 54 55 56 5749 50 51 52
67
13 14 15 17 181110 129
31 2 5
7
3837
90°➔0° 0°➔90°
+24 V DC
F2:T2AH
F1:T3,15AH
FS FS
BCU..F1
61 62
+24 V
41 44
0 V
42
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IC 40 connected to BCU..F1
▷Parameter 40 = 2.
▷Set IC 40 to operating mode27, see operating
instructions Actuators IC 20, IC 40, IC 40S.

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RBW valve connected to BCU..F
▷Parameter 40 = 3.
Continuous control via three-point step controller
N
RBW
M
R B W
90°➔0°
0°➔90°
L1
BCU..F2
45
65
46
66
47 48
68
53 54 55 56 5749 50 51 52
67
13 14 15 17 181110 129
31 2
5 7
3837
61 62
41 42 44
+24 V DC
F2:T2AH
F1:T3,15AH
FS FS
COM
HI
LO
AUTO
Continuous control via PLC
N
M
+ F -
0°➔90°
L1
mA
AD
OUT
+
-
RBW
BCU..F2
45
65
46
66
47 48
68
53 54 55 56 5749 50 51 52
67
13 14 15 17 181110 129
31 2
5 7
3837
61 62
41 42 44
+24 V DC
FS FS
F2:T2AH
F1:T3,15AH
COM
HI
LO
AUTO
PLC

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Flame control
▷BCU 560, 565 = 1 flame amplifier
▷BCU 580 = 2 flame amplifiers
▷
In the case of UV control, use Elster UV sensors
for intermittent operation (UVS 1, 5, 6, 10) or
flame detectors for continuous operation (UVC1).
BCU 560, 565
Ionization/single-electrode operation:
▷Parameter 04 = 0
BCU 560..F3
L1
V1 V2 V3
45
65
46
66 68
53 5449 50 51 52
N
0,6 x IN
67
13 14 15 17 18
1110
1231 2
5 7
P69
P72
P70
P71 P73
3837
pu
2
PZ
GZL
A
ϑ
9
+24 V DC
F2:T2AH
F1:T3,15AH
FS
FS
61 62
+24 V
41 42
0 V
P
HT
c
Z
UV control:
UVS 1, 5, 6, 10
▷Parameter 01 ≥ 5 µA
▷Parameter 04 = 3
BCU 560..F3
L1
V1 V2 V3
45
65
46
66 68
53 5449 50 51 52
N
0,6 x IN
67
13 14 15 17 181110 1231 2 5 7
P69
P72
P70
P71 P73
3837
pu
2
PZ
GZL
A
ϑ
9
+24 V DC
F2:T2AH
F1:T3,15AH
FS
FS
61 62
+24 V
41 42
0 V
P
HT
c
9 12
UVS
1
2
3
765
Z
UVC 1
▷Parameter 04 = 2
9
765
Z
UVC 1
4
3
2
1
N
PE
L
BCU 580
Pilot burner = single-electrode operation/
main burner = ionization:
▷Pilot burner in single-electrode operation
▷Ionization control for main burner
▷Parameter 04 = 0
BCU 580..F3
A
L1
V1 V2 V3
45
65
46
66 68
53 54 5749 50 51 52
N
0,6 x IN
67
13 14 15 17 18
1110 1298
31 2
5 7
P72
P70
P71 P73
3837
V4
pu
2
PZ
GZL
4
ϑ2
ϑ1
9
+24 V DC
F2:T2AH
F1:T3,15AH
FS
P69
P
HT
61
+24 V
41
0 V
42
62
43
FS
1 2
c
c
12
I
Pilot burner = single-electrode operation/
main burner = UVS:
▷Parameter 01 ≥ 5 µA
▷Parameter 04 = 3
9 12
7 865
UVS
1
2
3
Pilot burner = single-electrode operation/
main burner = UVC 1:
▷Parameter 04 = 4
9
7 865
UVC 1
4
3
2
1
N
PE
L
Pilot burner = UVS/main burner = ionization:
▷Parameter 02 ≥ 5 µA
▷Parameter 04 = 5
I
9 12
7 865
UVS
1
2 3

