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BCS 300Operation and
assembly instructions
Head offices and factoryKarl Dungs GmbH & Co. KGSiemensstraße 6-10D-73660 Urbach, GermanyTelefon +49 (0)7181-804-0Telefax +49 (0)7181-804-166
Postal addressKarl Dungs GmbH & Co. KGPostfach 12 29D-73602 Schorndorf, Germanye-mail [email protected] www.dungs.com
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Design and operation ..............................................................................................................................................3-22
Actuator drives ...................................................................................................................................................... .23-25
Flame detector .......................................................................................................................................................26-32
Basic settings.........................................................................................................................................................33-62
Power control .........................................................................................................................................................63-65
Fault memory .........................................................................................................................................................66-74
BCS startup with PC-support / BCS-Vision ............................................................................................................75-81
BCS-VISION Overview / application ......................................................................................................................82-95
Table of contentsBCS300
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BCS 300
Burner Control SystemDesign and operation
Product description, characteristics, functions 4Burner configuration / schematic diagram of BCS system 5General notes, technical data 6Block diagram of BCS 7Description of inputs and outputs 8-9Operational status messages / fault messages, selection of system programs 10BCS Gas firing mode - program flow diagrams 11
with ignition valve and 1 or 2 flame detectors, System program 1with ignition valve, 1 or 2 flame detectors and valve leakage control System program 4with ignition valve, 1 or 2 flame detectors and valve leakage control System program 3 12with ignition valve and 1 or 2 flame detectors System program 6with single flame detector (without ignition valve and valve leakage control) System program 2 13with single flame detector and valve leakage control System program 5
Program flow diagram „Controlled shutdown”BCS oil firing mode - program flow diagrams 14
with ignition valve and 1 or 2 flame detectors System program 10with single flame detector (without ignition valve) System program 11Solenoid valve for nozzle linkage and 1 or 2 flame detectors System program 12 15with solenoid valve nozzle linkage and single flame detector System program 13
Program flow diagram „Controlled shutdown” 16Gas valve leakage test (valve proving system) 17Gas valve leakage test - calculation of setting times with MultiBlocs and DMV 18Gas valve leakage test - calculation of setting times with individual solenoid valves 19Functional description of the outputs, general notes and installation instructions 20Functional description of the serial interface (RS 232) 21Dimensions, technical data 22
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Functions
Automatic burner control system suitable for non-permanent operationPermanent operationSteam systems in conformity with TRD
Number ofautomatic burner control programs 10
Valve proving system (VPS) internal
Number of VPS programs 1
Output control standard, run-on
Number of output control programs 2
02-controlwith expansion module EM1 optional
Frequency inverter drive circuitwith expansion module EM1 optional
Stepping motor drive circuits 3
Setting parameters with control unitwith PC
Control unit required for operation no
Product descriptionThe Burner Control System (BCS ) isa modular automatic burner controlsystem for open and closed loop con-trol of oil, gas and dual-fuel burnerswith medium to high output. It con-sists of the following distributed unitswhich intercommunicate via a safety-oriented bus system:
BCS basic modulefor attachment to burner with connec-tivity for:
24 VDC inputs(floating contacts)
- Boiler safety chainOil safety chain- Air pressure switch- Max. gas pressure switch- Min. gas pressure switch- Open-loop control chain- Fuel selection gas/oil- Valve proving system GW VDK- Release heavy oil- Reset
Analog input 4-20 mA- Output controller
230 VAC outputs(3.15 A per output, tot. 6,3 A)
- Solenoid valve, oil feed/return- Nozzle linkage- Ignition gas solenoid valve- Gas solenoid valve 1 (gas side)- Gas solenoid valve 2 (burner side)- Burner motor- Pump motor- Ignition transformers for gas firing
mode- Ignition transformers for oil firing
mode- Load reversal point indication- Fault indication- Gas/oil operation mode indication- Operational status indication
Stepping motors- Actuator drive GAS- Actuator drive OIL- Actuator drive AIR
RS 232- Connection for PC with BCS
visualization software
Flame detector BCS-FLW 05for connecting the following flamesensor:
for permanent operation- Ionization electrode- UV sensor (QRA 53)- Light sensor (RAR 7)- Intrinsically safe flame supervision
device with contact output
for non-permanent operation- UV sensor (QRA 2)
Operating and display unitwith illuminated 4-line LC display, with20 characters per line for startup andplain-text status display.
A mounting frame allows the controlunit to be installed on the front panelof a control cabinet.
Actuator drivesDigitally activated stepping motorswith control electronics.To monitor function and direction ofrotation, a driver with digital feedbackvia an encoder disc is integrated inthe system.
Features
• Open hardware structureExpandability via CAN-bus
• Open software structureincl.. PC interface / service
• software-implemented devices- Automatic burner control system- Gas leakage test- Flame supervision device- Output controller
• Standardized hardware for allexpansion levels
• Simple, menu-prompted systemprogramming
Burner Control SystemDesign and operation
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Burner configuration / schematic diagram of BCS system
DMV Double solenoid valve,solenoid valves on gasside and burner side
FRS Gas pressure controlGF Gas filterGW min. Min. gas pressure switchGW max. Max. gas pressure switchKH Ball valve
LGW Air pressure switchM Blower motorÖl-VL Oil solenoid valve supply lineÖl-RL Oil solenoid valve return lineÖl-D Nozzle linkage valveÖP Oil pumpÖV Oil supply lineÖR Oil return line
FRSKH GF
DMV
PT
M
Z-MV
ST-Öl
ST-GasST-Luft
Öl-Vl Öl-Rl Öl-D
BCS BCSVVisionision
ZT
LGW
5
1015
20
2530
3540
45
50
LGW
11/99 KST
510
15
2025
3035
40
4550
GW 50 A5
Made in GermanyI P 5 4
GWmin.
GWmax.
5
1015
20
2530
3540
45
50
GW
PC
M1
M3
M2
ÖW
ÖR
ÖV
ÖP
UV
.
B BurnerC ControlS System
FlammedetectorFLW 05
CAN-Bus
RS 232
Control unit
Burner Control SystemDesign and operation
ÖW Oil pressure switchPT ControllerST-Öl Oil control valve actuatorST-Gas Gas damper actuatorUV Flame sensorZ-MV Ignition gas solenoid valveZT Ignition transformer
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General notesThe BCS is an automatic burner con-trol system for oil and gas burners withan integrated gas valve proving sys-tem.It meets the following standards interms of its design and function:
• EN 298 Automatic Burner ControlSystems for Gas Burners and GasAppliances with and without Blower
• DINIEC 255• VDE 0435 Electr. Relays• DIN VDE 0700• EN 60730 Safety of El. Equipment
for Domestic Use• prEN 1643 Leak Testing Devices• EN 230 Oil atomizing burners of
monoblock type and all associatedstandards
Installation, startup and maintenancemay only be performed by authorizedspecialist personnel in accordancethe applicable directives and regula-tions:
• TRD 604 Technical Rules for SteamBoilers... without Continuous Sur-veillance
• DIN VDE 0116 Electrical Equipmentof Burners
• DIN VDE 0100 Requirements forErection of Power Installations withCapacities up to 1 kV
• DIN VDE 0101 Requirements forErection of Power Installations withCapacities over 1 kV
• DIN VDE 0160 Equipment of PowerInstallations with Electronic Devices
• TRD 411 - 414, Technical Rules forSteam Boilers ...-Burners on SteamBoilers
• DIN VDE 0631; EN 60730Special Requirements for Auto-matic, Electrical Burner Control andMonitoring Systems
• DINIEC 68 Environmental Tests• Potential Equalization in accordance
with EN60204-1, 8 must be ensured• Bus lines and lines conducting sup-
ply voltage must be laid separately• BCS lines and lines of electrical
equipment which generates highfrequency signals with a high level(e.g. frequency inverters, ignitiondevices etc.) must be laid sepa-rately. Attention must be paid to thephysical distance between BCSand above equipment.
Burner Control SystemDesign and operation
CAN Controller Area Networkensures- high availability- maximum safety- good cost-performance ratio- network extension to 1000 m at 25 kBit/s- message prioritization- standardization to ISO / DIS 11898- hardware implementation on microprocessor
The safety periods of theautomatic burner control
system cannot be changed by op-erating personnel. It is not permit-ted to extend these periods by us-ing external switching measures!
The manufacturer shall notbe liable for damages arising
due to the following reasons:• improper use• faulty installation or correctivemaintenance by the purchaser orthird party incl. installation of non-original parts
• Electrical equipment in the immedi-ate vicinity of the BCS must beequipped with suitable interferencesuppression devices.
• BCS activated switching elementsand actuators must, if necessary, beequipped with suitable interferencesuppression devices
Technical dataOperating voltage 230 V (+10%/-15%)Frequency 50...60 HzClass of protection II as per VDE 0660, EN 493-1Electrical switching cycles as per EN 298Mechanical switching cycles as per TRD 604Contact rating 3.15 A as per EN 298Analog input load impedance 25 OhmBack-up fuse max. 10 A (slow-acting)Equipment fuse 6.3 A (slow-acting)
0,1 A (slow-acting)Interference immunity EN 298Emission EN 50011 Class A
150 kHz - 1 GHzMax. permissible ambient temperatures
Storage - 20°C … + 70°COperation 0°C … + 60°C
Degree of protection provided byenclosure (EN 60529)BCS basic unit Enclosure IP 40, terminals IP 20Display and control unit Enclosure IP 54, terminals IP 20BCS-FLW 05, flame detector Enclosure IP 40, terminals IP 20
IP 40 must be provided by installation.Installation position: anyTerminals 2 x 1.5 mm or 1 x 2.5 mm, withdrawablePower consumptionBCS (incl. control unit) < 10 VAFLW 05 < 1.5 VABus topology due to the low transfer rate, the bus can
have a linear or radial configuration.
Classifications of the F B L L B Bautomatic burner control system
• The screen of the bus line must beconnected to the PE potential atboth ends of the cable. Care mustbe taken to ensure that there is nopotential difference between thescreen ends (see Potential equali-zation)
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Block diagram of BCS
P1NLPE
P1NLPE
Ist mA4…20
CAN
MGAS
M OIL
M AIR
Servomotors
Line voltage 230 VAC
14 VA powersupply unit
Oil valves
Ignition valve
Nozzlelinkage
Safety gasvalve
Main gasvalve
Ignitiontransformergas
Ignitiontransformeroil
Blowermotor
Oil pumpmotorGas/oil
Operation
LoadreversalFault
Outputs 230 VAC
20 VDC inputs
Control chainFuel type selection(GAS / OIL)Reset
GND
GW 1/2
GND
Boilersafety chain
Releaseheavy oilGND
Oilsafety chain
Air pressureswitch
Max. gaspressure switch
Min. gaspressure switch
Output controller4…20 mA
WD
RIN
CH
CL
GND
CAN
Control Unit
RS 232
PC
I/O m
odul
es
I/O m
odul
es
Saf
ety
com
pute
r 1
Saf
ety
com
pute
r 2
Net
wor
k co
mpu
ter
AutomaticburnercontrolsystemGAS
AutomaticburnercontrolsystemOIL
outputcontrol
Gas valveprovingsystem
Combinedfuel and airregulation
DDC
Systembus
P1NLPE
GW W R
GND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12
L1
PE
N
F1
F2
F3
F4
F5
F6
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
Flammedetector
Flammen-wächter
BCS
BCS
Burner
Control
System
GAS
Automatenprogramm Gasbetrieb Nr. => 1Enter Info
ÖL
F1 F2 F3
M P
R
BCS BCSVVisionision
EA
SA
EB
SB
OK
WD
GN
D
AA
MA
AB
MB
EA
SA
EB
SB
OK
WD
GN
D
AA
MA
AB
MB
EA
SA
EB
SB
OK
WD
GN
D
AA
MA
AB
MB
s
s
s
s
s
s
s
s
s
s
s
s
BCS
04/99 KST
P3
P2
P3
P2
P3
P2
Burner Control SystemDesign and operation
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BCS hardware
EPROMsafetycomputer
EPROMsafetycomputer
EPROMnetworkcomputer
Functional description of the inputsand outputs
InputsAll inputs are rated for 24 VDC.
Burner „on“ (open-loop controlchain)Terminals 1/4If no signal is applied, the burner doesnot come on when a control requestis issued. If the signal is canceledduring operation, an immediate shut-down follows.
Fuel type selection (oil / gas)Terminals 2/4Active = Oil firing modeIf the fuel type is changed over dur-ing operation, the system switches tolow load, shuts down, changes fueltype and restarts.
ResetTerminals 3/4To reset or unlock the system, pressthe Reset key.
Gas valve leakage test (GW VDK)Terminals 5/6see Program flow - leakage test.
Heavy oil release signalTerminals 7/8The contact is interrogated in the sys-tem program „oil firing with solenoidvalve nozzle linkage“ (Oil firing modewith solenoid valve nozzle linkage).Before the solenoid valve nozzle link-
Burner Control SystemDesign and operation
age opens, the contact must beclosed. If the contact is not closed,the system waits.The maximum waiting time is 45 s. Thewaiting time begins when the feed/re-turn solenoid valves open.If the contact is still open after thewaiting time expires, the system inter-locks.During the operational phase, open-ing of the contacts leads to a fault lock-out and a corresponding fault mes-sage is displayed in plain text.If the input is not required, terminals 7and 8 must be bridged.
Boiler safety chainTerminals 9/10Supervision period:from burner „ON“ (open-loop controlchain) until closing of fuel valves. Ifthe input is open for longer than 100ms during this period, the system in-terlocks.
Oil safety chainTerminals 11/12Supervision period:before opening of the oil valves andthen from 1 s after the start of the firstsafety period until closing of the oilvalves.If the input is open for longer than 1ms, the system interlocks after astartup.
Air pressure switchTerminals 13/14After 30% of the preventilation periodhas expired, the air pressure switchmust respond. If the contact of the airpressure switch is closed during theLDW idle state check,the system waits for max. 60 s andthen interlocks.LDW Idle state check = contact openbefore blower start.
„Max“ gas pressure switchTerminals 15/16Supervision period: before opening ofthe gas valves until closing of the gasvalves.If GWmax is opened during the su-pervision period, the system interlocksafter a startup (the contact opens).
„Min“ gas pressure switchTerminals 17/18When the contact opens (after con-troller „ON“), the burner shuts downimmediately (display).If the gas pressure switch opens morethan 4 times within 1 hour, a lockoutfollows.The contact is not interrogated duringthe 1st safety period or 2nd safetyperiod.
Output controller 4…20mATerminals 19/20for a floating sensor. Resolution: 8 bit.
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Burner Control SystemDesign and operation
OutputsAll outputs are implemented as 230VAC signals.
Terminals 4/5/6Oil solenoid valve feed/returnsee program flows
Terminals 7/8/9Nozzle linkagesee program flows
Terminals 10/11/12Ignition gas solenoid valvesee program flows
Terminals 13/14/15Gas solenoid valve (gas side)see program flows
Terminals 16/17/18Gas solenoid valve (burner side)see program flows
Terminals 19/20/21Ignition transformer for gas firingmodeThe ignition transformer for gas firingmode is switched on after the „igni-tion“ (Ignition) feedback signal is re-ceived. The signal is canceled shortlybefore the end of the 1st safety pe-riod.see program flows
Terminals 22/23/24Ignition transformer for oil firingmodeThe ignition transformer oil is switchedon after the „ignition“ (Ignition) feed-back signal is received. The signal iscanceled shortly before the end of the1st safety period.see program flows
Terminals 25Pump motor (oil pump)see program flows
Terminals 26Indication of gas/oil operatingmodeThe output is set when the fuel type„Oil“ is selected. The output is setwhen the fuel type „Gas“ is selected.This state also exists after changesare effected in the menu -M- or -P- forexample.
Terminals 27Indication of operationThe output is set from:end of safety period of automaticburner control programs until: shut-down of fuel feed.
Terminals 28Burner motor (blower)see program flows
Terminals 29Indication of load reversal pointThe output is set or not set in depend-ence on load points 1 to 100.
Terminals 30Indication of faultIf a lockout occurs, an external faultindicator lamp comes on.
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Actuator drive received no „ready“ signal
Heavy oil release open
Flame failure
Main flame signal during preventilation period
Ignition flame signal during preventilation period
Stabilization period after ignition flame failure
No ignition flame signal after safety period
No main flame signal after safety period
LDW switched prior to startup
LDW not switched during preventilation period
LDW deficiency of air during operation
Gas pressure missing
Gas-side valve defective
Burner-side valve defective
Flame simulation supervision after shutdown
Gas max.
