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Krom Schroder BCU 460 465

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0% found this document useful (0 votes)

565 views87 pages

Krom Schroder BCU 460 465

Uploaded by

Ergin ÖZIŞIK

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Burner control units BCU 460, BCU 465

Technical Information · GB
6 Edition 07.12

• Automatic burner control unit, ignition transformer, indicators and operating controls
in a space-saving metal housing which replaces the local burner control cabinet
• For directly ignited burners of unlimited capacity in intermittent or continuous
operation pursuant to EN 746-2
• Flame control by UV, ionization or a further option of using the furnace
chamber temperature
• Display of the program status, unit parameters and flame signal; manual
mode for burner adjustment and for diagnostic purposes
• Visualization and adaptation to the specific application via the PC programming
and diagnostic software BCSoft to simplify logistics management.
• Spacious connection chamber with plug-in terminal blocks and plug-in cable
glands for quick installation and servicing
• Air valve control on BCU..L relieves the furnace control
• Optional PROFIBUS DP interface for easy transmission of activation signals
and feedbacks via fieldbus cable
• EC type-tested and certified
• Certified for systems up to SIL 3 and compliant with PL e
Contents
Burner control units BCU 460, BCU 465 . . . . . . . . . . . . . . . . 1 3.1.14 BCU 465..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.15 BCU 465T..B1..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1.16 BCU 465T..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.2 BCU..P with 16-pin industrial plug connector . . . . . . . 32
1.1 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.3 PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1.1 BCU 460: Modulating-controlled burner . . . . . . . . . . . . . . . . 7 3.3.1 Safety-related control signals . . . . . . . . . . . . . . . . . . . . . . . 33
1.1.2 BCU 460..L: Two-stage-controlled burner . . . . . . . . . . . . . . 8 3.3.2 BCSoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1.3 BCU 460..L: Single-stage-controlled radiant tube burner . . 9 3.3.3 Configuration, Master-Slave procedure . . . . . . . . . . . . . . 34
1.1.4 BCU 465..L: Single-stage-controlled burner with 3.3.4 Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
pneumatic 3.3.5 Network technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
air/gas ratio control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3.6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1.5 BCU 465..L: Single-stage-controlled burner . . . . . . . . . . . . . 11 3.3.7 Bus communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1.6 BCU 460..B1 for PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . 13
1.1.7 BCU 460..D: High temperature equipment . . . . . . . . . . . . 13 3.4 BCU 460 program sequence . . . . . . . . . . . . . . . . . . . . 37
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.5 BCU 465 program sequence . . . . . . . . . . . . . . . . . . . 39
2.1 Certified pursuant to SIL . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.6 Program status and fault messages . . . . . . . . . . . . . 42
2.2 EC type-tested and certified . . . . . . . . . . . . . . . . . . . . . 14 4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . 45
2.4 FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.1 Burner flame signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.5 PROFIBUS User Organization . . . . . . . . . . . . . . . . . . . . 15 4.2.2 Switch-off threshold of the flame amplifier . . . . . . . . . . . . 46
2.6 Approval for Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.2.2 High temperature operation in the case of BCU..D2 or
3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 BCU..D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.2.3 UVS check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.1 BCU 460..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4.3 Behaviour in start-up position/standby . . . . . . . . . . . 50
3.1.2 BCU 460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4.3.1 Flame-simulation check in start-up position/standby . . . 50
3.1.3 BCU 465..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.3.2 Position indicator input on BCU 465T..O (POC) . . . . . . . . . 51
3.1.4 BCU 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.3.3 Minimum burner pause time tBP . . . . . . . . . . . . . . . . . . . 52
3.1.5 BCU 465T..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.4 Behaviour during start-up . . . . . . . . . . . . . . . . . . . . . . 53
3.1.6 BCU 465T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.4.1 Safety time on start-up tSA . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.7 BCU 460..P..E1 with industrial plug connector . . . . . . . . . . 22 4.4.2 Minimum burner on time tB . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.8 BCU 460..P with industrial plug connector . . . . . . . . . . . . 23 4.4.3 Flame proving period tFS . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.9 BCU 465..P..E1 with industrial plug connector . . . . . . . . . . 24 4.4.4 Burner start-up attempts . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.10 BCU 465..P with industrial plug connector . . . . . . . . . . . . 25 4.5 Behaviour during operation . . . . . . . . . . . . . . . . . . . . 55
3.1.11 BCU 460..B1..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.5.1 Safety time during operation tSB for V1 and V2 . . . . . . . . . 55
3.1.12 BCU 460..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.5.2 Fault lock-out or restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.1.13 BCU 465..B1..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.5.3 Immediate fault lock-out after installation fault . . . . . . . . 56

