WS D-71272 User manual

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Burner Control CBR
Burner Control CBR (Control Box Rekumat



/ Regemat



)
Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however,
remain principally the same.
Burner Control CBR
The CBR burner control box incorporates the following
components:
• Microprocessor controlled flame relay
• Safety relevant temperature measurement of a NiCr-Ni
dual thermocouple for release of the appropriate operating
mode and for thermal supervision of FLOX



operation
or safety relevant inputs for release of FLOX
®
/ flame
mode (XOR signal processing)
• Air / exhaust and cooling valve control
• Manual / Automatic operation
• Display of information, operating and fault status
messages, in a compact metal housing
The CBR controls, ignites (externally) and supervises
WS gas burners REKUMAT



/ REGEMAT



in intermittent
operation (pre-configured self test < 24 hours).
Signal exchange with the main process control can be achieved via
Profibus DP interface or via hard wired input/output.
Depending on the power supply voltage, 4 variations, which are project customized, pre-configured and tested.
Technical Specifications:
• Power Supply 230V AC –15% ... +10% 50/60Hz or
115V AC –15% ... +10% 50/60Hz
• Electrical connection Phase correct connection and ground connection
according to electrical diagram
Touch protection! Must be present for thermocouples
and the UV sensor / flame rod (powerless installation
and connection)
• Fuse 6,3A slow or 10A fast, integrated, replaceable
• Power consumption (self) < 14VA
• Power consumption (total) Max. current: 6,3A
• Power consumption (safety relevant
users) Max. 5A (for all gas valves and ignition transformer for
approx. 2 sec during ignition)
• Max. cable lengths to burner components
10m
• Protection class IP54
• Ambient temperature -20°C ... +60°C
• Storage and transportation -20°C ... +70°C
• Humidity DIN 60730-1, dew/condensation formation not allowed
• Dimensions 264x310x123mm (Width x Height x Depth)
• Installation orientation any
• Mounting On site, 4 female threads M8x1,25 (12mm deep) each
17mm from outside edge
• Weight 5 ... 15kg (depending on components and cable length)
• Certification EG-Construction Pattern Test Certificate
EG-Gas Device guide line (CE Nummer: 0085BT0439
/ Testing basis: EU/90/396/EWG; DIN EN298)
FM approved Class: 7610 (Test number PDR 3035948)

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Burner Control CBR
The burner control box has many diagnosis features for ease of
commissioning or trouble shooting:
Program sequence, device parameters, fault code history, operating hours
counter, combustion chamber temperature (measured by dual thermocouple)
or the flame signal strength can be indicated on the 7-segment display.
Three LED's visualize the most important operating states:
• green Flame signal strength (flashing when quality bad)
• yellow FLOX

- Status
• red Fault (flashing)
The functions of the buttons, button combinations, information, operating and fault codes are described on two
labels. Labels are available in different languages and are changeable.
Code label 1
Code label 2
Each CBR is configured for its specific application and tested prior to delivery.
The most important parameters can be visualized on the display (Comfort Configuration) by applying the
appropriate key combinations (refer to label 1). A Password is required to change parameters (except Profibus
address) and to activate manual operation.
You will receive your password from our sales, service or electronics department after completing registration.

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Burner Control CBR
Comfort Configuration
Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same.
NOTE: All configured parameters are documented in the burner control certificate. This certificate is archived according the serial number.
Please notify our electrical engineering department of any changes.
All configured parameters are documented in the burner control certificate. This certificate is archived according the
serial number. Please notify our electrical engineering department of any changes.