Oil safety chain
Ignition flame failure
Boiler safety chain
Controller signal < 3.5 mA
Operational status messages / fault messagesAll fault messages of the user program are displayed in plain text.
System program selectionAutomatic burner control programs for gas firing modeSystem program No.:1 1 or 2 flame detectors, with ignition valve, special
features: none
2 1 flame detector, without ignition valve, special fea-tures: none
3 Valve proving system, 1 or 2 flame detectors, withignition valve, special features: ignition gas take-off before valve on gas side. The valve on the gasside opens 5 s earlier than the valve on the burnerside
4 Valve proving system, 1 or 2 flame detectors, withignition valve,special features: ignition gas takeoff betweenvalves on gas side and burner side. The valve onthe gas side opens with ignition gas valve earlierthan the valve on the burner side
5 Valve proving system, 1 flame detector, withoutignition gas valve, special features:The valve on the gas side opens 5 s earlier thanthe valve on the burner side
6 2 flame detectors, with ignition gas valve, specialfeatures: monitoring of the ignition flame and mainflame during operation.
Automatic burner control programs for oil firing modeSystem program No.:10 1 or 2 flame detectors, with ignition valve without
nozzle linkage supervision (DG)Special features: none
11 1 flame sensor, without ignition valve without DG,special features: none
12 1 or 2 flame detectors, with ignition valve and DG,special features: the feed/return solenoid valvesopen at the end of the pre-ignition phase
13 1 or 2 flame detectors, without ignition valve, withDG,Special features: the feed/return solenoid valvesopen at the start of the pre-ignition phase.
Valve proving system program
Valve test prior to burner startup with gas valves
Burner Control SystemDesign and operation
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BCS Gas firing mode System program 1
Program flow diagram with ignition valve and 1 or 2 flame detectors(without valve leakage control)
BCS Gas firing mode System program 4Program flow diagram with ignition valve, 1 or 2 flame detectors and valve leakage control(ignition gas takeoff between safety valve and main gas valve)
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 1…250st 4 Air pressure switch must actuate after 30%
of the preventilation period has expiredt 5 Start of ignition feedback 0…250st 6 Pre-ignition 0…30st 7 Ignition 2st 8 1st safety period 3st 9 Stabilization period of ignition flame 0…10s
Safety period for ignition valve operation <1s=t 14t 10 within the period t 10 2s
Safety period for ignition valve operation <1s=t 14t 11 2nd safety period 3st 12 within the period
t 12 Safety periodMain valve operation <1s=t 14
t 13 Control release delay timet 14 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 5
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 1…250st 4 Air pressure switch must actuate after 30% of
the preventilation period has expiredt 5 Start of ignition feedback 0…250st 6 Pre-ignition 0…30st 7 Ignition 2st 8 1st safety period 3st 9 Stabilization period of ignition flame 0…10s
Safety period for ignition valve operation <1s=t 14t 10 within the period t 10 2s
Safety period for ignition valve operation <1s=t 14t 11 2nd safety period 3st 12 within the period
t 12 Safety periodMain valve operation <1s=t 14
t 13 Control release delay timet 14 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 5
Control chain
Servomotors
Blower motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 6
t 8
t 10
t 11
t 13 t 14
t 1
t 12
t 9
t 7
t 4 t 5
t 3
Flamefailure
FaultlockoutBCS-G 2
Control chain
Servomotors
Blower motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 6
t 8
t 10
t 11
t 13 t 14
t 1
t 12
t 9
t 7
t 4 t 5
t 3
Flamefailure
FaultlockoutBCS-G 1
Burner Control SystemDesign and operation
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BCS Gas firing mode System program 3
Program flow diagram with ignition valve, 1 or 2 flame detectors and valve leakage control(ignition gas takeoff before safety gas valve)
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 1…250st 4 Air pressure switch must actuate after 30%
of the preventilation period has expiredt 5 Start of ignition feedback 0…250st 6 Pre-ignition 0…30st 7 Ignition 2st 8 1st safety period 3st 9 Stabilization period of ignition flame 0…10s
Safety period for ignition valve operation <1s=t 15t 10 Period 5s
Safety period for ignition valve operation <1s=t 15t 11 within the period t 11 2s
Safety period for ignition valve operation <1s=t 15t 12 2nd safety period 3st 13 within the period
t 13 safety periodMain valve operation <1s=t 15
t 14 Control release delay timet 15 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 5
Control chain
Servomotors
Blower motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 6
t 8
t 10
t 11
t 13 t 14
t 1
t 12
t 9
t 7
t 4 t 5
t 3
Flamefailure
Faultlockout
Flamefailure
t 15
BCS-G 4
Control chain
Exhaust gas damper
Servomotors
Blower motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 6
t 8
t 10
t 12
t 14 t 15
t 1
t 13
t 9
t 7
t 4 t 5
t 3
Flamefailure
Faultlockout
t 11
BCS-G 3
Burner Control SystemDesign and operation
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 1…250st 4 Air pressure switch must actuate after 30%
of the preventilation period has expiredt 5 Start of ignition feedback 0…250st 6 Pre-ignition 0…30st 7 Ignition 2st 8 1st safety period 3st 9 Stabilization period of ignition flame 0…10s
Safety period for ignition valve operation <1s=t 14t 10 within the period t 10 2s
Safety period for ignition valve operation <1s=t 14t 11 2nd safety period 3st 12 within the period t 12: safety period
Ignition valve/main valve operation <1s=t 14t 13 Control release delay timet 14 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 5
t 15 Safety period for ignition flame detectoroperation <1s
BCS Gas firing mode System program 6
Program flow diagram with ignition valve and 2 flame detectors,ignition flame supervision during operation
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BCS Gas firing mode System program 2
Program flow diagram with single flame detector(without ignition valve and valve leakage control)
BCS Gas firing mode System program 5
Program flow diagram with single flame detector and valve leakage controlSafety valve opens before main gas valve (without ignition valve)
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 1…250st 4 Air pressure switch must actuate after 30% of
the preventilation period has expiredt 5 Start of ignition feedback 0…250st 6 Pre-ignition 0…30st 6´ Period 5st 7 Ignition 2st 8 1st safety period 3st 9 within the period
t 9 Safety periodMain valve operation <1s=t 11
t 10 Control release delay timet 11 Safety period of flame detector <1s
Duration of flame simulation supervisionfrom the end of t 4 until the start of t 5
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 1…250st 4 Air pressure switch must actuate after 30%
of the preventilation period has expiredt 5 Start of ignition feedback 0…250st 6 Pre-ignition 0…30st 7 Ignition 2st 8 1st safety period 3st 9 within the period
t 9 Safety periodMain valve operation <1s=t 11
t 10 Control release delay timet 11 Safety period of flame detector <1s
Duration of flame simulation supervisionfrom the end of t 4 until the start of t 5
Program flow diagram „Regelabschaltung” (Controlled shutdown)
Legend of time sequence chartt 20 Post-vent period 1…250st 21 Valve on burner side closes 2s
after valve ongas side to evaluate test section
t 22 Flame simulation monitoring 0…50safter controlled shut-down
Control chain
Exhaust gas damper
Servomotors
Blower motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 22
t 20
t 21
BCS-G 7
Faultlockout
Control chain
Servomotors
Blower motor
Air pressure switch
Ignition
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 6
t 8
t 10 t 11
t 1
t 9
t 6´
t 4 t 5
t 3
Flamefailure
t 7
BCS-G 6
Control chain
Servomotors
Blower motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Safety gas valve
Burner gas valve
Main flame detector
Output controllerModulation
t 6
t 8
t 10 t 11
t 1
t 9
t 7
t 4 t 5
t 3
Flamefailure
FaultlockoutBCS-G 5
Burner Control SystemDesign and operation
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BCS Oil firing mode System program 11
Program flow diagram with single flame detector(without ignition valve)
BCS Oil firing mode System program 10
Program flow diagram with ignition valve and 1 or 2 flame detectors
Legend of time sequence chartt 1 Air damper delay time 0…60s(star delta changeover)t 3 Preventilation period 15…250st 4 Idle state check of air pressure switch
(30% of preventilation period)t 6 Pre-ignition 0…30st 7 Ignition 4st 8 1st safety period 5st 9 Stabilization period of ignition flame 0…10s
Safety period for ignition valve operation <1s=t 14t 10 within the period t 10 4s
Safety period for ignition valve operation <1s=t 14t 11 2nd safety period 5st 12 within the period
t 12 safety periodMain valve operation <1s= t 14
t 13 Control release delay timet 14 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 6
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 5…250st 4 Idle state check of air pressure switch
(30% of preventilation period)t 6 Pre-ignition 0…30st 7 Ignition 4st 8 1st safety period 5st 9 within the period
t 9 safety periodMain valve operation <1s=t 11
t 10 Control release delay timet 11 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 6
Faultlockout
t 6
t 8
t 10
t 11
t 13 t 14
t 1
t 12
t 9
t 7
t 4
t 3
Flamefailure
Control chain
Oil safety chain
Servomotors
Blower motor
Oil pump motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Feed/returnsolenoid valve
Main flame detector
Output controllerModulation
BCS Oil firing mode 10
t 11.1
Faultlockout
t 6
t 8
t 10 t 11
t 1
t 9
t 7
t 4
t 3
Flamefailure
Control chain
Oil safety chain
Servomotors
Blower motor
Oil pump motor
Air pressure switch
Ignition
Feed/returnsolenoid valve
Main flame detector
Output controllerModulation
BCS Oil firing mode 11
t 8.1
Burner Control SystemDesign and operation
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BCS Oil firing mode System program 13
Program flow diagram with solenoid valve of nozzle linkageand single flame detector (without ignition valve)
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 15…250st 4 Idle state check of air pressure switch
(30% of preventilation period)t 6 Pre-ignition 0…30st 7 Ignition 4st 8 1st safety period 5st 9 Stabilization period of ignition flame 0…10st 9.1Thermostat release signal for heavy oil
operation(EL => input bridged)max. 45s (t 9.1 = 45s -t8 - t9) Safety period for ignition valveoperation <1s=t 14
t 10 within the period t 10 4sSafety period for ignition valve operation <1s=t 14
t 11 2nd safety period 5st 12 within the period
t 12 safety periodMain valve operation <1s=t 14
t 13 Control release delay timet 14 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 6
Legend of time sequence chartt 1 Air damper delay time 0…60s
(star delta changeover)t 3 Preventilation period 15…250st 4 Idle state check of air pressure switch
(30% of preventilation period)t 6 Pre-ignition 0…30st 6.1Thermostat release signal for heavy oil
operation (EL => input bridged)max. 45s (t6.1 = 45s -t6)
t 7 Ignition 4st 8 1st safety period 5st 9 within the period
t 9 safety periodMain valve operation <1s=t 11
t 10 Control release delay timet 11 Safety period of flame detector <1s
Duration of flame simulation supervision fromthe end of t 4 until the start of t 6
BCS Oil firing mode System program 12
Program flow diagram with ignition valve,Solenoid valve for nozzle linkage and 1 or 2 flame detectors
Faultlockout
t 6
t 8
t 10
t 11
t 13 t 14
t 1
t 12
t 9
t 7
t 4
t 3
Flamefailure
Control chain
Oil safety chain
Servomotors
Blower motor
Oil pump motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Feed/returnsolenoid valveNozzle linkage MV
Main flame detector
Output controllerModulation
BCS Oil firing mode 12
t 11.1
t 9.1
Faultlockout
t 6
t 8
t 10 t 11
t 1
t 9
t 7
t 4
t 3
Flamefailure
Control chain
Oil safety chain
Servomotors
Blower motor
Oil pump motor
Air pressure switch
Ignition
Ignition valve
Ignition flame detector
Feed/returnsolenoid valveNozzle linkage MV
Main flame detector
Output controllerModulation
BCS Oil firing mode 13
t 8.1
t 6.1
Burner Control SystemDesign and operation
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Burner Control SystemDesign and operation
Program flow diagram „Controlled shutdown”
Legend of time sequence chartt 20 Postventilation period 1…250st 21 Flame simulation supervision 0…50s
after controlled shutdown
t 21
t 20
Control chain
Servomotors
Blower motor
Air pressure switch
Feed/returnsolenoid valveNozzle linkage MV
Main flame detector
Output controllerModulation
BCS Oil firing mode 0
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Gas valve leakage test (valve provingsystem)
The leakage test is only performed in gasfiring mode during the preventilation pe-riod prior to burner startup. If no leakageis detected, burner startup is enabled. Ifa leakage is detected, the BCS remainslocked out.
The leakage test, in connection with gaspressure switch GW VDK, serves to checkthe soundness of two gas solenoid valvesconnected in series.
The valve on the gas inlet side (safety so-lenoid valve) is tested by evacuating thetest section and monitoring the increasein pressure. The valve on the burner side(main valve) is tested by filling the testsection and monitoring the decrease inpressure.
If the pressure rises above the max. per-missible value during the first test phaseor drops below the min. permissible valueduring the second test phase, the systeminterlocks and inhibits burner startup.
Operational sequence and programflow - leakage test
The distance between the two gas valves- from valve seat to valve seat - is de-scribed as the „test section“. All parts lo-cated within the test section, such as pres-sure switch, tubes, glands etc., are testedsimultaneously for leakage.
This test is performed at burner startup intwo phases:
1. Testing of valve on gas inlet side(MV 1)
2. Testing of valve on burner side (MV 2).
The test phase prior to burner startup be-gins with the preventilation period, andelapses in parallel with the preventilationperiod.If the preventilation period is shorter thanthe leakage test phase, the system waitsuntil the end of the test phase.If the test is conducted prior to burnerstartup, valve MV 2 is opened for 3 s whenthe controller is switched on.The pressure by test section drops to at-mospheric pressure or combustion cham-ber pressure.
During the variable test period from 3…30s, the pressure in the test section must notexceed the operating point of the GWVDK.
If this nevertheless occurs due to a leak-age of gas valve MV 1, the BCS interlocksin the fault state. A fault message is nowdisplayed.
After the end of a trouble-free first testphase, valve MV1 is opened for 3 s. Thetest section is subjected to gas pressureand the second test phase commences.
During the following test period, the pres-sure in the test section must not drop be-low the operating point of the GW VDK.
If the pressure drops due to a leakage ingas valve MV 2, the GW VDK is activated.
The BCS interlocks and enters the faultstate. A fault message indicating whichsolenoid valve is leaky now appears.
Burner Control SystemDesign and operation
Internal valve proving systemTest prior to burner startup (with fuel valves only)
MV 1 Gas valve on gas side (safety solenoid valve)MV 2 Gas valve on burner side (burner solenoid valve)GW VDK pressure switchTest section
BCS
MV 1 MV 2
GW 1/2
Outputs13/14/15
Inputs5/6 -GW 1/2
Outputs16/17/18
Schematic diagram Legend of sequence of operations
Zeit Function Fault messaget 1 Vent (3s)t 2 Test (3…30s) MV 1 leaky,
gas pressure set too hight 3 Fill (3s)t 4 Test (3…30s) MV 2 leakyafter start release ort 4 IgnitionControlled shutdown: MV 2 closes 2 s later than MV 1
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Pa (mbar) Gas pressure at GW VDKSetting value of pressure switch Pa /2.
Model calculation (1, 2):
Pa = 40 mbarSetting value of GW VDK 20 mbar
Vp = 1,7 dm3 (DMV…5080)
t2 or t4 (s) 40 • 1,7 • 3 / 275 = 0,74 sor t2 or t4 = 1 s.
Gas valve leakage testCalculation of setting time t 2 or t 4 with MultiBloc and DMV
Pe (mbar) Gas pressure at GW VDKSetting value of pressure switch Pe /2.
Model calculation (3):
Pe = 100 mbarSetting value of GW VDK 50 mbar
Vp = 1,7 dm3 (DMV…5080)
t2 or t4 (s) 100 • 1,7 • 3 / 745 = 0,68 sor t2 or t4 = 1 s.
Gas pressure control devicedownstream of DMV
Vp (dm3) Volume between gas valves to be moni-tored (test volume).In the case of double solenoid valves(DMV), the valve volume is a product of V1(outlet end) and V2 (inlet end).
3 Factor for conversion value, dimensionsand safety allowance.
Qp (dm3) Leakage rate as per EN 1643.Where V (gas flow rate) is equal to or<50 m3/h is Qp = 50 dm3, where > 50 m3/hQp = 0.1% of the gas flow rate at max.burner capacity, e. g.275 m3/h • 0.1 = 0.275 m3/h (275 dm3/h)
t2 or t4 (s) test time to be set (in seconds). The calcu-lated value applies to test time t2 or t4.Both times must be set to the same value!(according to input in level 3)
Test volume Vp The test volumes of DUNGS double sole-noid valves and MultiBlocs are specified inthe following table.