BCU 460, BCU 465 · Edition 07.12 ▼ = To be continued 2

4.5.4 Program status on last fault . . . . . . . . . . . . . . . . . . . . . . . . 57 6.8 Permanent remote reset . . . . . . . . . . . . . . . . . . . . . . . 70
4.6 Air valve control on BCU..L . . . . . . . . . . . . . . . . . . . . . . 58 6.9 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.6.1 Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.10 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.6.2 Cooling in start-up position/standby . . . . . . . . . . . . . . . . . 58
4.6.3 Air valve opens in the case of external activation (not 6.11 BCU and BCU..E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
during start-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.12 Signal distributor board . . . . . . . . . . . . . . . . . . . . . . . . 71
4.6.4 Air valve opens in the case of external activation (even 6.13 PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
during start-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 6.13.1 Safety-related control signals . . . . . . . . . . . . . . . . . . . . . . 72
4.6.5 Air valve opens with valve V1 . . . . . . . . . . . . . . . . . . . . . . . 59 6.13.2 Wiring the PROFIBUS plug connector . . . . . . . . . . . . . . . . 72
4.6.6 Air valve opens with valve V2 . . . . . . . . . . . . . . . . . . . . . . 59 6.13.3 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.6.7 Low fire over run-time tKN after a controlled shut-down . 60 6.13.4 Unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.6.8 Behaviour of the air valve after a fault lock-out . . . . . . . . 60 6.14 Third gas valve (can be shut down) on
4.7 Extended air control with BCU 465..L . . . . . . . . . . . . . . 61 BCU 460..L and BCU 465 . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.7.1 Air flow monitoring during purging (BCU 465..L) . . . . . . . . 61 6.15 BCU switched off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.7.2 Pre-ventilation time tVL before start-up (BCU 465..L) . . . . . 62
4.7.3 Air flow monitoring during operation (BCU 465..L) . . . . . . 63 6.16 Note on EC type-examination . . . . . . . . . . . . . . . . . . 74
4.7.4 Delayed air flow monitoring (BCU 465) . . . . . . . . . . . . . . . 64 7 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.7.5 Post-ventilation time tNL after a controlled shut-down 7.1 With ionization sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 75
(BCU 465..L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.2 With UV sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.7.6 Pre-ventilation time after safety shut-down (BCU 465..L) . 65
4.7.7 Pre-ventilation for restart/start-up attempts (BCU 465..L) 65 7.3 Via the temperature in high temperature
4.7.8 Pre-ventilation after reset (BCU 465..L) . . . . . . . . . . . . . . . 65 equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.8 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 8 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8.1 Manual mode limited to 5 minutes . . . . . . . . . . . . . . . . . . 66 8.1 High-voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 8.2 Industrial plug connector, 16-pin . . . . . . . . . . . . . . . . 76
5.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 8.3 PROFIBUS plug connector . . . . . . . . . . . . . . . . . . . . . . 76
6 Project planning information . . . . . . . . . . . . . . . . . . . . . 68 8.4 BCSoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 Cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.4.1 Opto-adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1.1 Ionization cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.5 “Changed parameters” stickers . . . . . . . . . . . . . . . . . . 77
6.1.2 Ignition cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.6 External securing bar . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1.3 UV cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.7 Fastening set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2 Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.8 Radio interference suppressed electrode plugs . . . . 78
6.3 Star electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.4 Calculating the safety time tSA . . . . . . . . . . . . . . . . . . 69
9.1 BCU..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.5 Minimum burner on time . . . . . . . . . . . . . . . . . . . . . . 70
9.2 PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.6 Safety interlock (Limits) . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.3 Safety-specific characteristic values . . . . . . . . . . . . . . . 81
6.7 Protection of safety-relevant outputs . . . . . . . . . . . . . 70
9.4 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