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Burner Control CBR
Electrical Connections
Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however,
remain principally the same.
Tools:
• screw driver
• wrench
• multi meter
Parts:
• Burner controls CBR (ready for connecting and pre-
configured to customers specifications)
• M8x1,25 screws or threaded studs (with washers and
nuts) 4x
Attention! Components under tension and high voltage!
Mount the burner control unit CBR in close proximity to the
burner. For mounting purposes the CBR has 4 molded nuts
(female threads) incorporated into the rear of the unit -
M8x1,25 (12mm deep).
Select a mounting location at which the ambient temperature
will not exceed 60°C .
From process control, connect the power supply 230V 50/60Hz
(optional 115V 50/60Hz) as well as the release signal „Safety
chain“, interlocked with the application safety chain, to the
control box. Make the connections according to the electrical
schematics supplied by WS. All connections must be fused
properly (depending on wire lengths, wire gauge, ambient
temperature, and power draw). The „safety chain“ signal
carries the load from the ignition transformer and the gas
valves connected to the burner. Signal exchange for burner
control can be hard wired (refer to electrical schematics) or it
can be achieved via Profibus communications (optional).
Connections from the CBR to the electrical components of the burner are pre-wired and pre-assembled
according to customer specifications. Please refer to the electrical schematics.
Please note, that NiCr-Ni dual thermocouples and the UV sensor must not be attached (changed)
with power ON. Danger of electrocution if phases of power supply are not connected correctly!
Prior to commissioning, all electrical connections and signal exchange must be verified by trained
electricians in accordance to local codes and regulations.

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Burner Control CBR
A FLOX
®
burner without the safety relevant temperature
acquisition via a NiCr-Ni dual thermocouple for release of
FLOX mode, must utilize the safety relevant inputs for
release of FLOX/Flame modes (XOR signal processing).
Input signals must are to be determined and activated by fail
safe temperature supervision. FLOX mode may only be
activated at the FLOX input terminal if the furnace temperature
is > 850°C via an active signal (230V AC L1 or optional 115V
AC L1). The input of the Flame release terminal must be
deactivated. A drop in temperature below the FLOX release
threshold, the FLOX release signal must be deactivated and the
Flame release signal must be activated. Switch over must occur
within one second, otherwise a fault shut-off will occur (F 57)
Prior to activating FLOX
®
mode, the FLOX/Flame switching logic, especially the electrical
connections, must be validated by trained personnel. Validation to be performed with the gas
supply turned off. Incorrect implementation can result in EXPLOSION!
Electrical connects are made directly inside the CBR terminal
section (remove power and lock out). As an option, the CBR
can be supplied with an industrial connector for power supply
and input/output signals.
Profibus is optional and the interface is provided in form of a
Profibus connector (9 pin sub-D)
The CBR is pre-wired and tested at our facility. A project
specific electrical schematic is included inside every CBR.
Prior to commissioning, wire termination and controls must be verified and tested diligently by
trained professionals, in accordance to local regulations.
NOTE: all parameter settings are documented on the burner test data certificate. This certificate is
archived according to WS serial numbers. Please notify our electrical engineering department of any
changes made.

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Burner Control CBR
Profibus DP with CBR
Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however,
remain principally the same.
Burner control CBR with Profibus (functional schematic)
SPS,PLC,CPE
L1,N,PE
BUS
(FLOX GWS)
CBR
BUS
X2:
X2:
BUS
X2:
BUS
Power supply, Safetychain, (FLOX/Flame)
Bus wire
1
2
3
CBR CBR
A maximum of 126 devices my be connected to a Profibus DP system (master and slaves). Each device receives an
individually defined address. The address can be entered into the CBR via the push buttons on the front panel.
The address range is from 0 to 126 (CBR delivered with invalid address 127!). All devices are connected in a bus
fashion (in line). Each individual line segment can have as many as 32 participants (masters and slaves). A bus
terminator must be placed at the beginning and end of each segment. Termination can be achieved via the switch
within each Profibus connector. To maintain fault free bus operation, each terminated device must have power
connected.
Repeaters (boosters) must be used for more than 32 devices or to extend the range of the bus network.
It is recommended to utilize shielded 2 wire cable (for example Lapp Unitronic –Best.-Nr. 2170-220T or Siemens –
Best.-Nr.6XV1830-OEH10) to protect the network against electromagnetic interference. The shield must be
connected on both ends, good conductivity of the shield is paramount. Do not switch the data lines A and B.
Furthermore, keep Profibus cables as far away from other highly radiating cables (for example, high voltage cables,
frequency converters, VFD, etc.)
Ascertain that the power potential level is compensated between various masters and slaves (uniform potential)
(Refer to Aufbaurichtlinien/ EMV-Maßnahmen im Fachbuch: “Profibus-DP/DPV1“ – Hüthig-Verlag – ISBN 3-
7785-2781-9).