Fitting Test volume (dm 3)Threaded connection Rp Flange connection DN1 11/4 11/2 2 21/2 40 50 65 80 100 125 150 200
Double solenoid valvesDMV…5… 0,25 0,25 0,25 0,6 0,36 0,36 0,6 1,7 2,3 3,75
Multiple actuatorsMB-…4… 0,25 0,28 0,25 0,25 0,6DMV-SE…5… 0,25 0,25 0,25 0,6 0,36 0,36 0,6 1,7 2,3 3,75DMV-VEF…5… 0,25 0,25 0,25 0,6 0,36 0,36 0,6 1,7 2,3 3,75
Double solenoid valves and MultiBlocs (MB-DLE, MB-VEF)
1
Pa Vp
GW VDK= Pa/2
MB… 3
Pe Vp
GW VDK= Pe/2
FRSDMV2 GW VDK= Pa/2
Pa Vp
FRS DMV
Burner Control SystemDesign and operation
Multiblock Gas pressure controldevice upstream of DMV
t2 = t4 = Pa • Vp • 3/Qp t2 = t4 = Pe • Vp • 3/Qp
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Pa (mbar) Gas pressure at GW VDKSetting value of pressure switch Pa /2.
Model calculation (4):
Pa = 40 mbarSetting value of GW VDK 20 mbar
Vp = 3,8 dm3 (MV…2080) + 0,25 m Tube= 1,25 dm3
t2 or t4 (s) 40 • (3,8 + 1,25) • 3 / 275 = 2,2 sor t2 or t4 = 3 s.
Gas valve leakage testCalculation of setting time t 2 or t 4 with individual solenoid valves
Pe (mbar) Gas pressure at GW VDKSetting value of pressure switch Pe /2.
Model calculation (5):
Pe = 100 mbarSetting value of GW VDK 50 mbar
Vp = 3,8 dm3 (MV…2080) + 0,25 m Tube= 1,25 dm3
t2 or t4 (s) 100 • (3,8 + 1,25) • 3 / 745 = 2,03 sor t2 or t4 = 3 s.
Gas pressure control downstream of the gas valves
Vp (dm3) Volume between gas valves to be moni-tored (test volume).In the case of double solenoid valves(DMV), the valve volume is a product of V1(outlet end) and V2 (inlet end).
3 Factor for conversion value, dimensionsand safety allowance.
Qp (dm3) Leakage rate as per EN 1643.Where V (gas flow rate) is equal to or< 50 m3/h is Qp = 50 dm3.where > 50 m3/hQp = 0.1% of the gas flow rate at max.burner output, e. g.275 m3/h • 0.1=0.275 m3/h (275 dm3/h)
t2 or t4 (s) test time to be set (in seconds). The calcu-lated value applies to test time t2 or t4.Both times must be set to the same value!(according to input in level 3)
Test volume Vp The test volumes of DUNGS double sole-noid valves and MultiBlocs are specified inthe following table.
Individual solenoid valves and pipe work
4FRS V1 V2
Pa Vp
GW VDK= Pa/2
5FRSV1 V2
Pe Vp
GW VDK= Pe/2
Burner Control SystemDesign and operation
Gas pressure control upstream of the gas valves
t2 = t4 = Pa • Vp • 3/Qp t2 = t4 = Pe • Vp • 3/Qp
Test volume (dm 3)Threaded connection Rp Flange connection DN1 11/4 11/2 2 21/2 40 50 65 80 100 125 150 200
Solenoid valvesMV…2/5… 0,2 0,5 0,9 1,3 0,7 1,2 2,0 3,8 6,5 12,5 17,7 46,0
Pipe workVolume dm3/m 0,5 0,9 1,3 2,0 4,0 1,3 2,0 3,3 5,0 7,9 12,3 17,7 31,4
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Relay or contactor terminalsIf a relay or contactor is connected tothe output terminals
26 Gas / oil indication27 Operation message29 Load reversal point30 Fault message,
then the matching RC combinationmust be provided for these compo-nents.
RS-232 interfaceIf the RS-232 interface or the controlunit is not used, the connectors mustbe sealed with the designated pro-tective caps.The connected PC is required to havea GS mark of conformity.
General notes and installation instructions
Pressing the „M“ or „P“ keys dur-ing operation
If the „M“ or „P“ key is pressed dur-ing the burner operation phase,
the relevant LED flashes but the pro-gram points of levels 0, 1, 2 and 3 arenot selected.
If the „M“ or „P“ key is pressed byaccident during operation,
the operating keymust be pressedimmediately .
The LED of the „M“ key or „P“ key thenstops flashing.
If this is not done, the burner remainsin „M“ mode or „P“ mode after an„OFF“ command is issued. Theburner cannot be restarted until the„Operation“ key is pressed .
M P
Changing settingsOn completion of each setting, thechanged curves must be retested:GAS —> Test gas curve „i“ in
Level 2OIL —> Test oil curve „i“ in
Level 2
Burner Control SystemDesign and operation
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Functional description of the serialinterface (RS 232)A PC can be connected to the serialinterface during the setting phase ofthe BCS 300 (Level 2) .
During the operation phase, a proc-ess control system can be connectedvia the RS 232-interface. The processcontrol system can retrieve or sendinformation from the BCS 300.
None of the data interchanged is rel-evant to safety.
The data interchange will be de-scribed in a separate protocol (onrequest). The connection to a proc-ess control system will be describedin greater detail in the following.
Settings of theRS 232 interface• Transfer rate: 2400 Baud• NO PARITY• 1 start bit• 1 stop bit• 8 data bit• no hand-shake• max. distance: 15 m
Settings of the BCS 300• Setting: controller type 2
(run-on controller)• Input of terminal 1 (Burner ON)
must remain open• Input of terminal 2 (Fuel selection)
must remain open• During the setting phase, the
connection must be broken(unplug interface connector )
Data interchangeProcess control system to BCS300The data from the process controlsystem are:• controller values (1…100)
1 = Min. load100 = Max. load
• Fuel type selection (gas or oil)• Burner ON (burner ON or OFF)
The input data should be sent cycli-cally, e.g. every 15 s.Each message is mirrored immedi-ately by the BCS.If no reply is sent within 1 second, themessage must be repeated afterapprox. 1 s. (shutdown of BCS in >30 s with error code 47)
Data interchangeBCS 300 to the process control sys-temAll incoming messages are immedi-ately mirrored to the process controlsystem. This procedure allows theprocess control system to check theconnection to the BCS.
If a change of state occurs (e. g. fault),the BCS immediately sends a mes-sage to the process control system.
The following information is sent to theprocess control system:• Mirroring of Input data• Operating states• Fault• Flame intensity.
Burner Control SystemDesign and operation
RS 232
BCS 300
RS 232
Process controlsystem
<---->15 m
Modem by-pass cable
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Technical data of BCS 300
Operating voltage 230 V (+10%/-15%)Frequency 50...60 HzClass of protection as per VDE 0660. EN 493-1Electrical switching cycles as per EN 298Mechanical switching cycles as per TRD 604Contact rating 3.15 A as per EN 298Analog input load impedance 25 OhmBack-up fuse max. 10 A (slow-acting)Equipment fuse 6.3 A (slow-acting)
0.1 A (slow-acting)Interference immunity EN 298Emission EN 50011 Class A, 150 kHz - 1 GHz
Max. permissible ambient temperatures Storage - 20°C … + 70°C Operation 0°C … + 60°C
Degree of protection provided by enclosure (EN 60529)BCS basic unit Enclosure IP 40, terminals IP 20Display and control unit Enclosure IP 54, terminals IP 20BCS-FLW 05, flame detector IP 40 must be provided by installa-tion.
Installation position: anyTerminals, withdrawable 2 x 1.5 mm or 1 x 2.5 mm
Power consumptions < 10 VABCS (incl. control unit) < 1,5 VAFLW 05
Bus topology Due to the low transfer rate, the buscan have a linear or radial configuration.
Classifications of automatic F B L L B Bburner control system
Dimensions ofBCS 300
4,2256
180
190
60
176
5
Handbediengerät PC-Daten RS 232
Ext. Vorsicherung max. 10 A flink
Max. Strombelastung
der ~(AC) 230 V Ausgänge 3,15 A
Netzspannung ~(AC) 230 V + 10 % - 15 %
Netzfrequenz 50 Hz - 6 % … 60 Hz + 6 %
Leistung unbegrenzt
Startlast < 120 kW
Sicherheitszeit < 5 s / 3 s / 1 s
Vorspülzeit 1 s … 250 s
Pmax. 5 bar
Schutzart IP 20
Zul. Umgebungstemperatur
Betrieb 0 °C … + 60 °CLagerung - 20 °C … + 60 °C
Art.-Nr. EE1023
Geräte-Nr. Muster
DIN Reg. xxxxxxxx DB
DIN-DVGW-Reg. xx.xx
für DG DB
CE-xxxx xx xxxx
Karl Dungs GmbH & Co.
D-73660 Urbach
Made in Germany
Handheld control unit
Flame detector FLW 05
Burner Control SystemDesign and operation
ÖL
BCS
Burner
Control
System
GAS
Automatenprogramm Gasbetrieb Nr. => 1Enter Info
200
112
31
F1 F2 F3
M P
R
46
114
78
130
106
9
4,2
X 2X 1
Technical data of actuator drive SAD 15.0
Max. torque: 15 NmActuating times (at 200 Hz) 22,3 s/90°Supply voltage 230 VAC +10/-15%, 50 HzDegree of protection IP 54Shaft, flattened ø 12h8with cylindrical pin DIN 6325-4 m6 x 30Ambient temperaturefor an ON period of 50 s/5 min -20 °C to +60 °Cand in energized wait state from -10 °Cat initial startup
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Burner Control SystemActuator drives
Actuator drives SAD 15.0 – Description of stepping motorElectronic actuator driveTechnical dataAmbient conditionsConnectionSettingsZero positionDimensions
24 24 24 24 25 25 25 25
SAD 15.0
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Actuator drives SAD 15.0The electronic BCS combined controlsystem uses digitally activated step-ping motors which offer major advan-tages over conventional synchronousmotors (with feedback potentiome-ter):• Precise positioning thanks to de-
fined fuel-air steps for each pointon the curve
• Hysteresis free (backlash compen-sation through external load)
• Positioning accuracy is independ-ent of potentiometer quality andservice life.
The actuator drive consists of thestepping motor and control electron-ics.Operation and direction of rotation aresupervised by an integrated driverwithdigital feedback via an encoder disc.
Digital feedback signals• Supervision of the mechanical and
electrical systems by a two-chan-nel optical incremental encoder witha resolution of 1.0° referred to theoutput shaft (50 steps).
• Reference point for defining themechanical zero position of the out-put shaft.This reference pulse need not agreewith the zero position of the damp-er (an offset is permitted).
Electronic actuator driveThe electronics consist of a drivemodule for the stepping motor with A-B interface, components for inde-pendent supply and electronics forfeedback. The actuator drive elec-tronics are connected to the BCS and,like the BCS, are connected to linepotential.The max. length of the cable betweenthe BCS and the actuator drive is 20m.The complete system burner is re-quired to meet the applicable EMCrequirements.
Technical dataMax. torque 15 NmGear reduction ratio 745:1Actuating times (at 200 Hz) 22.3 s/90°Positioning accuracy < +/- 0.3°Direction of rotation anticlockwise towards input shaft
as seen from the zero referencemark after 90°
Angular resolution stepping motor 0.02°Rotation monitoring 1°
Backlash compensation through external load(air flow to flap, spring)Pretensioning force: 0.6 Nm
Supply voltage 230 VAC +10/-15%, 50 HzCurrent reduction 20 ms +/-30%
after last stepDegree of protection IP 54Shaft, flattened ø 12h8with cylindrical pin DIN 6325-4 m6 x 30Weight 1.50 kg
Ambient conditions during operation, storage and transportationAmbient temperature with a switch-onduration of 50 s/5 min and in energizedwait state, -20°C to +60°Cat initial startup from -10°CMoisture condensation is not permittedTransportation and storage temperature -40°C to 70°COscillatory stress 10 Hz to 58 Hz
0.075mm excursionFree fall 100 mm
Burner Control SystemServomotors
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Dimensions
Settings
Direction of rotation clockwise from zero referencemark as seen after 90°
Motor position closed (shaft in Min. position)Max. adjusting angle 90° operating range and
additional 10° adjustment range
The operating positions or load points can be set with theoperating unit. Each actuator drive can be activated indi-vidually during the setting phase.
Zero position
When attaching the stepping motor, care should be takento ensure that the drive is in the zero position (closedposition).
Connection
P1
P3
P2
NLPE
EA SA 1EB SB 2OK WD 3
GND 4AA MA 5AB MB 6
Auf
Zu
17
22
30
1
4
33,5
45,5
10,5
-0,2
ø12
h8
ø 1
8 h8
142
144
120
58
93
91
43,3
6.4
6.4
thro
ugh-
hole
for
M 6
PG 11 cable gland withearthing wire
ø 68
90°
closed open
Burner Control SystemServomotors
closed
open
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FLW 05
Burner Control SystemBCS flame detector
27282828282828292929303030303131313232
BCS flame detector system FLW 05UV flame detector module, method of operationFlame sensor QRA 53 operationFlame signal intensity measurementFlame sensor QRA 2 operationReplacement specifications for UV diodesBCS operation phase, flame supervision device UV QRA 53BCS operation phase, preventilation unit UV QRA 53BCS operation phase, frequency evaluation unit UV QRA 53BCS operation phase, flame unit QRA 53Ignition flame contact or main flame contact, method of operationIonization flame detector module, method of operationBCS flame unit ionization current of 3µABCS ignition flame contact testLight sensor flame detector module, method of operationFlame intensity measurementMonitoring for flame simulation states (outside light)BCS flame unit light sensor RAR 7Flame detector FLW 05 configuration: selection combination with main flame detector
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BCS flame detector system FLW 05The FLW 05 flame detector consistsof four separate monitoring systems(UV, ionization, light, contact) whichare• integrated in a housing• fully assembled with hardware and
supplied with voltage• selectable and configurable via the
BCS program.
The flame sensors are interrogated bythe safety computers via the CAN-buson the CAN controller, which receivesa continuous flow of information fromthe flame sensor and initiates flamedetector tests according to the select-ed configuration.Applications (mode dependent):Permanent operation• UV sensor QRA 53 (cyclic self-test)• Ionization electrode with amplifier
test• Light sensor RAR 7 (selenium
photoelement with fault-proofphotovoltage) and amplifier test
• Intrinsically safe flame detectorwhich is connected to the „IGNIT“(IGNITION) and/or „MAIN“ (MAIN)contact input.
Non-permanent operation• UV sensor QRA 2 with continuously
live UV diode (with startup supervi-sion)
Method of operation of flame sensorUV sensor QRA 53The flame sensor operates automati-cally and dynamically. As soon as UVradiation impinges on the diode, itgenerates a flame signal via the flamesignal amplifier. This signal is used todrive a stepping motor in the flamesensor. The stepping motor closes theincident light aperture and reopens itafter 200 ms. The flame signal mustbe canceled as a consequence ofthis. After the incident light apertureis released, the presence of a flameis signaled again.
UV sensor QRA 2The flame sensor operates continu-ously. The self-monitoring function isexecuted at startup only.The system, therefore, must beswitched off at least once within 24hours.
Schematic diagram
4
5
6
7
8
9
11
1-
2+
3
4
5
6
1
3
2 W020V
W020V
W020V
W020V
CL
CH
RIN
BC
S s
yste
mbu
s
GND
L1
PE
N
10
Mµ controllerwith CAN
ActivationQRA 53
Activation ofionization
Activation oflight sensor
230 VAC
Q
RA
53
1
2
3
4
5 P
E
Flame signalamplifier withfloating contactoutput
Activation ofcontacts
230 VAC
230 VACFlame signal -->
Fl.-inten. frequency -->
<-- Shutter stop
Fl.signal -->
<-- Test
Fl.signal -->
<-- Test
V1 B0241
V2 B0241
Ionizationelectrode
RAR 7
QR
A 2
-
+
+
Burner Control SystemFlame detector
Ionization electrodeThe ionization monitoring device uti-lizes the rectifier effect of a flame andis classified as fault-proof.In permanent operation, the amplifieris tested for reliable operation every10 s.The ionization flame supervision de-vice normally uses the burner nozzleas earth. For this reason, it is impor-tant to ensure good flame adhesionat the burner nozzle.The burner nozzle serves as a returnline for the ionization current and musthave a low-ohmic connection to PE.In normal system conditions, the op-posite pole -N- is connected to PEpotential.In this case, the earth terminal or PEterminal need only be connected toburner earth.If, however, an isolating or controltransformer is used to supply BCS-FLW05 with supply voltage, it is im-perative that the pole connected inplace of -N- be earthed or connect-ed to burner earth. Otherwise the ion-ization current will have no return line.Despite good flame formation andcorrect electrode positioning, no oronly a weak ionization current canflow.The material of the ionization elec-trode and its insulation must be heatresistant. The material Kanthal, incombination with a ceramic insulationlayer made of aluminium oxide, has
proved to be an effective electrodematerial. The insulation resistanceshould be more than 50 MOhm.