BCU 460, BCU 465 · Edition 07.12 ▼ = To be continued 3

9.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11.1 Waiting time tW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11.2 Safety time on start-up tSA . . . . . . . . . . . . . . . . . . . . . 84
11.3 Ignition time tZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11.4 Flame simulation/Flame simulation delay time tLV . 84
11.5 Safety time during operation tSB . . . . . . . . . . . . . . . . 85
11.6 Flame signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.7 Fault lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.8 Safety interlocks (Limits) . . . . . . . . . . . . . . . . . . . . . . . . 85
11.9 Pilot gas valve V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.10 Main gas valve V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.11 Continuous operation . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.12 Air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.13 Diagnostic coverage DC . . . . . . . . . . . . . . . . . . . . . . 86
11.14 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.15 Safe failure fraction SFF . . . . . . . . . . . . . . . . . . . . . . . 86
11.16 Probability of dangerous failure PFHD . . . . . . . . . . . 86
11.17 Mean time to dangerous failure MTTFd . . . . . . . . . . 86
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

BCU 460, BCU 465 · Edition 07.12 ▼ = To be continued 4

The BCU unites the
functionally interre-
lated components
of automatic burner
control unit, igni-
tion transformer,
Manual/Automatic
mode and display
of operating and
fault statuses in
a compact metal
housing.

1 Application The BCU 465..L is fitted with air flow monitoring and pre- and
The burner control units BCU 460 and BCU 465 control, ignite post-ventilation for use on recuperative burners.
and monitor gas burners for intermittent or continuous opera- The program status, the unit parameters and the level of the
tion. As a result of their fully electronic design, they react quickly flame signal can be read directly from the unit. The burner
to various process requirements and are therefore suitable can be controlled manually for commissioning and diagnostic
for frequent cycling operation. purposes.
They can be used for directly ignited industrial burners of un- If the local requirements on the burner control unit change, the
limited capacity. The burners may be modulating or stage- PC software BCSoft can be adjusted to the unit parameters of
controlled. The BCU is installed near the burner to be monitored. the application by using the optical interface.
On industrial furnaces, the BCU reduces the load on the cen- ▼
tral furnace control by taking over tasks that only relate to the
burner, for example it ensures that the burner always ignites
in a safe condition after it has been restarted.
The optional air valve control on the BCU..L assists the furnace
control for cooling, purging and capacity control tasks.

BCU 460, BCU 465 · Edition 07.12 5

Application
The service personnel is supported by a convenient visualiza-
tion system of the input and output signals and the error history.
The new power management scheme reduces installation and
wiring costs. The power for the valves and ignition transformer
is supplied via the power supply of the BCU, protected by a
replaceable fine-wire fuse.
The conventional wide-spread systems used in industrial fur-
nace and kiln construction require bridging of large distances
Roller hearth kiln
for signal processing. The optionally available BCU..B1 for
in the ceramics
industry connection to the PROFIBUS DP fieldbus is equipped for this
purpose.
As a standardized fieldbus system, the PROFIBUS DP consider-
ably reduces development, installation and commissioning
costs compared to conventional wiring.
The use of a standard bus system offers massive benefits com-
pared to manufacturer-specific bespoke solutions. Time-tested
hardware components, standardized connection methods
and a series of tools of bus diagnostics and optimization are
available on the market from a whole range of manufacturers.
BCU on radiant The widespread use of the system ensures that the planning
tube burner and service personnel are very familiar with how the system
operates and how to handle it and can therefore operate the
system efficiently.