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Burner Control CBR
Profibus interface connection:
CBR burner control units have a bus connection (9 pin SUB-D) integrated into the flange plate.
To complete the connection, a Variosub-D connector (9-pin male) is available (included in orders with
Profibus interface). This connector includes two cable glands with gaskets for cable diameters from 5 to
9mm, terminals for connections, termination device. The termination device can be activated from out
side the plug via an integrated switch. Bus termination between the two conductors A and B is
approximately 220 Ohm. A multi meter should be used to test and confirm this resistance between pins 3
and 8. The bus terminals within the connector are labeled 1A,1B,2A,2B. Make sure the same conductor
colour is maintained throughout devices and that they are connected to the same label throughout.
There is no applicable code pertaining to wiring colours for Profibus. It has become „semi“ standard to
use green for A and red for B. Incoming connections are terminated on 1A, 1B and the outgoing
connections are terminated on 2A, 2B. The shield is to be connected securely by the shield bracket.
(Refer to the installation instructions of the plug manufacturer).
CBR Profibus – Data Cable Connections
1B 2A 2B
8 3
6 5 1
CBR Control box
220
green
green
red
red
shield shield
Incomming bus cable
Outgoing bus cable to next CBR
1A
5
9
6
1
Sub - D 9-pin
Variosub Profibus -
9 -pin connector
WS T.- - Nr. 970-00-440
Note: Bus connector can be removed from the CBR without interrupting the bus.

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Burner Control CBR
Declaration of the Profibus interface:
Manufacturers tag 0x3218 (UNIGATE IC-Profibus der Firma Deutschmann Automation
GmbH)
ASCIC-Type VPC3+B
Sync- und Freeze- Mode - is supported
(Sync- command: all outputs of addressed slaves frozen
Freeze- command: freeze all inputs of addressed slaves)
Cycle time Maximum duration until response of a request telegram, depending on bus
transfer rate:
9,6kBit/s – 500kBit/s →15 Bit times
1500kBit/s →20 Bit times
3000kBit/s →35 Bit times
6000kBit/s →50 Bit times
12000kBit/s →95 Bit times
Diagnostic The Profibus module creates an external diagnosis when a fault is detected.
The diagnostic information of the DP slave consists of standard data( 6
Bytes) and a user specific diagnostic number (2 Bytes):
Octet 1:
Bit 0 = Diag.station does not exist (set by master)
Bit 1 = Diag.station not_ready: slave is not ready for data transfer
Bit 2 = Diag.cfg_fault: configuration files do not correspond
Bit 3 = Diag.ext_diag: slave has external diagnostic data
Bit 4 = Diag.not supported: requested function not supported by slave
Bit 5 = Diag.invalid_slave_response (perm. sets slave to 0)
Bit 6 = Diag.prm_fault: incorrect set up (ID number etc.)
Bit 7 = Diag.master_lock (set by master): slave configured by other master
Octet 2:
Bit 0 = Diag.prm_req: slave must be reconfigured
Bit 1 = Diag.stat_diag: statistical diagnosis (Byte Diag-Bits)
Bit 2 = 1
Bit 3 = Diag.wd_on: polling supervision activated
Bit 4 = Diag.freeze_mode: freeze command received
Bit 5 = Diag.sync_mode: Sync command received
Bit 6 = reserved
Bit 7 = Diag.deactivated (set by master)
Octet 3:
Bit 0 – Bit 6 = reserved
Bit 7 = Diag.ext_overflow
Octet 4:
Diag.master_add: master address after configuratin (FF without configuration)
Octet 5: ID number High byte
Octet 6: ID number Low byte
Octet 7: external diagnosis: header length
Octet 8: internal UNIGATE- fault code
Parameter - supports only cyclic communication
automatic Baud rate
recognition - supported
Cable length:
Following table valid for cable type A per EN 50170
Baud rate (kbit/s): 9,6 19,2 45,45 93,75 187,5 500 1500 3000 6000 12000
Distance (m): 1200 1200 1200 1200 1000 400 200 100 100 100