Light sensor RAR 7The flame sensor contains a seleni-um photoelement which generates aphotovoltage on exposure to lightand is classified as fault-proof.For permanent operation, the ampli-fier is tested for reliable operationevery 10 s.
Flame detector with contact outputThe flame detector must be fault-prooffor permanent operation as only thepart located in the BCS flame detec-tor is tested for reliable operation eve-ry 10 s.
Flame signal intensity measure-mentThe intensity of all flame sensor sig-nals (UV, ionization, light) is evaluat-ed and displayed by the BCS.This also allows remote transmissionof this data possible and a messageindicating the need for preventivemaintenance to be displayed when amin. value is undershot.
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UV flame detector moduleMethod of operationThe flame sensor, a UV – diode, is agas tube which is made electricallyconductive by UV radiation emittedfrom burner flames. As these UV di-odes are not fault-proof and can gen-erate a flame signal due to defect oraging, it is important that failure oraging of the UV diode be detectedduring the operation of flame detec-tors designated for permanent oper-ation.To detect a faulty UV diode, it is nec-essary to prevent the incidence of UVlight from the burner flame and alsoto check whether this causes the UVdiode to lose its electrical conductiv-ity.In the case of burners designed fornon-permanent operation, startupsupervision is only necessary prior toburner startup. As faulty UV diodesignited by UV light tend to remainelectrically conductive even withoutUV – light exposure, it is important thatthe flame sensor circuit remain con-nected to the supply voltage evenduring the controlled burner shut-down so that such a defect is detect-able.To be able to perform on UV flamesensors designed for permanent op-eration the cyclic test for safe shut-down after flame failure, a shutterwhich can be used to „dim“ the UVdiode is attached to the incident-lightaperture of the flame sensor.
Flame sensor QRA 53 operationIn the case of den QRA 53 flame sen-sors, the shutter is closed by the flamesignal, held shut by the built-in elec-tronics for 200 ms and subsequentlyreopened. As a result, the signalpresent at the flame signal outputmust change constantly. The BCSchecks that this change takes placewithin 1 second. If this signal changedoes not occur, a fault shutdown fol-lows.
Flame signal intensity measure-mentFor this purpose, the electric currentflowing through the UV – diode ismeasured, converted to a frequencyand transferred to the host computervia the CAN-bus. The host computerthen outputs the flame intensity as anumeric value. The cyclic test is halt-ed for a short period of time so thatthe UV current can stabilize.Monitoring for flame-simulatingstates (outside light)Fuel release and after burner shut-down.During the period from the start of thepreventilation period until fuel release,a flame signal triggers a fault lockout.It is possible to set the time after whichno flame may be present after burnershutdown. If the presence of a flameis indicated after the set time expires,a fault lockout follows.
Flame sensor QRA 2 operationUnlike QRA 53 sensors, QRA 2 sen-sors have lower resistance values. Forthis reason, the measured flame in-tensity under the same conditions isapproximately one third higher.
Replacement specifications for UVdiodesSince UV diodes are subject to ag-ing, they must be replaced in QRA 2sensors after 10,000 operating hoursat the latest.It is recommended that the QRA 53be replaced after 10,000 operatinghours at the latest. However, the cy-clic test detects critically defective UVdiodes.
BCS operational phase Flame supervision device UV QRA 53
FlameP 3.0
OFF
ON
UV currentFrequencyP 3.5
ShutteropenP 1.1
Stop (open)
running
typ. 0,5 s
> 0,2s<0,8s
Flame OFF
Normal Fault case 1
Shutter too fast,more than 12pulses within 0.8 s
Fault case 2
Flame failure
Fault case 3
Shutterdefective,does not close
Operation
MeasureUV current
Fault case 4
Flame failureduringmeasurementcycle
>1s >1s
Burner Control SystemFlame detector
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FlameP 3.0
OFF
ON
FrequencyP 3.5
15 ms 10 s
t 1 t 2 t 3
t
t
t1 = Start (flame intensity)t2 = End of frequency measurementt3 = Start of next measurement cycle
Burner Control SystemFlame detector
BCS operational phase Flame unit QRA 53
FlameP 3.0
OFF
ON
UV currentFrequency
TestShutterP 1.1
Stop
running
Flame OFF
0,8
Transientresponse
Cancel
1,6 2,4 3,2 4,0 14 14,8 15,6 16,2
CountNoevaluation
t s
BCS operational phase Frequency evaluation UV QRA 53
FlameP 3.0
OFF
ON
UV currentFrequencyP 3.5
ShutteropenP 1.1
Stop (open)
runnning
Fault
Outside light during preventilation period
2. Wechsel —> Fault
BCS operation phase preventilation UV QRA 53
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Ignition flame contact or mainflame contact, method of operationThe complete input circuit is checkedevery 10s if a flame is present.If the flame signal is not canceledwithin 13 ms (typical value 0.5 ms),the system interlocks (fault message:„KT ignition flame present“ or „KTmain flame present“). This test is per-formed once for the A computer andthen for the B computer.
Ionization flame detector moduleMethod of operationThe actual flame sensor circuit - theionization process - utilizes the elec-trical conductivity of the hot plasmaof a flame. If the electrodes are ar-ranged accordingly, a rectifier effectoccurs making this arrangementpractically fault-proof. Burners de-signed for permanent operation incombination with fault-proof, self-monitoring flame detectors, therefore,only require that the amplifier modulebe tested cyclically during operation.For this purpose, the BCS flame de-tectors store the actual effective sig-
t1 = Flame must be present. Start of test mode (for A computer)t2 = Flame OFF. End of test mode (for A computer)t3 = Flame must be present. Start of test mode (for B computer)t4 = Flame OFF. End of test mode (for B computer)The test is performed every 10s if a flame is present!
t1 = Initial flame formation after burner startupt2 = Flame amplifier test. The flame must have logged off prior to t3 otherwise a fault message is displayed (ION
flame logoff) and the system interlockst3 = Start of flame logon period or start of intensity measurement up to first edge change (flame P 3.3)t3 = Possible flame logon period (depending on intensity)t4 = Flame must be present otherwise a fault message is displayed (ION test flame missing, system locked out)t5 = Start of next measurement cycle
Burner Control SystemFlame detector
FlameP 3.2
OFF
ON
Main flamecontact testP 1.7
500 µs
t 1 t 2 t 3
t
t
OFF
ON
500 µs
t 4
BCS test, ignition flame contact
nal (the DC ionization current) in acapacitor. This capacitor is repeatedlydischarged during the cyclic test. Thefollowing charging period, duringwhich the ionization current chargesthe capacitor up to the responsethreshold of the flame signal amplifi-er, serves as a gauge of flame inten-sity.The flame detector computer controlsand monitors this process. The com-plete operation must take place with-in defined time windows. If flame in-tensity is high, the charging cycle isrelatively short. If intensity is low, thecharging cycle takes longer. The
complete operation takes place with-in max. 1s.Charging time at lowest flame inten-sity (smallest ionization current) isapproximately 700 ms. At high flameintensity, the charging cycle takesapprox. 50 ms. The default setting is350 ms and corresponds to an ioni-zation switch-off current of approxi-mately 3 µA. The switch-off currentcan only be changed by replacing theE-PROMS which are used to definethe time window. The cyclic self-test,and hence also the flame intensitymeasurement, is performed every 10sduring operation with flame.
FlameP 3.3
OFF
ON
TestIONP 1.3
10 s
t 1 t 2 t 3
t
t
OFF
ON
110 ms
t 4 t 5t 3
375 ms 10 s
BCS flame unit ionization current of 3 µA
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Light sensor flame detector moduleMethod of operationThe actual flame sensor – a seleniumphotoelement - generates from thelight of the burner flame a photovolt-age which is used to activate an op-eration amplifier. As open circuits,short circuits or poor insulation resist-ance cannot generate photovoltage,this type of flame sensor is classifiedas fault-proof. Burners designed forpermanent operation, therefore, onlyrequire that the amplifier module betested cyclically during operation.For this purpose, the BCS flame de-tectors repeatedly short out the actu-al effective signal - the photovoltage- at the input of the flame signal am-plifier by means of cyclic tests in or-der to test the following flame signalamplifier, which must repeatedly in-dicate „Flame OFF“ during thesetests. The flame detector computercontrols and monitors this process.The complete test - short-circuiting ofthe photovoltage, „Flame OFF“ indi-cation, elimination of short circuit andindication of „Flame present“ - musttake place within 1 second. Thesetests are are performed every 10s.Since – the flame is required to logon and off within 1s during the test, avoltage of at least 120 mV is requiredfor actual operation so that the flamecan log on within the required periodof time.
Flame intensity measurementThe level of the photovoltage is de-pendent on the lightness of the lightof the burner flame impinging on thelight sensor.The amplified photovoltage can beeasily converted to a digital signal viaan analog-to-digital converter anddisplayed by the computer.
Check for flame-simulating states(outside light) prior to fuel releaseand after burner shutdownThe response sensitivity of the flamesignal amplifier is approximately 1.5µA. In other words, ionization currentsof approximately 1.5 µA or higher trig-ger a flame signal within 1s if thecharging time measurement functionis inactive.This applies to the period from thestart of preventilation until fuel releaseand leads to a fault lockout if a flamesignal is generated. It is possible toset the time after which no flame maybe present after burner shutdown. Ifthe presence of a flame is indicatedafter the set time expires, a fault lock-out follows
Check for flame-simulating states(outside light) prior to fuel releaseand after burner shutdownThe switch-on sensitivity of the flamesignal amplifier corresponds to a lightsensor voltage of 100 mV. Switch-offsensitivity is 90 mV. This correspondsto a luminous intensity of approxi-mately 50 Lux of the RAR7 sensor.The flame supervision phase beginswith the preventilation period andends with fuel release when the burn-er is started.Additional flame simulation supervi-sion takes place at a defined time af-ter burner shutdown.
The following rule applies to both cas-es:If a flame signal is detected at thespecified times, an immediate faultshutdown follows and the system in-terlocks.
Burner Control SystemFlame detector
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t1 = Initial flame formation after burner startupt2 = Start of test for flame shutdownt3 = Flame signal may no longer be present otherwise a fault message is displayed
(test light „Flame present“, system interlocks)t4 = Flame must be present otherwise a fault message is displayed
(light flame missing, system interlocks)t5 = Start of next measurement cycle
BC
S s
yste
m b
us
Flam
e si
gna
lam
plif
ier
with
float
ing
con
tact
outp
ut
Ioni
zatio
nel
ectr
ode
- + QRA 2
X 2
L N PE230 VAC50/60 Hz
1 2 3 4 5 6
IGN
IT
WD
CL
CH
RIN
1 2 3 4 5 6 7 8 9 10 11
X 9
Main flame detector QRA 2
-
BC
S-S
yste
mbu
s
+
1 2 3 4 5 6 7 8 9 10 11
Flam
e si
gna
lam
plif
ier
with
float
ing
con
tact
outp
ut
Ioni
zatio
nel
ectro
de
RAR 7
X 2
L N PE PE 5 4 3 2 1QRA 53230 VAC
50/60 Hz
1 2 3 4 5 6
IGN
IT
WD
CL
CH
RIN
X 9
Main flame detector QRA 53
+
BC
S s
yste
m b
us
- +
Flam
e si
gna
lam
plif
ier
with
float
ing
cont
act
outp
ut
Ioni
zatio
nel
ectro
de
X 2
L N PE230 VAC50/60 Hz
1 2 3 4 5 6
IGN
IT
WD
CL
CH
RIN
1 2 3 4 5 6 7 8 9 10 11
X 9Main flame detector RAR 7
RAR 7+
-
BC
S-S
yste
mbu
s
+
1 2 3 4 5 6 7 8 9 10 11
Flame signalamplifier withfloating contactoutput
Ioni
zatio
nel
ectr
ode
RAR 7
X 2
L N PE PE 5 4 3 2 1QRA 53230 VAC
50/60 Hz
1 2 3 4 5 6
IGN
IT
WD
CL
CH
RIN
X 9
Main flame detector, contact 1
MA
IN
+
Flame detector FLW 05 configuration: selection combination with main flame detector
Burner Control SystemFlame detector
FlameP 3.1
OFF
ON
TestlightP 1.5
10 s
t 1 t 2
t
tOFF
ON
110 ms
t 4 t 5t 3
500 ms 10 s
BCS flame unit light sensor RAR 7
-
BC
S-S
yste
mbu
s
+
1 2 3 4 5 6 7 8 9 10 11
Flam
e si
gna
lam
plif
ier
with
float
ing
con
tact
outp
ut
Ioni
zatio
nel
ectr
ode
RAR 7
X 2
L N PE PE 5 4 3 2 1QRA 53230 VAC
50/60 Hz
1 2 3 4 5 6
IGN
IT
WD
CL
CH
RIN
X 9Main flame detector, ionization
- + QRA 2
+
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Burner Control SystemBasic settings
BCS softwareBasic settings in levels 0, 1, 2, 3 with the ranges „a“ up to „r“
Software structureBasic settings „a“ in level 0 without access authorizationBasic settings „b“ in level 3 GAS FIRINGCombination between input circuit ignition and main flameBasic settings „b“ in level 3 OIL FIRINGBasic settings „c“ in level 2 GAS FIRINGBasic settings „c“ in level 2 OIL FIRINGBasic settings „d“ in level 2 CONTROLLER PARAMETERSBasic settings „e“ in level 2 Modify GAS CURVE, without flame, without PCBasic settings „f“ in level 2 Modify OIL CURVE, without flame, without PCBasic settings „g“ in level 2 GAS, settings with Gas, without PCBasic settings „g“ in level 2 GAS burner settings: Gas index 1Test Basic settings „i“ in level 2Test Basic settings „g“ in level 2Basic settings „h“ in level 2 OIL, settings with oil, without PCBasic settings „g“ in level 2 OIL, burner settings: Oil Index 1Test oil curve „i“ in level 2Basic settings „g“ in level 2 Display oil curve „k“ in level 2Output controller settings „m“ in level 1Basic settings in level 2Basic settings „p“ in level 2Basic settings „r“ in level 2 CRC entriesPress „M“ or „P“ key during operation
343536-373839-4041-4243-4445-4647484950515253-54555657575859-616262s
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M P
Switch on mains voltage orsystem reset
Press M key straightafter switching on
BurnerON / OFF
for operator withoutaccess authorizationDisplay- clock/date- Hours/startups- Display test- Info PROM- Fault memory
a
Code No.for level 3
Code No.for level 2
Code No.for level 1
m b
e. g.Erase fault bufferAdjust clock time
e. g.Curve adjustmentwith/without PCCRC entryController typeselection
e. g.Automatic burner controlsystem selectionValve testTime setting
c
Press P key straight afterswitching on
System start
Start system withvalid CRC Level 0
Enter accessauthorization
Level 1 Level 2 Level 3
System startSwitch on mains voltage or activatereset
Software structure
Basic settings in level 0 „a“ without access authorization
Basic settings in levels 1,2 and 3„b...r“with access authorization only
Burner startupWithout changing setting
SET WITH PC Settings without PC
Function testInputs/outputs
Basic setting ofactuator drives
Set actuatordrives
Hours / startups
Test gas curve Display gascurve
Display oil curve Enter CRC
Controllerparameter
Delete gas curve
Delete oil curve
Modify gas curve(without flame)
Modify oil curve(without flame)
Settings with GAS
Settings with OIL
Set postventilationperiod GAS
Blower air dampersDelay time
Dwell timeIgnition position
Dwell timeController release
Load reversal
END
MODIFYPARAMETERS
BCS data to PC
Settings with GAS
PC data to BCS
Settings with OIL
Level 2
Test oil curve
System responseInput signal <4 mA
Burner Control SystemBasic setting
BCS system configurationintermittent
System programs
Leakage testavailable
Ignition valveavailable
Flame simulation supervisionafter shutdown
Setpre-ignition
Setpreventilation period
Load factory settings
Operation withgas / oil gas oil
Input circuitMain flame
Level 3
Input circuitIgnition flame
otherwise same as level 2
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Basic settings „a“ in level 0 without access authorizationSelect desired basic setting with + Enter.• Clock/date display• Hours / startups• Display test• PROM information• Fault memory
Press + key can to retrieve the indi-vidual items in the fault memory. Seesection „Fault memory“.