Hardening furnace
with lots of industri-
al burners located
side-by-side

BCU 460, BCU 465 · Edition 07.12 6

Application

1.1 Examples of application

1.1.1 BCU 460: Modulating-controlled
burner
Control: continuous.
The external control system moves the
butterfly valve for air to ignition posi-
L1, N, PE tion. The burner starts at low-fire rate,
DI P and a controller controls the burner
capacity via the butterfly valve for air after
mA PLC the operating state has been signalled.

BCU 460 6 3 5 4

19
18
µC
17
16

12 9

VG..L GIK

BIO
BIC
DK+GT M

BCU 460, BCU 465 · Edition 07.12 7

Application > Examples of application
1.1.2 BCU 460..L: Two-stage-controlled
burner
Control: ON/OFF or ON/HIGH/LOW/OFF
intermittent operation.
The BCU supports the cooling and purg-
ing processes. The burner starts at low-
fire rate. When the operating state is
L1, N, PE reached, the BCU advises the control
DI P unit. The PLC can now pulse the air valve
in order to control the burner capacity.
PLC

DI P A
6 3 5 22 23 4

19
18
µC
17
16

BCU 460..L 12 26 9

VG..N GIK..B

BIO
BIC

VR..R

BCU 460, BCU 465 · Edition 07.12 8

Application > Examples of application
1.1.3 BCU 460..L: Single-stage-
controlled radiant tube burner
Control: ON/OFF.
The BCU supports the cooling and purg-
ing processes.

L1, N, PE
DI P

PLC

DI P A
6 3 5 22 23 4

19
18
µC
17
16

BCU 460..L 12 26

Application > Examples of application
1.1.6 BCU 460..B1 for PROFIBUS DP
The bus system transfers the control
signals for starting, resetting and for
L1, N, PE
DI P
controlling the air valve from the con-
trol system (PLC) to the BCU..B1. In the
opposite direction it sends operating
BUS
PLC
status, the level of the flame signal and
the current program status.
PROFIBUS DP
Control signals that are relevant for safe-
BCU 460..B BCU 460..B BCU 460..B
ty, such as the safety interlocks and digi-
tal input, are transferred independently
1…51 BUS 1…51 BUS 1…51 BUS
of the bus communication by separate
cables.
1 2 3

1.1.7 BCU 460..D: High temperature

equipment
Indirect flame control using the tempera-
STM > 750°C ture. During the start-up process, as long
as the wall temperature is below auto
L1 ignition temperature, the flame must
BCU 4xx..D BCU 4xx..D be controlled by conventional methods.
When the working temperature has ex-
C C
ceeded 750°C, the safety temperature
monitor (STM) takes over the indirect
DI 6 DI 6
9 9 flame control.

BCU 460, BCU 465 · Edition 07.12 13

2 Certification 2.3 CSA
2.1 Certified pursuant to SIL

Certified to CAN/CSA–22.2 No. 199-M89 (R 2004), Canadian

Standards Association Class: 3335-01 and 3335-81 “Systems
SIL 3 according to EN 61508. (Gas)-Automatic Ignition and Components”
The compliance is based on evaluation to EN 13611 A2 (2011). http://directories.csa-international.org
Pursuant to EN ISO 13849-1:2006, Table 4, the BCU can be 2.4 FM
used up to PL e.

2.2 EC type-tested and certified

pursuant to The BCU is FM approved,

Factory Mutual Research Class: 7610 “Combustion Safeguards
– Gas Appliances Directive (2009/142/EC) in conjunction
and Flame Sensing Systems”.
with EN 298:2003,
– Low Voltage Directive (2006/95/EC) in conjunction with Suitable for applications pursuant to NFPA 86.
EN 60730, www.fmglobal.com  Products and Services  Product Cer-
– Electromagnetic Compatibility Directive (2004/108/EC) in tification  Approval Guide
conjunction with the relevant standards relating to radia-
tion.