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Burner Control CBR
Profibus configuration:
When engineering a Profibus DP system, parameters and addresses must be configured for each device.
A GSD file is provided to simplify and standardize this engineering process. The GSD file format is
standardized, so it can be read and recognized by devices of all manufacturers.
Please contact our sales, service or engineering department for the GSD file applicable for your project.
The steps required to access the file should be available from your automation system manual.
The „Basic I/O“ version (minimum configuration) for data transfer, includes only the output byte (AB0)
and the 2 input bytes (EB0 + EB1).
The „Standard I/O“ version can transfer and analyze the four input bytes (EB0,EB1,EB2,EB3) as well the
output byte (AB0).
More information regarding the „Extended I/O“ version can be obtained upon request.
The address of individual bus devices can be set via the CBR function keys (refer to Profibus Address
Setting). Each CBR is delivered with the invalid address 127 preselected. However, it is still possible to
operate the burner control unit in manual mode, without a valid Profibus address.
Data transfer (Bytes/Bits) from master (host) to the CBR burner control unit:
Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures
however, remain principally the same. Please contact our sales or engineering department.
Following tables illustrate the data transfer between master (host) and slave (CBR).
Table 1: Output byte (Master →CBR):
Bit Output byte AB0
0 Remote reset (impuls 0,5s)
1 Heat demand
2 Cooling
3 Purge
4 unused
5 Flame mode
6 unused
7 reserved
Table 2: Input bytes (CBR →Master):
Bit EB0 EB1 EB2 EB3
0 Burner operation Manual mode State/Error byte *) Main gas valve ON
1 Burner fault Delta-p switch air 1
(min) Flame gas valve ON
2 Air valve ON Safety chain OK Gas valve FLOX 1 ON
3 Air purge ON Excess temperature,
heating Gas valve FLOX 2 ON
4 Cooling ON Excess temperature
burner head/exhaust Delta-p switch 2 (max)/ exhaust gas thermost.
5 Flame sensed Cooling valve or air/
exhaust valve 1 ON Delta-p switch 3
6 FLOX -mode ON Eductor valve or air/
exhaust valve 2 ON Gas pressure switch
(optional)
7 Heating stand-by Common exhaust flap
ON State/Error byte *) POC switch for main
gas valve (optional)
*) see table 3

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Burner Control CBR
Tab.3: Status byte EB2 – signal reference (CBR →Master):
(In dependence of Bit 1 (EB0) „burner fault“, either the operating status (State) may be analyzed at
„0“ or the fault code may be analyzed at „1“
Byte
(decimal)
Byte
(HEX) Display CBR State Text
0 Fxx 0 Fault – Fault Code
1 01 00 1 Pre-purge
2 02 d3 2 Safety chain interrupted – self resetting
3 03 01 3 Test R1 (Relay SHK is tested for 5 seconds)
4 04 1 4 Watchdog loading phase
5 05 A0 5 Flame: waiting for heat demand
6 06 A1 6 Flame: false flame signal
7 07 A1 7 Flame: idle check air delta-p switch 1
8 08 H1 8 Manual mode pause 1
9 09 A1 9 Flame : air pre-purge
10 0A A1 10 Flame: Ignition on
11 0B A1 11 Flame: Ignition off
12 0C A1 12 Flame: Flame supervision
13 0D A2 13 Flame: minimum time start mode
14 0E A2 14 Flame: Start mode (max 24 h)
15 0F H2 15 Manual mode pause 2
16 10 A3 16 Flame: minimum time flame mode
17 11 A3/H3 17 Flame: Flame operation / manual mode pause
18 12 H4 18 Manual mode pause 3
19 13 A4 19 Flame: Post purge
20 14 A4 20 Flame: Post combustion duration
21 15 A4 21 Flame: Minimum pause flame mode
22 16 b0 22 FLOX: waiting for heat demand
23 17 b1 23 FLOX: idle check air delta-p switch 1
24 18 b2 24 FLOX: air pre-purge
25 19 b2 25 FLOX: Start FLOX mode
26 1A b2 26 FLOX: Minimum time FLOX mode
27 1B H6 27 Manual mode: Pause 4
28 1C b2 28 FLOX: Operation (max. 24h)
29 1D b4 29 FLOX: Post purge
30 1E b4 30 FLOX: Minimum pause FLOX mode
31 1F Pd 31 Air purge: Idle check air delta-p switch 1
32 20 P0 32 Air purge
33 21 d1 33 Excess temperature burner head
34 22 C0 34 Cooling (cooling air)
35 23 d2 35 Start and flame mode not released
36 24 H5 36 Manual mode: Pause 5
37 25 d4 37 False flame during restart attempt