Burner Control SystemBasic setting
F1 F2 F3
Display test0123456789+yes-no%
Enter
F1 F2 F3
Fault memory 5Outputs Basic module 28 1 0Cancel next
F1 F2 F3
Hours / startupsGas : 280 h / 16Öil : 280 h / 16Enter
F1 F2 F3
Fault memory 5Inputs FLW-Modul 2 160Cancel next
F1 F2 F3
Clock/date Display 8:2629 / 03 / 99
Menu
F1 F2 F3
Settings CRC value
162Enter
F1 F2 F3
Fault memory 5Inputs Basic module225 0 232 12Cancel next
F1 F2 F3
PROM information1.0 | 1.0 | 2.0
Network: 3 FLW: 2Enter
F1 F2 F3
Fault memory 5Date Clock time29/03/99 06:42Cancel next
F1 F2 F3
Fault memory 5Outputs FLW-Modul
0Cancel next
F1 F2 F3
Fault memory 5Fault / internal103 122 194Cancel next
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Basic settings „b“ in level 3 with access authorization only Gas firing mode
After entering the code number, the basic data of the burner can be selected and set: preventilation period, pre-ignition, flame simulation supervision after switch-off, ignition valve, stabilization period the ignition flame.
Press key F2
Press key F2
Only if F2 was pressed.Press key F3.
min.: 0 secmax.: 30 secDefault: 2 sec
min.: 1 secmax.: 50 secDefault: 10 sec
min.: 0 secmax.: 30 secDefault: 2 sec
If F2 was pressed
Burner Control SystemBasic settings
F1 F2 F3
Enter yourCode number: 0 0 0
^Enter ^
F1 F2 F3
Set afterburn timeGas firing
10 secEnter
F1 F2 F3
Operation with:
Gas/Oil Gas OilF1 F2 F3
Set pre-purge time,gas firing! 30 sec.
Enter
F1 F2 F3
Gas ignition valveMode available?
Enter yes no
F1 F2 F3
Loadfactory settings
No yes
F1 F2 F3
Important!!Set values
will be deletedNo yes
F1 F2 F3
Stabilization timeGas firing 1 sec.
Enter
F1 F2 F3
Set pre-ignitionSet gas! 2 sec.
Enter
F1 F2 F3
Please wait!
min.: 1 secmax.: 250 secDefault: 30 sec
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Basic settings „b“ in level 3 with access authorization only
Additional basic data of the burner can be selected and set:leakage test, system program for gas firing, system configuration (operation mode), input circuit of the ignition andmain flame.
Burner Control SystemBasic settings
F1 F2 F3
Leakage testavailable?
Enter yes no
F1 F2 F3
Test timeLeakage test
15 secEnter
F1 F2 F3
System program No. 11-2 FLW ignition gas
upstream V1Enter
Select program with + / -Note: see section „Selecting systemprograms“
F2:Choose between PERMANENTOPERATION and NON-PERMA-NENT OPERATION.
F1 F2 F3
System configurationPERMANENT OPERATION
Enter Selection
F1 F2 F3
System programGas firing mode
No. => 1Enter Info
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F2: Choose betweenNo connectionIonization (with test)UV (QRA 53)UV (QRA 2)Light (RAR 7)contact 1contact 2
Basic settings „b“ in level 3 with access authorization only Gas firing mode
Additional basic data of the burner can be selected and set:leakage test, system program for gas firing, system configuration (operation mode), input circuit of the ignition andmain flame.
Burner Control SystemBasic settings
F1 F2 F3
Input circuitIgnition flame
Ionization with testEnter Selection
F1 F2 F3
Input circuitMain flame
UV (QRA 53)Enter Selection
F2: Choose betweenIonization (with test)UV (QRA 53)UV (QRA 2)Light (RAR 7)contact 1
Depending on ignition flame selec-tion, the main flame combinationsopposite are possible.
otherwise same as level 2
Combination between input circuit ignition and main flame
Main flame QRA 53 QRA 2 ION RAR 7 Contact 1 Contact 2 Ignition flame QRA 53 x 0 + 0 + 0 QRA 2 0 x 0 0 0 0 ION + + x + + 0 RAR 7 + 0 + x + 0 Contact 1 + + + + x + Contact 2 0 0 0 0 + x No connection + + + + + +
x ➔ Ignition flame sensor = main sensor 0 ➔ Combination not approved + ➔ Approved combinations
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Basic settings „b“ in level 3 with access authorization only OIL FIRING
After entering the code number, the basic data of the burner can be selected and set: preventilation period, pre-ignition, flame simulation supervision after switch-off, ignition valve, stabilization period the ignition flame.
Press key F3.
Press key F2.
Only if F2 was pressed.Press key F3.
min.: 1 secmax.: 250 secDefault: 30 sec
min.: 0 secmax.: 30 secDefault: 2 sec
If F3 was pressed.
Burner Control SystemBasic settings
F1 F2 F3
Operation with:
Gas/Oil Gas Oil
F1 F2 F3
Load factorysettings
No Yes
F1 F2 F3
Set pre-ignition,time oil firing!
2 sec.Enter
F1 F2 F3
IMPORTANT!!Set values
will be deletedNo Yes
F1 F2 F3
Please wait!
F1 F2 F3
Set afterburn timeOil firing10 sec
Enter
F1 F2 F3
Set pre-purge time,oil firing! 30 sec.
Enter
F1 F2 F3
Enter yourcode number: 0 0 0
^Enter ^
min.: 1 secmax.: 50 secDefault: 10 sec
If F2 was pressed.
F1 F2 F3
Ignition valve foroil available?
Enter Yes No
F1 F2 F3
Stabilization timeOil firing!
1 sec.Enter
min.: 0 secmax.: 30 secDefault: 5 sec
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Basic settings „b“ in level 3 with access authorization only OIL FIRING
Additional basic data of the burner can be selected and set:Valve nozzle linkage, system program for oil firing, system configuration (Mode), input circuit of ignition and mainflame.
Select program with + / -
Note:see section „Selecting systemprograms“
F2: Choose between PERMANENT OPERATION and NON-PERMANENT OPERATION.
F2: choose betweenNo connectionIonization with testUV (QRA 53)UV (QRA 2)Light (RAR 7)Contact 1Contact 2
F2: choose betweenIonization with testUV (QRA 53)UV (QRA 2)Light (RAR 7)Contact 1
otherwise as per level 2
Burner Control SystemBasic settings
F1 F2 F3
Valve nozzle linkageavailable?
Enter Yes No
F1 F2 F3
System program No. 101-2 FLW Ignition gas
without DGEnter
F1 F2 F3
Input circuitMain flame
UV (QRA 53)Enter Selection
F1 F2 F3
System configurationCONTINUOUS OPERATION
Enter Selection
F1 F2 F3
Input circuit Ignition flame
Ionization with testEnter Selection
F1 F2 F3
System programOil firing
no. => 10Enter Info
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Basic settings „c“ in level 2 Modify parameters with access authorization only Gas firing mode
Additional basic data of the burner can be selected and set:postventilation period, blower air damper delay period (star delta changeover), dwell time in ignition position, dwelltime in controller release state, function test of outputs / inputs.
min.: 0 secmax.: 250 secDefault: 10 sec
Star delta changeovermin.: 0 secmax.: 60 secDefault: 8 sec
min.: 0 secmax.: 60 secDefault: 10 sec
min.: 0 secmax.: 60 secDefault: 10 sec
Burner Control SystemBasic settings
F1 F2 F3
Set post-purge time for gas firing!
10 sec.Enter
F1 F2 F3
Blower air damperdelay time
8 sec.Enter
F1 F2 F3
Dwell timeIgnition position
10 sec.Enter
Outputs are set if F3 is pressed.
Outputs:Fuel indication, blower motor, oilpump motor, load reversal point, ig-nition transformer for gas firing, sole-noid valve DG, ignition gas solenoidvalve, safety valve, main valve, sup-ply and return solenoid valves, sta-tus indication, ignition transformer foroil firing.
If F2 was pressed.
Selection of outputs
Use F2 to choose between low loadand interlock
F1 F2 F3
System responseInput signal < 4 mALow loadEnter Selection
F1 F2 F3
Important!!Shut off fuelsupply line!
Enter
F1 F2 F3
Test of outputsFuel indication
End Test
F1 F2 F3
Dwell timeController release
10 sec.Enter
F1 F2 F3
Function test ofoutputs / inputs
No Yes
F1 F2 F3
Load reversal pointIndex: > 1 OpenIndex: > 1 ClosedEnter Selection
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Basic settings „c“ in level 2 with access authorization only Gas firing mode
Additional basic data of the burner can be selected and set:basic setting of the actuator drives, test actuator drives and define adjustment ranges, hours and startups.
Burner Control SystemBasic settings
The symbol „ | „ is displayed aslong as the motor is running.Actual: momentary position of the
motorKey F3: motor in MAX. positionKey F2: choose between GAS
motor or AIR motor
Wenn F2 gedrückt wurde.
Actual: modify motor adjustmentrange.
Example: 4600 increments.max: maximum adjustment range
of motor according. toman-ufacturer specifications.
Use F2 to choose between theactuator drives for GAS and AIR.
Input selection:
Inputs:Burner ON, fuel prelim., oil safetychain, air pressure switch, ignitionflame, main flame, Gas min., Gasmax., Gas VDK, heavy oil release.Analog input 0…20 mA.
Use F2 to choose between theactuator drives for GAS and AIR.
Motor ramps up
Motor ramps down
Feedback signals are not evaluated.
F1 F2 F3
Input testBurner ON
Input state: ONEnde
F1 F2 F3
Define gasadjustment range
Actual: 4800 | max.: 4800End Selection
F1 F2 F3
Set actuatordrives
No Yes
F1 F2 F3
Setactuator drives
No Yes
F1 F2 F3
Test actuator drivesGAS
Actual: 0 | max.: 4800End Selection max.
F1 F2 F3
Hours / startupsGAS : 3010 h / 240OIL : 310 h / 30
Enter delete
F1 F2 F3
Basic setting ofactuator drives
GASEnter Selection
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Basic settings „c“ in level 2 Modify parameters with access authorization only OIL FIRING
Additional basic data of the burner can be selected and set:postventilation period, blower air damper delay period (star delta changeover), dwell time in ignition position, dwelltime in controller release state, function test of outputs / inputs.
Outputs are set if F3 is pressed.
Outputs:Fuel indication, blower motor, oilpump motor, load reversal point, ig-nition transformer for gas firing, sole-noid valve DG, ignition gas solenoidvalve, safety valve, main valve, sup-ply and return solenoid valves, sta-tus indication, ignition transformer foroil firing.
min.: 0 secmax.: 250 secDefault: 10 sec
Star delta changeovermin.: 0 secmax.: 60 secDefault: 8 sec
min.: 0 secmax.: 60 secDefault: 10 sec
min.: 0 secmax.: 60 secDefault: 10 sec
Selection of outputs
Select all the following time settingvalues with
Burner Control SystemBasic settings
F1 F2 F3
Dwell timeIgnition position
10 sec.Enter
F1 F2 F3
Load reversal pointIndex: > 1 OpenIndex: > 1 CloseEnter Selection
Use F2 to choose between low loadand interlock
F1 F2 F3
System responseInput signal < 4 mALow loadEnter Selection
Wenn F2 gedrückt wurde.
F1 F2 F3
Important!!Shut off
fuel supply line!Enter
F1 F2 F3
Test ofoutputs message
End Test
F1 F2 F3
Dwell timeController release
10 sec.Enter
F1 F2 F3
Set post-purge time for oil firing!
10 sec.Enter
F1 F2 F3
Blower air damperdelay time
8 sec.Enter
F1 F2 F3
Function test ofoutputs / inputs
No Yes
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Basic settings „c“ in level 2 with access authorization only OIL FIRINGAdditional basic data of the burner can be selected and set:basic setting of the actuator drives, test actuator drives and define adjustment ranges, hours and startups.
with F2 choose between the actua-tor drives for GAS, oil and air
Motor ramps up
Motor ramps down
Feedback signals are not evaluated.
The symbol „ | „ is displayed aslong as the motor is running.Actual: momentary position of the
motorKey F3: motor in MAX. positionKey F2: choose between OIL motor
or AIR motor
If F2 was pressed.
Actual: modify motor adjustmentrange.Example: 4600 increments.
max: maximum adjustment rangeof motor according. tomanufacturer specifica-tions.
Use F2 to choose between theactuator drives for OIL and AIR.
Input selection:
Inputs:Burner ON, fuel prelim., oil safetychain, air pressure switch, ignitionflame, main flame, Gas min., Gasmax., Gas VDK, heavy oil release.Analog input 0…20 mA.
Burner Control SystemBasic settings
F1 F2 F3
Setactuator drives
No Yes
F1 F2 F3
Basic setting ofactuator drives
OILEnter Selection
F1 F2 F3
Define oiladjustment range
Actual: 4800 | max.: 4800End Selection
F1 F2 F3
Hours / startupsGAS : 3010 h / 240OIL : 310 h / 30
Enter delete
F1 F2 F3
Setactuator drives
No Yes
F1 F2 F3
Input testBurner ON
Input state: ONEnde
F1 F2 F3
Test actuator drivesOIL
Actual: 0 | max.: 4800End Selection max.
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Basic settings „d“ in level 2 with access authorization only
CONTROLLER parameter: selection of controller type, sensor actual values, pressure range.The following screens only appear when „Default controller“ is selected.
If F2 was pressed.
Burner Control SystemBasic settings
F1 F2 F3
ParametersLoad
factory settingsNo Yes
F1 F2 F3
Please wait!
Selection:Standard controllerRun-on controller
Use F2 to choose betweenTEMPERATUREPRESSURE
F1 F2 F3
ParametersController type: 1
Enter Info
F1 F2 F3
Please select:Controller parameter
Enter
F1 F2 F3
Controller parametersSensor actual value
TEMPEnter Selection
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Basic settings „d“ in level 2 with access authorization only
CONTROLLER parameters: system response, switching difference, setpoint adjustment,Kp value, Tn value, Tv value, neutral zone PID.
All setting values can be incrementedor decremented by 10 with the F2 andF3 key or by 1 with the +/- key.
Burner Control SystemBasic settings
F1 F2 F3
Controller parameterDistance
2Enter -10 +10
F1 F2 F3
Controller parameter 20 mA corresponds
to 250Enter -10 +10
F1 F2 F3
Controller parameterTn
30,0 secEnter -10 +10
F1 F2 F3
Controller parameterSetpoint 1:
90Enter -10 +10
F1 F2 F3
Controller parameterTv
1 secEnter
F1 F2 F3
Controller parameterKp10
Enter -10 +10
F1 F2 F3
Controller parameterNeutral zone PID
1Enter -10 +10
F1 F2 F3
Controller parameterSwitching difference
5Enter -10 +10
F1 F2 F3
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Basic settings „e“ in level 2 only with access authorization without PC
Modify GAS CURVE, without flame
Burner Control SystemBasic settings
Fuel:
Enter by pressing the P key
M P
After F1 is pressed, the desiredindex appears:
Note: entry into table after leavingthe ignition position
Use F2 to select all indices:1, 10, 20, ……… 100.
F1 F2 F3
Please select:Set without PC
Enter
F1 F2 F3
Gas index: 30Fuel : 980 P = EnterAir : 1030+ / - L - L +
F1 F2 F3
Enter output40 %
Enter
F1 F2 F3
First indexafter ignition
1Enter
F1 F2 F3
Set without PCModify gas curve(without flame)
Enter Back
F1 F2 F3
Gas index:: 30Modify
Enter Select Cancel
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Basic settings „f“ in level 2 only with access authorization without PC
Modify OIL CURVE, without flame
Burner Control SystemBasic settings
M P
After F1 is pressed, the desiredindex appears:
Fuel:
Enter by pressing the P key
Note: the program enters the tableafter leaving the ignition position
Use F2 to select all indices:1, 10, 20, ……… 100.