BCU 460, BCU 465 · Edition 07.12 14

Certification

2.5 PROFIBUS User Organization

BCU 460..B1
PUO = PROFIBUS User Organization,
Certificate no. Z 00692 pursuant to EN 50170-2

2.6 Approval for Russia

Certified by Gosstandart pursuant to GOST-TR.

Approved by Rostekhnadzor (RTN).

BCU 460, BCU 465 · Edition 07.12 15

s1 (BCU 460..L) (BCU 460..C) BCU 460..E1
Test
F1
V1 V2 C N S L

40 41 42 43 44 45 46 47
µC
88 F3
O N1

230V~
I N1 c1 v1 N1 v2 N1 n s l
c2 l N1
1 2 3 4 5 6 PE 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 26 27 30 31 32 33 34 35 36 37 38 50 51

max. 2 A, max. 2 A,
253 V 253 V

A
Z I V1 V2
ϑ DI P

L1 (L1)
N (L2)
PE
7 8 9 7 8 9 10 11

1
UVS 2
3

3 Function
3.1 Connection diagrams
3.1.1 BCU 460..E1
For cable selection and wiring, see page 68 (Project plan-
ning information).
For the explanation of symbols, see page 83 (Legend).

BCU 460, BCU 465 · Edition 07.12 16

Function > Connection diagrams

Test
F1
V1 V2 C N S M L

40 41 42 43 44 45 46 47
C
88 max. 2 A, max. 2 A,
F3
O N1

230V~
253 V 253 V
I v1 N1 v2 N1 n s m l
c2 N1 c1 l N1

1 2 3 4 5 6 PE 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 50 51

16 15 14 8 7 6 12 11 10 9 4 3

Z I V1 V2 p

DI P A 7 8 9 7 8 9 10 11

8 7 6 4 3

16 15 14 12 11 10 9

1
UVS 2
PE 3
L1
N

3.1.9 BCU 465..P..E1 with industrial plug connector

L1 (L1)
N (L2)
PE
7 8 9 7 8 9 10 11
BCU..B1/1
* = BCU 465T..D2
= BCU 465T..D3
2A 2B 1A 1B
** = BCU 465T..O ON ON
OFF OFF

1
UVS 2
3
PROFIBUS-DP

3.1.15 BCU 465T..B1..E1

For cable selection and wiring, see page 68 (Project plan-
ning information).
For the explanation of symbols, see page 83 (Legend).

BCU 460, BCU 465 · Edition 07.12 30

Function > Connection diagrams

s1 (BCU 465..C) BCU 465T..L..B1

Test
F1
V1 V2 C N S M L

40 41 42 43 44 45 46 47
C
88 F3

230V~
O
I N1 c2 N1 c1 v1 N1 v2 N1 s
l N1 m l

1 2 5 6 PE 7 8 9 10 11 12 13 14 15 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 35 36 37 38 50 51

max. 2 A,
253 V

OCS**
Digital input*

Z I V1 V2
DI P

L1 (L1)
N (L2)
PE
7 8 9 7 8 9 10 11
BCU..B1/1
* = BCU 465T..D2
= BCU 465T..D3
2A 2B 1A 1B
** = BCU 465T..O ON ON
OFF OFF

1
UVS 2
3
PROFIBUS-DP

3.1.16 BCU 465T..B1

For cable selection and wiring, see page 68 (Project plan-
ning information).
For the explanation of symbols, see page 83 (Legend).

BCU 460, BCU 465 · Edition 07.12 31

Function

3.2 BCU..P with 16-pin industrial plug connector

The burner control units BCU 460..P and BCU 465..P can
be supplied with an industrial plug connector (pursuant to
VDE 0627). This 16-pin plug connector ensures fast connecting
or disconnecting of units without any additional wiring required.
This simplifies replacing units and reduces standstill times.
All signals to the higher-level control system, the mains supply
and the safety interlocks are routed via this plug, see page
76 (Accessories).