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Pilot burner = UVC/main burner = UVC:
▷Parameter 04 = 6
9
7 865
UVC 1
4
3
2
1
N
PE
L
UVC 1
4 3
2
1
Pilot burner = UVC/main burner = ionization:
▷Parameter 04 = 7
I
9
7 865
N
PE
L
UVC 1
4 3
2
1
Pilot burner = UVC/main burner = UVS:
▷Parameter 02 ≥ 5 µA
▷Parameter 04 = 8
9
7 865
N
PE
L
UVC 1
4 3
2
1
UVS
1
2
3
Adjustment
In certain cases, it may be necessary to change the
parameters set at the factory. Using the separate
software package BCSoft and a PC opto-adapter, it
is possible to modify parameters on the BCU, such
as the pre-purge time or the behaviour in the event
of a flame failure.
▷ The software package and the opto-adapter
are available as accessories– see page27
(Accessories).
▷ Changed parameters are saved on the integrated
parameter chip card.
▷
The factory settings are secured with a program-
mable password.
▷ If the password has been changed, the end cus-
tomer can look up the changed password in the
plant documentation or ask the system supplier.
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
A3 Flame proving period 1
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
U I Remote control (with OCU)
Data transfer (programming mode)
0.0.
(blinking dots) Manual mode
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 has been ensured.
1 Switch on the system.
▷The display indicates –– .
 Switch on the BCU by pressing the On/Off but-
ton.
▷The display indicates 00 .
▷ If the display blinks (fault), reset the BCU by
pressing the Reset/Information button.

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BCU 560..F0
 Apply the start-up signal to terminal1.
▷The display indicates 01 .
▷The display indicates 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 indicates
04
. The burner is in op-
eration.
BCU 560..F, BCU 565..F
▷If the air actuator is activated externally for cool-
ing in the start-up position, the display indicates
A0 .
 Apply the start-up signal to terminal1.
▷The display indicates 01 or A1 if the air actuator
has been activated.
▷The display indicates 02 or A2 if the air actuator
has been opened. The gas valves open and the
burner ignites. Safety time1 starts to elapse.
▷ The display indicates
03
during flame proving pe-
riod1 or A3 if the air actuator has been opened.
▷The display indicates 04 or A4 if the air actuator
has been opened. The burner is in operation.
BCU 580..F
▷If the air actuator is activated externally for cool-
ing in the start-up position, the display indicates
A0 .
 Apply the start-up signal to terminal1.
▷The display indicates 01 or A1 if the air actuator
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 proving pe-
riod1 or A3 if the air actuator has been opened.
▷The display indicates 04 or A4 if the air actuator
has been opened. The pilot burner is in operation.
▷The display indicates 06 or A6 if the air actuator
has been opened. The main burner (burner2)
ignites and safety time2 starts to elapse.
▷ The display indicates
07
during flame proving pe-
riod2 or A7 if the air actuator has been opened.
▷The display indicates 08 or A8 if the air actuator
has been opened. The main burner is in opera-
tion. 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), controlled air flow (terminal2)
and remote reset (terminal3). The function of the
controller enable/emergency stop input (termi-
nal46) is retained.
▷Manual mode is terminated by switching off the
BCU or in the event of a power failure.
▷ Parameter 67 = 0: Manual mode unlimited in
time. The burner control unit may continue to
be operated manually in the event of failure of
the control system or the bus.
▷Parameter 67 = 1: The BCU will terminate Man-
ual 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 the two dots in the display start to
blink.
▷
If the Reset/Information button is pressed briefly,
the current step in Manual mode is shown.
▷
If the Reset/Information button is pressed for
>1s, the BCU proceeds to the next program
step.
 Keep pressing the Reset/Information button (for
>1s at a time) until the BCU has reached the
Burner operation program step (BCU560, 565=
display0.4. /BCU580= display0.8. ).
BCU..F1 with IC 0
▷
Following the burner operating signal (BCU56x=
display
0.4.
, BCU580= display
0.8.
), actuator
IC20 can be opened and closed as required.
 Press the Reset/Information button.
▷ If the button continues to be held down, the
actuator opens further until it reaches the posi-
tion for maximum capacity.
▷The display indicates A. .with blinking dots.
▷ Once the button has been released, the butterfly
valve stops in the relevant position.
4 Press the Reset/Information button again.
▷ If the button continues to be held down, the
actuator closes further until it reaches the posi-
tion for minimum capacity.
▷The display indicates A. .with blinking dots.
▷A change of direction takes place each time the
button is released and pressed again. When the
butterfly valve has reached its final position, the
dots disappear.
BCU..F1 with IC 40, BCU..F with RBW or
frequency converter
▷Following controller enable (BCU56x= display
0.4.
, BCU580= display
0.8.
), it is possible to
move between the positions for maximum and
minimum capacity on a binary basis.