F1 F2 F3
Please select:Set without PC
Enter
F1 F2 F3
Oil index: 30Fuel : 980 P = EnterAIR : 1030+ / - L - L +
F1 F2 F3
Enter output40 %
Enter
F1 F2 F3
Set without PCModify oil curve(without flame)
Enter Back
F1 F2 F3
Oil index:30Modify
Enter Select Cancel
F1 F2 F3
First indexafter ignition
1Enter
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Basic settings „g“ in level 2 with access authorization without PC only
Settings with gas: purge position, ignition point, full load /100% to min. load.
To ignite, press the P key
M P
Burner Control SystemBasic settings
Pre-purge time30 sec
F1 F2 F3
Pre-purge time
Zero adjust, motors
M P
Preventilate with the P key
Fuel:
F1 F2 F3
Pre-purge time
F1 F2 F3
Pre-purge time30sec.
Actuator > running
F1 F2 F3
Set ignition point
Actuator > ignition
Ignition
Flame signalreceived!
F1 F2 F3
Gas index: 100Fuel: 3200 P = EnterAir : 2700+ / - L - L +
Fuel:
Enter by pressing the P key
M P
F1 F2 F3
Save point ?
Yes No
F1 F2 F3
Please select:Set without PC
Enter
F1 F2 F3
Set purge pos.Fuel : 290 P = ventAir : 250+ / - L - L +
F1 F2 F3
Set ignition pointFuel: 320 P = ignitionAir : 270+ / - L - L +
F1 F2 F3
Set without PCSet with gas
Enter Back
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Basic settings „g“ in level 2 with access authorization without PC only
GAS burner settings: Gas index
M P
Fuel:
M P
Repeat with gaz index80, 70, 60, 50, 40, 30, 20, 10 und 1.
F1 F2 F3
Enter output:100 %
Enter
F1 F2 F3
Gas index: 90Fuel : 480 P = EnterAir : 400+ / - L - L +
Enter by pressing the P key
Fuel:
F1 F2 F3
Save point ?
Yes No
F1 F2 F3
Enter output:85 %
Enter
F1 F2 F3
First indexafter ignition
1Enter
Post-purge time
F1 F2 F3
Please wait!
F1 F2 F3
Gas index: 1Fuel : 130 P = EnterAir : 280+ / - L - L +
F1 F2 F3
Save point ?
Yes No
F1 F2 F3
Enter output: 14 %
Enter
Enter by pressing the P key
F1 F2 F3
Zero adjust, motors
Burner Control SystemBasic settings
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Test GAS CURVE „i“ in level 2
Key „F3“ is pressed:
Key F 2 can be used to choose be-tween deficiency of air and fuel sur-plus.Note: only the fault is tested here, notthe accuracy of the network (damperblocked, cable breakage etc.).The point on curve must be selectedwith sufficient air surplus to prevent ahazardous situation arising when theburner is switched off.
Burner Control SystemBasic settings
Pre-purge time
F1 F2 F3
Pre-purge time5 sec
Actuator > running
F1 F2 F3
Pre-purge time
Zero adjust, motors
F1 F2 F3
Ignition position
Actuator > ignition
F1 F2 F3
Gas index: 21Fuel : 1500Air : 1800OFF Test Motor
F1 F2 F3
Please select:Test gas curven
Enter
F1 F2 F3
Pre-purge time30 sec
F1 F2 F3
Motor limit valuesDeficiency of air
Enter Select Cancel
Ignition
Flame signalreceived!
The complete, set curve can beexecuted by pressing + / -.
It is not possible to modify a curvehere.
The motor ramps down slowly. Afault is simulated.
Limit reached. The system wouldswitch off during operation. After theF3 key is pressed, the air motor re-turns to the correct position.
F1 F2 F3
Motor limit valuesDeficiency of air
Alarm Cancel
F1 F2 F3
Motor limit valuesDeficiency of air
Test running Cancel
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Basic settings „g“ in level 2 with access authorization without PC onlyGAS burner settings: Gas index 1
Burner Control SystemBasic settings
Display GAS CURVE „k“ in level 2
Use F2 and F3 to display the gastable (index)Index 101 —> ignition positionIndex 102 —> purge position
F1 F2 F3
Gas index: 21Fuel : 1500Air : 1800OFF Test Motor
F1 F2 F3
Post-purge time
F1 F2 F3
Zero adjust, motors
F1 F2 F3
Please select:Display gas curve
Enter
F1 F2 F3
GAS TABLEIndex after ignition
1End + -
F1 F2 F3
GAS TABLEInd | Bren | Air | Lei | Pk10 | 320 | 270 | 10 | *End + -
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Basic settings „h“ in level 2 with access authorization without PC only
Settings with oil: purge position, ignition point, full load /100% to min. load.
Burner Control SystemBasic settings
F1 F2 F3
Set purge pos.Fuel : 290 P = ventAir : 250+ / - L - L +
M P
Preventilate with the P key
Fuel:
F1 F2 F3
Set without PCSet with OIL
Enter Back
Pre-purge time30 sec
F1 F2 F3
Set ignition point
Actuator > ignition
F1 F2 F3
Set ignition pointFuel : 320 P = ignitionAir : 270+ / - L - L +
Ignition
F1 F2 F3
Oil index: 100Fuel : 3200 P = EnterAir : 2700+ / - L - L +
F1 F2 F3
Save point ?
Yes No
Enter by pressing the P key
M P
To ignite, press the P key
M P
F1 F2 F3
Please select:Set without PC
Enter
Fuel:
F1 F2 F3
Pre-purge time
Zero adjust, motors
Flame signalreceived!
Pre-purge time
F1 F2 F3
Pre-purge time30 sec
Actuator > running
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Enter by pressing the P key
M P
F1 F2 F3
Oil index: 90Fuel : 480 P = EnterAir : 400+ / - L - L +
F1 F2 F3
Save point ?
Yes No
Basic settings „h“ in level 2 with access authorization without PC only
Settings with oil: purge position, ignition point, full load /100% to min. load.
Burner Control SystemBasic settings
F1 F2 F3
Enter output:100 %
Enter
Fuel:Repeat with oil index:80, 70, 60, 50, 40, 30, 20, 10 und 1.
F1 F2 F3
Enter output:85 %
Enter
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Basic settings „g“ in level 2 with access authorization without PC only
OIL burner settings: Oil Index 1
Enter by pressing the P key
M P
Fuel:
Burner Control SystemBasic settings
Post-purge time
F1 F2 F3
Oil index: 1Fuel : 130 P = EnterAir : 280+ / - L - L +
F1 F2 F3
Save point ?
Yes No
F1 F2 F3
Enter output 14 %
Enter
F1 F2 F3
Please wait!
F1 F2 F3
First indexafter ignition
1Enter
F1 F2 F3
Zero adjust, motors
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Test OIL CURVE „i“ in level 2
Burner Control SystemBasic settings
F1 F2 F3
Please select:Test oil curve
Enter
key „F3“ is pressed:
Key F 2 can be used to choose be-tween deficiency of air and fuel sur-plus.Note: only the fault is tested here, notthe accuracy of the network (damperblocked, cable breakage etc.).The point on curve must be selectedwith sufficient air surplus to prevent ahazardous situation arising when theburner is switched off.
Pre-purge time
F1 F2 F3
Pre-purge time
Zero adjust, motors
F1 F2 F3
Pre-purge time5 sec
Actuator > running
The complete, set curve can beexecuted by pressing + / -.
It is not possible to modify a curvehere.
F1 F2 F3
Pre-purge time30 sec
F1 F2 F3
Oil index: 21Fuel : 1500Air : 1800OFF Test Motor
F1 F2 F3
Motor limit valuesDeficiency of air
Enter Select Cancel
Ignition
Flame signalreceived!
F1 F2 F3
Ignition position
Actuator ignition
The motor ramps down slowly. Afault is simulated.
Limit reached. The system wouldswitch off during operation. After theF3 key is pressed, the air motorreturns to the correct position.
F1 F2 F3
Motor limit valuesDeficiency of air
Test running Cancel
F1 F2 F3
Motor limit valuesDeficiency of air
Alarm Cancel
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Basic settings „g“ in level 2 with access authorization without PC only
OIL burner settings: Oil Index 1 Display OIL CURVE „k“ in level 2
Use F2 and F3 to displaythe oil table (index)
Index 101 —> ignition positionIndex 102 —> purge position
Burner Control SystemBasic settings
F1 F2 F3
Öil index: 21Fuel : 1500Air : 1800OFF Test Motor
F1 F2 F3
Please select:Display oil curve
Enter
F1 F2 F3
Zero adjust, motors
F1 F2 F3
Set clock/date 11:44 24 / 03 / 99 ^^ ^^ +1 Start
Output controller settings „m“ in level 1 with access authorization only
Erase FAULT MEMORY, set CLOCK/DATE.
Use F2 and F3 to man adjust clock/date.
F1 F2 F3
Set clock/date
No Yes
F1 F2 F3
Delete faultmemory
No Yes
F1 F2 F3
OIL TABLEInd | Bren | Air | Lei | Pk10 | 320 | 270 | 10 | *End + -
F1 F2 F3
OIL TABLEIndex after ignition
1End + -
F1 F2 F3
Post-purge time
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Basic settings in level 2 with access authorization only with PC
PC DATA transfer „n“
Burner Control SystemBasic settings
F1 F2 F3
Please select:PC —> BCS data
Enter Back
File is loaded from PC.
Find data on PC and load.
F1 F2 F3
Load BCS data18 %
Cancel
F1 F2 F3
BCS datasuccessfully loaded
Enter
F1 F2 F3
Load BCS dataPlease wait!
Cancel
F1 F2 F3
Load BCS data
Cancel
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Data are loaded into the PC
F1 F2 F3
BCS datasuccessfully sent
EnterPre-purge time
F1 F2 F3
Set with PCSet with gas
Enter Back
Pre-purge timeZero adjust, motors
F1 F2 F3
Send BCS data
Cancel
F1 F2 F3
Please select:BCS —> PC data
Enter Back
Basic settings in level 2 with access authorization only with PC
BCS DATA transfer „o“ GAS burner settings „p“
F1 F2 F3
wait for PC
Cancel
F1 F2 F3
Pre-purge time30 sec
If „rinsing“ (Purge) button on PC ispressed.
F1 F2 F3
Pre-purge time30 sec
Cancel
F1 was pressed. Ignition via BCSonly (not from PC).
If „Zünd“ (Ignition) button on PC ispressed.
The ignition point can be set.
Ignition
F1 F2 F3
Pre-purge time0 sec
Cancel
F1 F2 F3
Set ignition point
Ignition
Burner Control SystemBasic settings
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The ignition point can be setF1 was pressed. Ignition via BCSonly (not from PC).
Pre-purge time
Zero adjust, motors
Pre-purge time30 sec
Ignition
F1 F2 F3
wait for PC
Cancel
Basic settings „p“ in level 2 with access authorization with PC only
OIL burner settings „q“
Burner Control SystemBasic settings
The gas curve can now be testedand set via the PC.If F1 is pressed:
F1 F2 F3
Setting phase, gasIntensity: 5
OFF
F1 F2 F3
Post-purge time
F1 F2 F3
Flame signalreceived!
Pre-purge time
If „rinsing“ (Purge) button on PC ispressed.
F1 F2 F3
Set ignition point
Ignition
F1 F2 F3
Set with PCSet with OIL
Enter Cancel
F1 F2 F3
Pre-purge time0 sec
Cancel
F1 F2 F3
Pre-purge time30 sec
Cancel
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The oil curve can now be testedand set via the PC.If F1 is pressed:
F1 F2 F3
Flame signalreceived!
F1 F2 F3
Setting phase, oilIntensity: 4
OFF
F1 F2 F3
Post-purge time
Basic settings „p“ in level 2 with access authorization with PC only
OIL burner settings „q“
Burner Control SystemBasic settings
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Basic settings „r“ in level 2 with access authorization only
CRC entries
Note:
The values in a line must always be equal.
Left-hand value calculated by systemRight-hand value stored value since last transfer
Settings CRC over the safety relevant settings of the system
Gas curve CRC over the complete gas curve
Oil curve CRC over the complete oil curve
Burner Control SystemBasic settings
If the „M“ key or „P“ key is pressedduring the burner operation phase,
the relevant LED flashes without theprogram points of levels 0, 1,2 and3 being selected.
M P
Pressing keys „M“ or „P“ during operation
If the „M“ or „P“ key is pressed byaccident during operation, the oper-ating key must be pressed immedi-ately .
The LED of the „M“ key or „P“ key thenstops flashing.
If this is not done, the burner remainsin „M“ mode or „P“ mode after an„OFF“ command is issued. Theburner cannot be restarted until the„Operation“ key is pressed .
If the values are not equal, pressSave.
F1 F2 F3
Please select:Enter CRC
Enter
F1 F2 F3
Settings 90 | 90Test gas curve 80 | 80Show oil curve 89 | 89Enter Save
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Burner Control Systemoutput controller
BCS output controller
100
Tem
per
atur
e/p
ress
ure
%of
fina
l val
ueBaseload 0 4 10 20 mA
Controller types 1 + 2 standard controller, run-on controllerBurner ON/OFF functions for standard controller
6465
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Controller type 1Settings as standard controller
• Sensor actual value(TEMP / PRESSURE)
• Output control input• Sensor adaptation at 20 mA
(corresponds to e.g. 250°C)• Switching difference Setpoint• Distance Setpoint• Setpoint 1• Kp range
Gain, P proportion• Tn I proportion• Tv D proportion• Neutral zone I (PID)
Favourable setting values:
100
Tem
per
atur
e/p
ress
ure
%of
fina
l val
ue
Baseload 0 4 10 20 mA
Input: Output controller
Controller type 2Settings as run-on controller :• Base load 4 mA• Full load 20 mA
(not variable)• System response
Input signal < 4 mALow load or lockout
ON/OFF function via control switch,Input terminal: Control chain
4
19
20
externaltransmitter
BCSInput Terminal:
Control chain
Output control4…20 mAGND
e.g. of sensor e.g. of external controller
BCS output controllerTwo controller types can be selected:
• Controller type 1:standard controller
• Controller type 2:run-on controller
The input current is 4…20 mA. The en-try „System response to input signal <4 mA“ defines how the BCS respondsto an input signal less than 4 mA.• The controller ramps up to low load.
The system interlocks.
100
Bur
ner
outp
ut in
%
0 4 10 20 mA
Output control input
Baseload
Burner Control SystemOutput controller
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Burner Control SystemOutput controller
Burner ON/OFF functions for standard controller
Switching difference The switching difference is the totaldifference above and below thesetpoints.
ON/OFF point, symmetrical Example of a symmetrical ON/OFFpoint:Setpoint 90°C,Switching difference 10 K,Switch-off point 5K above setpointmeans:• Switch off at 95°C• Switch on at 85°C
ON/OFF point, asymmetrical upwards Example of an asymmetrical ON/OFFpoint:Setpoint 90°C,Switching difference 10 K,Switch-off point 8K above setpointmeans:• Switch off at 98°C• Switch on at 88°C
ON/OFF point, asymmetrical downwards Example of an asymmetrical ON/OFFpoint:Setpoint 90°C,Switching difference 10 K,Switch-off point 3K above setpointmeans:• Switch off at 93°C• Switch on at 83°C
Setpoint
ON OFF
Setpoint
Actual value20°C 120°CSwitching difference
Setpoint
ON OFF
Setpoint
Actual valueDistance toswitch-off point
20°C 120°C
Setpoint
ON OFF
Setpoint
Actual valueDistance to switch-off point,upwards
20°C 120°C
Setpoint
ON OFF
Setpoint
Actual valueDistance to switch-off pointdownwards
20°C 120°C
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BCS fault list, operating system fault code 01…33BCS fault list, operating system fault code 34…65BCS fault list, user program fault code 100…125Read out fault memoryFault memory inputs of the basic moduleFault memory inputs of the flame detector modeFault memory outputs of the basic moduleFault memory outputs of the flame detector modeDisplay safety computers 1 and 2List of numbers
BCS fault memory
67686970717272737374
Burner Control SystemErase fault memory
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BCS fault listThere are two types of fault:operating system faults and user program faults
A= lockout after startupB= lockout
Burner Control SystemErase fault memory
Error code
01 A Error codeDuring RAMTEST_1, no difference was found when comparing RAM_1 and RAM_2 . 02 B During RAMTEST_1, the identifier of RAM_1 was not found. 03 B During RAMTEST_1, the identifier of RAM_2 was not found. 04 B During RAMTEST_1, a difference between RAM_1 and RAM_2 was detected (apart from RAMKENNUNG). 05 B During RAMTEST_2, RAMTEST_3, RAMTEST_4 or RAMTEST_5, the identifier of RAM_1 or RAM_2 was not
found. 06 B During RAMTEST_6, RAMTEST_7, RAMTEST_8 or RAMTEST_9, the identifier of RAM_1 or RAM_2 was not
found. 07 B During RAMTEST_6, RAMTEST_7, RAMTEST_8 or RAMTEST_9, the value obtained from RAM_1 or RAM_2 is incorrect. 08 B During RAMTEST_10, the identifier of RAM_1 was not found. 09 B During RAMTEST_10, the identifier of RAM_2 was not found. 10 B During RAMTEST_11, the identifier of RAM_1 was not found. 11 B During RAMTEST_11, the identifier of RAM_2 was not found. 12 B During the PROMTEST, the signature does not match the PROM contents. 13 B CPUTEST faulty. 14 B No more free cells available. 15 B Identifier (basic computer 1 or 2) is not explicit. 19 B More than 5 restarts during the start phase. 21 B Watchdog fault. K1 or K2 picked up during the start phase. (system voltage 24V) 22 B Watchdog fault. Fault in the safety chain during the start phase. 23 B Watchdog fault. Quick shutdown faulty during operation. 24 B Watchdog fault. Monostable flip-flop (74123) is not executed during operation. 25 B System frequency (64 Hz) faulty. 26 B EEPROM is not writable. 27 B EEPROM signature generally faulty. 28 B The 64 Hz can no longer be checked. ( 65 ms interrupt faulty) 29 B Watchdog fault. The relay drops out during the start phase. 30 B A cyclic test was omitted. 31 B The system tests are not invoked regularly. (> 60 minutes) 32 B EEPROM signature of gas curve faulty. 33 B EEPROM signature of oil curve faulty.