BCU 460, BCU 465 · Edition 07.12 32

Function

3.3 PROFIBUS DP
BCU..B1 features the same scope of functions and performance
of a BCU® without a PROFIBUS connection.
PROFIBUS is a manufacturer-independent, open fieldbus stand-
L1, N, PE
ard for diverse applications.
DI P
PROFIBUS DP is a bus variant for communication between
SPS automation systems and distributed peripherals at the field
PLC
level, optimized for speed and low connection costs.

BUS
API
On PROFIBUS DP, the individual bus stations are connected
via a 2-core shielded cable as standard.
PROFIBUS DP
The bus system transfers the control signals for starting, re-
BCU..B setting and for controlling the air valve to purge the furnace
or kiln or for cooling in start-up position and heating during
1– 6 BUS operation from the control system (PLC) to the BCU..B1. In the
opposite direction, it sends operating status, the level of the
flame signal and the current program status.
1
3.3.1 Safety-related control signals
BCU..B Signals from the safety interlocks and digital input are trans-
ferred independently of the bus communication by separate
1– 6 BUS cables. The air valve used to purge the furnace or kiln can
either be activated via the PROFIBUS or via a separate cable
to terminal 22. The purging process must be monitored by
2
further measures, e.g. flow monitoring.
BCU..B

1– 6 BUS

BCU 460, BCU 465 · Edition 07.12 33

Function > PROFIBUS DP
3.3.2 BCSoft 3.3.4 Addressing
The Windows software BCSoft allows extended access to in- A maximum of 126 units (masters and slaves) can be con-
dividual statistics, protocol functions, line recorders and the nected to a PROFIBUS DP system. Each station is assigned an
parameterization of the burner control unit via an optical in- individual PROFIBUS address which can be set between 0 and
terface. Unit parameters which are not relevant to safety can 126 using two code switches on the BCU..B1 board.
be set and adjusted to the specific application.
3.3.3 Configuration, Master-Slave procedure
PROFIBUS DP is structured as a Master-Slave system. This al-
lows mono-master or multi-master systems to be implemented.
A distinction is made between three device types:
– DP Masters Class 1 (DPM1)
DPM1 devices are central controllers which exchange
data with the distributed stations (slaves) on the basis of a
defined cycle. This includes, for instance, the PLC, PC, CNC
or VME systems with which the PROFIBUS DP is operated.
– DP Masters Class 2 (DPM2)
DPM2 devices are programming, project planning or
operator-control devices. They are used for configuration
and commissioning of the system or for system operation
and visualization in ongoing operation.
– DP Slaves
The devices which transmit input information from the
periphery to the master and which issue output informa-
tion from the master to the periphery are referred to as
“slaves”.
This also includes the BCU..B1.

BCU 460, BCU 465 · Edition 07.12 34

Function > PROFIBUS DP
3.3.5 Network technology 3.3.7 Bus communication
All devices are connected in a bus structure (line). Up to 32 Input bytes (BCU ➔ master)
stations (masters or slaves) can be connected in a single seg- Bit Byte 0 Byte 1 Byte 2 Byte 3 Byte 4
ment. The beginning and end of each segment is fitted with 0 / 1
an active bus terminator. Both bus terminators must have a

and fault messages)

42 (Program status
1 2

See table on page

permanent power supply to ensure error-free operation. The

1
2

/
power supply for the bus terminator is provided by the BCU.

0 – 25.5 µA 2
255 steps

255 steps
Reserved
The bus terminator can be connected in the bus connection 3 A on

0 – 25.5 µA
plug. 4 P on

If more than 32 stations are implemented or if there is a need 5 DI on

to expand the network area, repeaters (amplifiers) must be 6
used to link the individual bus segments. 7
3.3.6 Configuration
When planning a PROFIBUS DP system, unit-specific param- BCU 460/465/480 basic I/O
eters of each station are to be taken into account.
To allow for simple and standardized planning, the param- BCU 460/465 standard I/O
eters of the BCU..B1 have been summarized in a so-called
device master data file (GSD). The file structure is standard-
BCU 480 standard I/O
ized so that it can be read by the planning devices of different
manufacturers. Output bytes (master ➔ BCU)
The GSD file is supplied on the BCSoft CD which is included in Bit Byte 0
the delivery of BCU..B1. The GSD file can also be ordered at 0
www.docuthek.com. The steps required to copy the file are 1 / ϑ1
described in the instructions for the automation system.
2 A
3 P