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Assistance in the event of
malfunction
DANGER
Electric shocks can be fatal! Before working on
possible live components, ensure the unit is discon-
nected from the power supply.
Fault-clearance must only be undertaken by author-
ized 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.
?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 1 A 1
? The display blinks and indicates 01 or A 1.
! 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01 in order to adapt
the switch-off threshold of the flame amplifier for
burner1.
0 2 A 2
? Start-up – no ignition spark – the display
blinks and indicates 02 or A 2 .
! 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 02 orA 2 .
! 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 3
A 6
0 6
A 2
0 7
A 3 A 7
? Start-up– flame burning – nevertheless, the
display blinks and indicates
2
or
3
on the
pilot burner/burner (burner1) or
6
or
7
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01) or burner2 (parameter02), 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 2

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0 5 A 5
? The display blinks and indicates 05 or A 5 .
! 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 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02 in order to adapt
the switch-off threshold of the flame amplifier for
burner2.
0 8 A 8
? Operation– flame burning– burner inter-
rupted– the display blinks and indicates
08
or
A8
.
! Flame failure during operation or during delayed
controller enable.
• Read off the flame signal, see page23 (Read-
ing off the flame signal, fault messages and the
parameters).
▷ If the flame signal is lower than the switch-off
threshold for the flame signal from burner2
(parameter02), 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.
! Short-circuit or discontinuity on the flame signal
cable.
! Soiled UV sensor.
• Remedy fault.
1 0
? The display blinks and indicates 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 1
? The display blinks and indicates 11 .
!Too many restarts for burner1. More than 5re-
starts initiated within the last 15minutes.
•Check burner setting.
•Press the Reset/Information button on theBCU.
1 2
? The display blinks and indicates 12 .
!Too many restarts for burner2. More than 5re-
starts initiated within the last 15minutes.
•Check burner setting.
•Press the Reset/Information button on theBCU.
2 0
? The display blinks and indicates 20 .
!Voltage is applied to the output at terminal56.
•Check the wiring and ensure that the voltage
outputs and inputs have the same polarity and
are not reversed.
!The unit has suffered an internal fault in the power
module.
•Replace the power module.

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2 1
? The display blinks and indicates 21 .
! Inputs 51 and 52 are activated simultaneously.
• Check input 51.
▷ Input 51 may only be activated if the valve is open.
• Check input 52.
▷Input 52 may only be activated if the valve is in
the position for ignition capacity.
2 2
? The display blinks and indicates 22 .
! Actuator IC 20 has been wired incorrectly.
• Check the wiring. Wire the outputs and inputs
of connection terminals 52–55 as shown in
the connection diagram – see page 9 (IC
20 connected to BCU..F1).
! The unit has suffered an internal fault in the power
module.
• Replace the power module.
2 3
? The display blinks and indicates 23 .
! 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/Closed of
the butterfly valve is constantly signalled back
via terminal52.
2 4
? The display blinks and indicates 24 .
! Faulty activation via the bus. Requirements for
“Open” and “Close” set simultaneously.
• Ensure that “Open” and “Close” are not activated
simultaneously.
3 0
? The display blinks and indicates 30 .
! 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4 (Cable selection).
• If the measures described above do not help,
remove the unit and return it to the manufacturer
for inspection.
3 1
? The display blinks and indicates 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4 (Cable selection).
• If the measures described above do not help,
remove the unit and return it to the manufacturer
for inspection.
3 2
? The display blinks and indicates 32 .
! Supply voltage too low or too high.
• Operate the BCU in the specified mains voltage
range (mains voltage +10/-15%, 50/60Hz).
! The unit has suffered an internal fault.
• Remove the unit and return it to the manufacturer
for inspection.
3 3
? The display blinks and indicates 33 .
! Faulty parameterization.
• Check parameter settings using BCSoft.
! The unit has suffered an internal fault.
• Remove the unit and return it to the manufacturer
for inspection.
43
? The display blinks and indicates 34 .
! Faulty actuation of the air valve.
! The unit has suffered an internal fault.
• Remove the unit and return it to the manufacturer
for inspection.