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BCS – Fault list
Operating system faults
Example:Fault 49 has occurred: „Compositemodule; safety relevant outputs Testroutine 1 (software / hardware)“
see BCS fault list „Operating systemfaults“.
A= interlock after startupB= interlock
Burner Control SystemErase fault memory
Fault code
34 A Operating system fault: ERROR_IN_VERB.35 A Operating system fault: ILLEGAL_STATE.36 A Operating system fault: ILLEGAL_VERB_CODE.37 A Operating system fault: ILLEGAL_DEV_NAME.38 A During the PROMTEST, the signature does not match the contents.40 A Dynamic test of composite module; test pattern was twice incorrect.41 A No message received from composite module.42 A Composite module; RAM test fault.43 A Composite module; EPROM fault.44 A Composite module; CPU test fault.45 A Composite module; safety relevant outputs Test routine 2. (hardware)46 A Composite module; safety relevant inputs faulty.47 A RS 232-Interface faulty > 30 s.49 A Composite module; safety relevant outputs Test routine 1. (software / hardware)50 A Dynamic test of FLW module; test pattern was twice incorrect.51 A No message received from FLW module.52 A FLW module; RAM test fault.53 A FLW module; EPROM fault.54 A FLW module; CPU test fault.55 A FLW module; non selected input has switched.60 A CAN fault (BUS-OFF, table too small).61 A Gas motor fault (zero adjust, sen. signals do not arrive orinput oscillating).62 A Oil motor fault (zero adjust, sen. signals do not arrive or input oscillating).63 A Air motor fault (zero adjust, sen. signals do not arrive or input oscillating).64 A ALIVE-MSG of network computer missing ( safety computer is not operating).65 A Motor fault (steps ).
Fault code 49
Erase fault memory
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BCS – Fault list
User program fault
Example:Fault 105 has occurred: „Air pres-sure switch, deficiency of air“.
see BCS fault list, „User programfaults“
A= interlock after startupB= interlock
Burner Control SystemErase fault memory
Fault code plain text on display
100 A Gas pressure MAX open.102 B Heavy oil release open.103 B Flame failure.104 B Air pressure switch diid not switch during preventilation period.105 B Air pressure switch Deficiency of air.106 A Oil safety chain open.107 B Gas pressure too low. 3 attempts failed.108 A Air pressure switch Idle state check.109 A FUEL actuator drive defective. (+display of nominal and sens values)110 B Ignition flame signal present during preventilation period.111 B No main flame signal received after safety period.112 B Leakage test V1 leaky.113 B Flame simulation supervision after deactivation.114 A No ignition flame signal received after safety period.115 B Main flame signal during preventilation period116 B Stabilization period Ignition flame signal failure.117 B Controller signal < 3.5 mA120 B Boiler safety chain open.122 B Leakage test V2 leaky.123 B Ignition flame failure.124 A Actuator drive (no completion report received).125 A Air actuator drive defective. display of nominal and sens values.
Fault code 105
Erase fault memory
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The fault memory can be read out during „operation“ and in the „Burner OFF“ state (Basic settings „a“ in level 0).For each fault, all input or output states are stored.
Procedure:
F1 F2 F3
F1 F2 F3
Fault memory 5Date clock time29/03/99 06:42Cancel Next Fault memory 5
Fault / internal103 122 194Cancel Next
Press the F2 key to read out thenext fault memory.
Maximum no. of entries 10.The smallest number is the oldestentry.
Assignment of input and outputstates to the numbers:
Press + key can to retrieve theindividual items in the fault memory.
Gas
Max
. G
as M
in.
Oil
safe
ty c
hain
LD
W
— Boi
ler
safe
ty c
hain
— —
8 7 6 5 4 3 2 1
1. Get input /output mask from list of numbers2. Store input /output mask under template.
Con
trol
ler
ind
ex 1
…10
0
TemplatesInputsBasic module
Tem
plat
e fo
r 2n
d di
git
Tem
plat
e fo
r 3r
d di
git
Burner Control SystemErase fault memory
Rel
ease
hea
vy o
il — — — — — — —
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
x x x x
Fue
l typ
e se
lect
ion
Gas
/Oil
VD
K
— Bur
ner
ON
— — — —
Fault memory 5Inputs Basic module 225 0 232 12
Fault No. Input/output mask8 7 6 5 4 3 2 1
0 128 x1 129 x X2 130 x X3 131 x X X4 132 x X5 133 x X X6 134 x X X7 135 x X X X8 136 x X9 137 x X X
10 138 x X X11 139 x X X X12 140 x X X13 141 x X X X14 142 x X X X15 143 x X X X X16 144 x X17 145 x X X18 146 x X X19 147 x X X X20 148 x X X21 149 x X X X22 150 x X X X23 151 x X X X X24 152 x X X25 153 x X X X26 154 x X X X27 155 x X X X X28 156 x X X X29 157 x X X X X30 158 x X X X X31 159 x X X X X X32 160 x X33 161 x X X34 162 x X X
8 7 6 5 4 3 2 1
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Fue
l sel
ectio
n ga
s/oi
l V
DK
— Bur
ner
ON
— — — —
Fault memory 5Inputs basic module225 0 232 12Cancel Next
All inputs of thebasic module (in the event of a fault)are stored.
The definitions of the numbers areas follows (see list of numbers).
Controller index 1 … 100
8 7 6 5 4 3 2 1
— — — Rel
ease
hea
vy o
il
— — — —
8 7 6 5 4 3 2 1
99 227 x x x x x x100 228 x x x x101 229 x x x x x102 230 x x x x x103 231 x x x x x x104 232 x x x x105 233 x x x x x106 234 x x x x x
Gas
Max
.
Oil
safe
ty c
hain
LD
W
— Boi
ler
safe
ty c
hain
— —
undefinedBurner ON = onFuel selection = oilInput: VDK = closed
Note:The number range extends from 0 to 255Number range 1 = 0 to 127 —> input / output mask valid 1 to 7Number range 2 = 128 to 255 —> input / output mask valid 1 to 8
Example: number 12 Example: number 195
Fault Fault in input/output mask
No. 8 7 6 5 4 3 2 1 0 128 x 1 129 x x 2 130 x x 3 131 x x x 4 132 x x 5 133 x x x 6 134 x x x 7 135 x x x x 8 136 x x 9 137 x x x10 138 x x x11 139 x x x x12 140 x x x13 141 x x x x
Fault Fault in input/output mask
No. 8 7 6 5 4 3 2 164 192 x x65 193 x x x66 194 x x x67 195 x x x x68 196 x x x69 197 x x x x
8 invalid
8 7 6 5 4 3 2 1
93 221 x x x x x x94 222 x x x x x x95 223 x x x x x x x96 224 x x x97 225 x x x x98 226 x x x x
Burner Control SystemErase fault memory
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Fault memory 5Inputs FLW module2 205Cancel Next
Intensity of flame signal where:
QRA53 >200 goodQRA2 >200 goodRAR7 >200 goodIONISATION <6 good
— — — — — — Igni
tion
flam
e de
tect
or M
ain
flam
e de
tect
or
Inputs of the flame detector mode (FLW module)
Fault memory 5Outputs Basic module28 1 0Cancel Next
Outputs of the basic module
8 7 6 5 4 3 2 1
Fau
lt m
essa
ge B
urne
r m
otor
, blo
wer
Mai
n va
lve
Fue
l Con
trol
ler
rele
ase
Igni
tion
valv
e S
afet
y va
lve
Fee
d/re
turn
val
ves
Noz
zle
valv
e
8 7 6 5 4 3 2 1
— — — — — — Pum
p m
otor
Igni
tion
trans
form
er, g
as fi
ring
8 7 6 5 4 3 2 1
Fue
l gas
/oil
mod
e
Fue
l bur
ner
oper
atio
n
— Igni
tion
trans
form
er, o
il fir
ing
— — — —
8 7 6 5 4 3 2 1
Burner Control SystemFault memory
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Outputs of the flame detector mode (FLW module)
Display of safety computer 1
The fault memory is deleted in level 1 „m“.
Each of the two safety computers has its own fault memory.
Display of safety computer 2
The display constantly changes between safety computer 1 (8 sec.) andsafety computer 2 (4 sec.).To deactivate the change of display, follow this procedure:
• Display for safety computer 1 onlyPress key „M“ and key „—“ simultaneously for 4 sec.
• Display for safety computer 2 onlyPress key „M“ and key „+“ simultaneously for 4 sec.
• Display for safety computers 1 and 2 onlyPress key „M“, key „—“ and key „+“ simultaneously for 4 sec.
Burner Control SystemFault memory
Fault memory 5Outputs FLW module
0Cancel Next
No outputs available
— — — — — — — —
8 7 6 5 4 3 2 1
Fault memory 5Outputs Basic module28 1 0Cancel Next
Fault memory 5Outputs Basic module28 1 0Cancel Next
No bar at bottom right. Bar at bottom right.
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List of numbers
Burner Control SystemFault memory
Fault No. Input/output mask8 8 7 6 5 4 3 2 10 128 x1 129 x X2 130 x X3 131 x X X4 132 x X5 133 x X X6 134 x X X7 135 x X X X8 136 x X9 137 x X X
10 138 x X X11 139 x X X X12 140 x X X13 141 x X X X14 142 x X X X15 143 x X X X X16 144 x X17 145 x X X18 146 x X X19 147 x X X X20 148 x X X21 149 x X X X22 150 x X X X23 151 x X X X X24 152 x X X25 153 x X X X26 154 x X X X27 155 x X X X X28 156 x X X X29 157 x X X X X30 158 x X X X X31 159 x X X X X X32 160 x X33 161 x X X34 162 x X X35 163 x X X X36 164 x X X37 165 x X X X38 166 x X X X39 167 x X X X X40 168 x X X41 169 x X X X42 170 x X X X43 171 x X X X X44 172 x X X X45 173 x X X X X46 174 x X X X X47 175 x X X X X X48 176 x X X49 177 x X X X50 178 x X X X51 179 x X X X X52 180 x X X X53 181 x X X X X54 182 x X X X X55 183 x X X X X X56 184 x X X X57 185 x X X X X58 186 x X X X X59 187 x X X X X X60 188 x X X X X61 189 x X X X X X62 190 x X X X X X63 191 x X X X X X X
8 7 6 5 4 3 2 1 Fault No. Input/output mask
8 7 6 5 4 3 2 164 192 x X65 193 x X X66 194 x X X67 195 x X X X68 196 x X X69 197 x X X X70 198 x X X X71 199 x X X X X72 200 x X X73 201 x X X X74 202 x X X X75 203 x X X X X76 204 x X X X77 205 x X X X X78 206 x X X X X79 207 x X X X X X80 208 x X X81 209 x X X X82 210 x X X X83 211 x X X X X84 212 x X X X85 213 x X X X X86 214 x X X X X87 215 x X X X X X88 216 x X X X89 217 x X X X X90 218 x X X X X91 219 x X X X X X92 220 x X X X X93 221 x X X X X X94 222 x X X X X X95 223 x X X X X X X96 224 x X X97 225 x X X X98 226 x X X X99 227 x X X X X
100 228 x X X X101 229 x X X X X102 230 x X X X X103 231 x X X X X X104 232 x X X X105 233 x X X X X106 234 x X X X X107 235 x X X X X X108 236 x X X X X109 237 x X X X X X110 238 x X X X X X111 239 x X X X X X X112 240 x X X X113 241 x X X X X114 242 x X X X X115 243 x X X X X X116 244 x X X X X117 245 x X X X X X118 246 x X X X X X119 247 x X X X X X X120 248 x X X X X121 249 x X X X X X122 250 x X X X X X123 251 x X X X X X X124 252 x X X X X X125 253 x X X X X X X126 254 x X X X X X X127 255 x X X X X X X X
8 7 6 5 4 3 2 1
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Burner Control SystemBCS startupwith PC support
BCS-Vision
767778-81
Preparatory workLoad BCS with existing curve from PCSet or modify the curve with the PC
A knowledge of burner technology is required.
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Preparatory work
• Connect PC to BCS(modem by-pass cable)jack-jack
• Switch on PC and BCS.At power-on, immediately pressthe P key on the BCS operatingconsole
several times.Entry of code number for level 2
Operate using keys F2. - and +
Use the + key to select the programitem „Einstellung with PC“ (Set with PC).
Press key F1Use the + key to select the „PC =>BCS Daten“ (PC => BCS data)
Screen if connection available.
Is no connection is available, open menu item „options“ (Options) andcheck interface selection.
Load the PC program
Burner Control SystemBCS startupwith PC support
F1 F2 F3
Enter yourcode number: 0 0 0
^Enter ^
F1 F2 F3
Set with PC PC --> BCS Data
Enter Back
F1 F2 F3
Please select:Set with PC
Enter Backs
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The interface to the BCS can bespecified in the submenu item„Schnittstelle“ (Interface). After aselection is made, the data aresaved to the BCS.DAT file.The default setting is COM 1 (evenif the file BCS.DAT does not exist).
Press the F1 key on the BCS controlunit.
A stored file can be selected. This fileis is loaded into the main memory ofthe program and the following windowis opened.
Open file.
Load BCS with an available curve from the PC
Check he file and „Daten laden“(Load data) pushing.
After the data are loaded successfully,CRC-PC, CRC-A and CRC-B mustmatch.If not, they must be reloaded.The following display appears onthe BCS control unit :
Press the F1 key and then the + key.
F1 F2 F3
BCS datasuccessfully loaded
Enter
Burner Control SystemBCS startupwith PC support
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Set or modify the curve with the PC
F1 F2 F3
Set with PCSet with gas
Enter Back
Press key F1
Click the „Start“ button on the PC.The motors run to purge position.When the position is reached,„Spülposition erreicht“ (Purge positionreached) appears at the bottom left.The values for purge position can nowbe modified.Enter the new number and press „En-ter“.The CRC-PC changes. Press„Einzelwert“ (Individual value).The motor ramps up to the new posi-tion. All 3 CRCs are now identical.
Now click the mouse on the „rinsing“(Purge) button. The set preventilationperiod counts back to 0. Then clickthe „Zündposition“ (Ignition position)button. The motors ramp up to theignition position.As with the purge position previously,the ignition position can be modifiedin the fields„Zündposition“ (Ignition position). Usethe „Einzelwert“ (Individual value) keyto transfer the values to the BCS andto approach these new values with theBCS.
Burner Control SystemBCS startup withPC support
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„Zündung“ (Ignition) appears on theBCS control unit .
Press key F1 to ignite the burner (keymust be pressed for at least 1 s).
After a flame forms, the following dis-play appears:
The ignition position can be changedagain and the new values can betransferred with the „Einzelwert“ (In-dividual value) key.
An operating point (line) must be se-lected for the point of entry into thetable where the position for the airdamper matches the ignition positionmost closely.If the value is to be changed, activatethe field with a click of the mouse andenter the new number (usually be-tween 1 and 15). Confirm with the„Enter“ key.Before entering the table, changes invalues with calculation must be trans-ferred to the BCS. To enter the table,click the red arrow button and enterthe corresponding operating point.
After pressing the OK key, the motorsleave the ignition position and rampup to the selected operating point.
Burner Control SystemBCS startup withPC support
F1 F2 F3
Set ignition point
Ignition
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The motors ramp from the ignitionposition 1050 990 to 1061 1008.
Use the red arrow keys to approachthe operating point on the motorcurves.
The red arrow keys on the left-handside move the operating point oneincrementup or down.The red arrow keys on the right-handside move the operating point 10 in-crements in the chosen direction. TheBCS individually approaches eachoperating point in between the 10values.
The current curves can be viewed inthe graphics window.The numbers 1, 10, 20, 30, 40, 50,60, 70, 80, 90 and 100 are interpola-tion points (marked x in Pkt. type).To change the value, click on a fieldin the table.An operating point can be convertedto an interpolation point by:- changing the fuel, air or output value- double clicking on any cell in the
line
To remove an interpolation points,double click on the „x“.
Example:Modifying the air motor position.There is a deficiency of air at operat-ing point 7.• Click on field in line No. 7 and in
the „Luft“ (Air) column .• Increment the number (press En-
ter).The CRC-PC changes.
• Click on individual value. The airmotor ramps up to the new position(all CRCs will again be identical).
• Repeat the points for „PositionLuftmotor ändern“ (Modify air mo-tor position) until the desired com-bustion setting is reached. The fi-nally value must be transferred byclicking on „Berechnung“ (Calcula-tion) to linearize the points betweenthe interpolation points.
Example: Modifying several points.
The air curve must be partially raised.
• Modify corresponding interpolationpoints for air.
• Click on „Berechnung“ (Calcula-tion).
• Check graphics .• Click on „OK“
(the complete curve is transferredto the BCS).
The 3 CRCs must now be identicalagain.• Click on red arrow keys. The mo-
tors ramp up to the newly enteredcurve.
If all points on the curve are correct,ramp the burner down to the low op-erating point.Shut down via the BCS.
F1 F2 F3
Setting phase, gas Intensity:: 247
Index: 9Off
Intensity: 247 is the flame signal in-tensity
Burner Control SystemBCS startup withPC support
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F1 F2 F3
After shutting down the burner, thefollowing message appears on thedisplay of the BCS control unit:
Press F2 key,press + key until„CRC eingetragen“(CRC entered)appears, press F1 key.
Set with PCSet with gas
Enter Back
F1 F2 F3
Setting : 58 | 58Gas curve : 44 | 44Oil curve : 245 | 245Enter Save
Note:
The values in a line must always be equal.
Left-hand value calculated by system
Right-hand value stored value since last transfer
Settings CRC over the safety relevant settings of the system
Gas curve CRC over the complete gas curve
Oil curve CRC over the complete oil curve
Burner Control SystemBCS startup withPC support
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838383-848585-868788899091-93949595
BCS-VISIONOverview / application
Burner Control SystemBCS -VisionOverview / application
Main windowSettings in the menuAccess for fittersSetting window for data processing without BCSComponents in the setting windowMenu itemsData transfer from PC to BCSData transfer from BCS to PCSetting window for data processing with BCSSet the BCSEnter memosThe graphics windowSettings in the menuOld documentatio
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Main windowThe main window provides access tothe setting window by entering apassword or a keyword. Existing files(motor curves) can be edited in thesetting window. At the bottom edgeof the window there is a status dis-play which indicates whether a con-nection to the BCS exists, andwhether the BCS system has abortedor interlocked.
Settings in the menu
Menu item „Datei“ (File)
„Beenden“ (Exit) ends BCS Vision
Optional for exitingthe programs.
Menu item „Optionen“ (Options)
Any keyword can be selected in thesubmenu „Kennwort ändern“(Change keyword).
Optional for changing thekeyword.
The „Kennwort Änderung“ (Keywordchange) window (see right) isopened.
After entering the password for fitter access (234) and the valid keyword (de-fault setting: „Maier“), the new keyword can be entered.
The fitter can use the „NeueKennwort“ (New keyword) to gener-ate his own keyword.
Burner Control SystemBCS -VisionOverview / application
„Zugang für Monteure“ (Access forfitters) can be obtained by enteringthe general password (234) or theself-defined keyword in the field„Passwort“ (Password).
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The PC interface for BCS data trans-fer can be specified in the submenuitem „Schnittstelle“ (Interface). Aftera selection is made, the data aresaved to the BCS.DAT file.The default setting is COM 1 (even ifthe file BCS.DAT does not exist).
Access for fitters(access for the operator is not imple-mented)
Procedure:
The item „Monteur“ (Fitter) is auto-matically selected in the left-hand fieldof the Main window.The password or the (freely selected)keyword must be entered in the field„Passwort“ (Password).
Press OK key.
The right-hand field of the main win-dow changes.
By selecting „Daten von Datei“ (Datafrom file) (and pressing the OK key),previously savedcurve settings can be retrieved andedited in the setting window.
Burner Control SystemBCS -VisionOverview / application
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Example:After pressing the OK key, the dialogfor opening a file appears.
Click on the „Öffnen“ (Open) key toload the marked file. The setting win-dow for editing without BCS (Offline)is displayed.
By selecting „Aktuelle DatenBearbeiten“ (Edit current data) in themain window (and pressing the OKkey ), previously loaded curves fromthe BCS or a file can be edited in thesetting window.
Setting window for data processing without BCS
All curve settings can be changedand checked in the setting windowfor data processing without BCS.
Burner Control SystemBCS -VisionOverview / application
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Components in the setting window
• The currently selected curve „Gas/Oil“ is displayed in the windowheader
• „Gaskurve“ (Gas curve) and„Ölkurve“ (Oil curve) key U s eto select curve to be edited.
• „Grafikfenster“ key Opens awindow in which the curve valuescan be graphically represented(check)
• „Berechnung“ (Calculation) keyLinearizes points on the curve andupdates the values in the table.
• Fields „Anlage“ (System), „Datum“(Date) and „Monteur“ (Fitter)Here you can specify the system,the date of change and the nameof the fitter..
• Table at top leftIn the table you can view the set-tings for the curve currently se-lected (gas curve or oil curve).To change the settings, click on afield with the mouse and enter avalues using the keyboard. Thearrow keys on the keyboard canalso be used for navigating withinthe table.
The column „Nr“ displays the op-erating point or the line number.100 operating points (motor posi-tions) are available in a table.
The column „Brennstoff“ (Fuel)contains 100 motor values (posi-tions) for the fuel motor (gas or oil).
The column „Luft“ (Air) contains100 motor values for the airdamper motor.
The column „Leistung“ (Output)contains the output of the burnerin percent.The fitter must enterthese values when setting theburner at the factory (no automaticinput). The column „PktArt“ iden-tifies the interpolation points. Theycan be identified as an interpola-tion point or deleted by double-clicking on the selected field. Thevalues between the interpolationpoints are linearized.
Burner Control SystemBCS -VisionOverview / application
This means that it is only neces-sary to select one pair of lines inwhich the motor values are en-tered and identified as an interpo-lation point. When the„Berechnung“ (Calculation) key ispressed, the program calculatesthe intermediate values.Operating points 1, 10, 20, 30, ...,100 are defined as interpolationpoints and cannot be deleted.
Fields below the tableThe first fields below the table con-tain the values of the motors forthe ignition position.
The fields below them contain thevalues of the motors for the purgeposition.
The fields at the bottom left con-tain the maximum allowable mo-tor positions.These values must be set in theBCS and cannot be changed inBCS Vision.
• Clicking the „Tabelle in Dateispeichern“ (Save table as file) but-ton opens a dialog which can beused to enter a file name or selectan existing file for saving the up-dated data to the „*.BCS“ file.
• „Exit“ keyExits the setting window and dis-plays the main window.Old documentatio
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Menu item „data“• „Eintrag rückgängig“ (Undo entry)
Allows the previously changedvalue to be restored.
• „Anzeigen der Memo-Einträge“(Display memo entries)Opens the dialog window for se-lecting a memo file (*.mem).Afterconfirming, the following windowappears.
If no memo file exists, see „Memoseintragen“ (Enter memos).
Burner Control SystemBCS -VisionOverview / application
The name of the selected file is dis-played as the first entry.The lines inthe table which are stored with a textare displayed below it.
• „Daten anzeigen“ (Display data)BCS setting parameters and op-erating data are displayed.
• „Drucker einrichten“ (Set upprinter)For selecting and setting theprinter.
• „Daten ausdrucken“ (Print data)For printing out:- BCS setting parameters- BCS operating data- Table of gas curve values- Table of oil curve values- System / fitter name, setting andprinting dates (footer text)
Menu item „Kurvenanhebung/Kurvenabsenkung“ (Raisecurve/lower curve)A complete motor curve can beraised or lowered by a definedpercentage or by a fixed value withthe menu items „Kurvenanhebung“(Raise curve) and„Kurvenabsenkung“ (Lowercurve).
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Data transfer from PC (BCS -Vision) to BCS
Selection of level 2 at the BCS con-trol unit
Enter code numberPress the Enter key
Press the + key until the option„Einstellungen mit PC“ (Settings withPC) is displayed, and then press „En-ter“
F1 F2 F3
Enter yourCode number: 0 0 0
^Enter ^
Selection of points „PC => BCS Daten“(PC => BCS data).
The data of the gas/oil curves canbe checked in the table.
Button functions
• „Gaskurve“ (Gas curve), the valuesof the gas curve can be checked inthe table.
• „Ölkurve“ (Oil curve), the values ofthe oil curve can be checked in thetable.
• „Grafikfenster“ (Graphics window)is for graphical representation of themotor curves
• „Exit“ closes the window.
• „Daten laden“ (Load data) starts thedata transfer to the BCS. A progressdisplay shows the status of the datatransfer.After the data is loaded into theBCS, the window can be closedwith the „Exit“ button or by press-ing the F1 key (Enter) on the BCScontrol unit.
Burner Control SystemBCS -VisionOverview / application
A previously saved file can be selected. To load this file, press the „Öffnen“(Open) button. The following window now appears.
The following dialog appears onscreen of the PC.
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Selection of level 2 at the BCS con-trol unit
Enter code numberPress the Enter key
Data transfer from BCS to PC (BCS -Vision)
F1 F2 F3
Enter yourCode number: 0 0 0
^Enter ^
The window has the same structureas for „Datenübertragung zum BCS“(Data transfer to BCS) except that thedata can be saved as a file and arenot transferred to the BCS.
When the key „Tabelle in Dateispeichern“ (Save table as file) ispressed, a dialog for selecting the fileor the filename appears. The data aresaved to this file (*.BCS).
Burner Control SystemBCS -VisionOverview / application
Select „BCS => PC Daten“ (BCS =>PC data).The data are transferredfrom the BCS to the PC. The progressdisplay appears on the PC screen.
After the transfer is completed, a win-dow for checking and saving the datais displayed.
Press the + key repeatedly until theoption „Einstellungen mit PC“ (Set-tings with PC) is displayed.Then pressdie Enter key.
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Setting window for data processing with BCS (setting operation)
To call up this window, it is necessaryto load data beforehand from the PCto the BCS, or from the BCS to thePC.
F1 F2 F3
Set with PCSet with gas
Enter Back
The menu „Einstellung mit Gas“ (Set-ting with with gas) or „Einstellung mitÖl“ (Setting with oil) can be selectedwith the + key on the BCS control unit(in the submenu „Einstellung mit PC“(Setting with PC).
Then confirm with the F1 key.
The setting window is opened.
The CRC fields contain the CRC re-sults of the BCS setting data and ta-bles.
CRC-PC -> Calculation by PCCRC-A -> Calculation by BCS -
safety computer ACRC-B -> Calculation by BCS -
safety computer B
The data of all computers is identicalare there is no transfer fault if all threeCRC values match up.
Burner Control SystemBCS -VisionOverview / application
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Set the BCS
The system startup procedure can bedefined in the „Einstellungen“ (Set-tings) menu.That is to say, you canspecify whether the BCS is to stop inthe purge position and whether thepurging procedure and ramp-up toignition position are to be started fromthe PC, or whether the BCS itself con-trols the start phase until commence-ment of ignition.In both cases the BCS utilizes the pre-set values of the automatic burnercontrol program.
Options:• „Einzelabfrage“ (Individual query)
stops the system program after thepreventilation position is reached.
• „Autostart“, the system program ofthe BCS runs until the ignition posi-tion is reached.
Click the „Start“ button at the top rightof the window, and the BCS motorswill ramp up to purge position (belowtable)
The „Aktive Zeile“ (Active line) windownow displays the position which theBCS motors have ramped up to.
The position of the motors for thepurge position can be changed, ifnecessary, in the fields for the purgeposition.
Use the „Einzelwert“ (Individual value)key to transfer the new values for thepurge position to the BCS; the BCSthen ramps up to this position.
After clicking the „Spülen“ (Purge)button at the top left of the window,the purge operation is started.
The preventilation period (purge time)and all other settings for the automaticburner control system were previouslyentered when setting the parameterson the BCS control unit.
Burner Control SystemBCS -VisionOverview / application
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Press the „Zündposition“ button, andthe BCS will ramp up to this position.
As described previously for the purgeposition, the ignition position can bechanged in the fields „Zündposition“(Ignition position); the values can betransferred to the BCS and the BCSservomotors can be ramped up tothese new values with the „Einzelwert“(Individual value) button.
The ignition display appears on theBCS control unit display.
Press the F1 key to ignite the burner(key must be pressed for at least 1s).
The ignition position can again bechanged and the new values trans-ferred with the „Einzelwert“ (Individualvalue) button.
After clicking one of the red arrowbuttons, the point of entry No. can beselected in the table.
Burner Control SystemBCS VISIONOverview / application
F1 F2 F3
Set ignition point
Ignition
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The operating points on the motorcurves can be approached with thered arrow buttons.
The arrow buttons on the left movethe operating point one increment upor down.
The table values are linearized withthe „Berechnung“ (Calculation) but-ton. Note: all changed values in be-tween the interpolation points will berecalculated.The curve should, there-fore, be executed again.
The data can be checked in thegraphics window before they aretransferred to the BCS.
Press the OK key to transfer the tableto the BCS.
The arrow buttons on the right movethe operating point 10 increments inthe selected direction (the BCS ap-proaches each individual operatingpoint in between these 10 values).
Burner Control SystemBCS -VisionOverview / application
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Enter memos
To store a memo in a lines in the ta-ble, this line must first be marked withthe left mouse button and then clickedwith the right mouse button. A dialogfor opening a file now appears.
If no file has been generated as yet,the procedure must be aborted aftercalling up the dialog.
After a file is selected, the Memo fieldis opened.In this field you can enterdata of the operating point or specialpoints to note regarding this operat-ing point.
Press „OK“ to close the memo fieldand save the entry to the file selectedpreviously.If no file has been opened as yet, adialog „Datei speichern unter“ (Savefile as) appears in the Memo fieldwhen the OK key is pressed.
A separate memo file is generated forthe gas table and oil table.
Once all settings have been made,setting mode can be exited by press-ing the F1 key (OFF) on the BCS con-trol unit.
The setting window on the PC isclosed and the main window isopened.
Burner Control SystemBCS -VisionOverview / application
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The graphics window
The red-shaded curve of the legendcan be edited in the graphics window.
To edit a curve in the graphics win-dow, click the left mouse button onthe interpolation point. Hold mousebutton down and move the interpola-tion point to the desired position. Re-lease the mouse button to drop theinterpolation point. The values in be-tween the interpolation points arelinearized automatically.
Menu item „Datei“ (File)=•“Drucker einrichten“ (Set up printer)
For defining and setting up theprinter.
• „Fenster Drucken“ (Print window)Print the graphic
• „Beenden“ (Exit) Closes the windowand opens the setup window.
Menu item „Daten“ (Data)•“Motor Kurven“ (Motor curves) The
motor curves for gas firing or oil fir-ing can be selected.
• „Leistung“ (Output) The outputcurve for the fuel type currently inuse is displayed.
• „Kurvenauswahl“ (Curve selection)Fuel type selection for motor curve.
• „Rückgängig Kurve verschieben“(Undo shift curve) can be used toundo the previous change to thecurve in the graphics window.
Burner Control SystemBCS -VisionOverview / application
• „Motorkurve bearbeiten“ (Edit mo-tor curve) Selection of fuel curve orair curve.The selected curve is shaded redin the legend at the bottom left. Thiscurve can be edited in the graph-ics window.
• „Berechnen“ (Calculate) The curvesare linearized in between the inter-polation points (line equation).
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