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53
? The display blinks and indicates 35 .
! The bus module and control unit are incompat-
ible.
• Check the bus system and PLC for Profibus
compatibility.
! Bus module does not support the selected func-
tion.
• Check the setting of parameter75.
3 6
? The display blinks and indicates 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.
! The unit has suffered an internal fault.
• Replace the power module.
• Remove the unit and return it to the manufacturer
for inspection.
3 9
? The display blinks and indicates 39 .
! Short-circuit on one of the outputs of the safety
circuit.
• Check the wiring.
• Check fine-wire fuseF1 (3.15A, slow-acting,H).
▷ The fine-wire fuse can be replaced once the
power module has been removed.
• Then check the faultless processing of all input
and output signals.
! The unit has suffered an internal fault in the power
module.
• Replace the power module.
4 0
? The display blinks and indicates 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.
• Change parameter56 (Measurement timeVp1)
using BCSoft.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
4 1
? The display blinks and indicates 41 .
! The downstream gas solenoid valve (V2) is leak-
ing.
• 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 inlet pressure.
• Check the wiring.
! The test period is too long.
• Change parameter56 (Measurement timeVp1)
using BCSoft.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
4 2
? The display blinks and indicates 42 .
! One of the burner-side gas solenoid valves (V2/
V3) is leaking.
• Check the burner-side solenoid valves.
! 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 period is too long.
• Change parameter56 (Measurement timeVp1)
using BCSoft.
• If the fault cannot be remedied by doing this,
remove the unit and return it to the manufacturer
for inspection.
4 4
? The display blinks and indicates 44 .
! Faulty pressure switch signal.
• Check the wiring and setting of the pressure
switch.

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4 5
? The display blinks and indicates 45 .
! Faulty valve actuation, reversed valve connection.
• Check the wiring of the solenoid valves.
5 1
? The display blinks and indicates 51 .
! Interruption of signal at the “Safety interlock/
Controller enable/Emergency stop” input (ter-
minal46).
• Check voltage supply to terminal46.
5 2
? The display blinks and indicates 52 .
! The BCU is permanently reset by remote reset.
• Check voltage supply to terminal3.
• Apply voltage to terminal3 only for reset, approx.
1second.
5 3
? The display blinks and indicates 53 .
! The time between two starts is less than the
min.time (timingcycle).
• Comply with the min. timing cycletzmin:
tzmin [s] = (tVZ + 0.6 × tSA1) + 9
Example:
Pre-ignition time tVZ = 2 s
1st safety time on start-up tSA1= 3s
tzmin = (2 + 0.6 × 3) + 9 = 12.8 s
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66).
• Check whether parameter 71=20 (LDS ignition
position check).
5 6
? The display blinks and indicates 56 .
! Faulty wiring of multi-flame control. A flame signal
and an incorrect flame signal are sent to the BCU
at the same time.
• Check the wiring.
5 7
? The display blinks and indicates 57 .
! Faulty actuation of the input at terminal44. The
BCU is prompted to go into menox mode, even
though there is no signal for high temperature
operation (>750°C) at terminal49.
• Check the wiring.
8 9
9 9
9 5 9 6
9 8
9 4
? The display blinks and indicates
89
,
94
,
95
,
96 ,98 or 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4 (Cable selection).
• Ensure that the EMC regulations for the sys-
tem are satisfied– particularly for systems with
frequency converters – see page 4 (Cable
selection).
• 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 4
? The display blinks and indicates 94 .
! The inputs 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 7
? The display blinks and indicates 97 .
! No PCC.
• Insert compatible PCC.
! Contact problems on the power module.
• Remedy contact problems.
! Power module is defective.
• Replace power module.