4 ϑ2
5 Reserved
6 Reserved
7 Reserved
▼

BCU 460, BCU 465 · Edition 07.12 35

Function > PROFIBUS DP > Bus communication
I/O bytes: the programmer can choose the data to be trans-
ferred.
Inputs Outputs
460/465 basic I/O 1 byte 1 byte
460/465 standard I/O 4 bytes 1 byte
480 basic I/O 1 byte 1 byte
480 standard I/O 5 bytes 1 byte
Baud rate: up to 1500 kbit/s.
The max. range per segment depends on the baud rate:
Baud rate [kbit/s] Range [m]
93.75 1200
187.5 1000
500 400
1500 200
The specified ranges may be increased by using repeaters.
No more than three repeaters should be connected in series.
The specified ranges relate to bus cable type A (two-core,
shielded and twisted), e.g.
Siemens, Order No.: 6XV1830-0EH10, or
Lapp cable unitronic, Order No.: 2170-220T.

BCU 460, BCU 465 · Edition 07.12 36

Function

BCU 460..L 3.4 BCU 460 program sequence

Switch on BCU 460 with air valve control features the Normal start-up
following additional functions.
If an “old” fault is still being signalled
In the event of fault signal:
reset after switching on, it will be necessary
to reset this first.
Safety interlock (Limits)
When the safety interlocks are closed,
the BCU reverts to start-up position
and conducts a self-test. If it does not
00 Start-up position/Standby In start-up position, the air valve
determine a malfunction of the internal
can be opened for cooling A .
electronic circuitry or of the flame sensor,
If parameter P15 = 1: the burner can be started.
flame simulation check
The flame simulation check is conducted
during start-up position or after applying
01 Start-up with ϑ signal Using parameter 31, it can be the start-up signal (ϑ), depending on
determined whether the air valve
can be activated externally dur- parameter 15.
Wait until ing start-up. After the min. burner pause time tBP has
min. burner pause time tBP
has elapsed (P21) elapsed, the BCU opens valve V1 and
ignites the burner. The ignition time tZ
is constant.
If parameter P15 = 0:
flame simulation check If a flame is detected during the safety
time tSA, the flame proving period tFS
02 Safety time tSA The air valve can be set to open starts after this safety time has elapsed.
running (P22), together with V1 (display A2 ) via Valve V2 opens and the operation sig-
ignition in process, parameter 30. nalling contact between terminals 16
V1 opens and and 17 closes. This completes start-up.
min. burner on time tB
starts to elapse (P20) An adjustable min. burner on time tB en-
sures that the burner burns for a defined
period even if the start-up signal (ϑ) is
If no flame detected: switched off beforehand.
max. 3 start-up attempts
or fault lock-out ▼

BCU03
460, BCU 465 · Edition 07.12 37
Flame proving period tFS
max. 3 start-up attempts
or fault lock-out
Function > BCU 460 program sequence
The burner can also be started manually
with the aid of the switch on the BCU.
03 Flame proving period tFS Voltage must be applied continuously
running (P23) to terminals 1, 4 and 5 in order for this
to occur.
In the event of flame failure: The BCU can also be operated in Manual
fault lock-out
mode for start-up.

04 The air valve can also be set to Start-up without flame signal
Operation signalling
contact closes open with V2 or to be activated If no flame is detected during the safety
and V2 opens externally (display A4 ) via pa- time tSA, either a fault lock-out occurs or
rameter 30. up to two further start-up attempts occur.
In the event of flame failure: The required functions and, if applicable,
restart or the number of start-up attempts must be
fault lock-out specified when ordering. (Parameter 10,
“Burner start-up attempts”).
Behaviour in the event of flame failure
04 Controlled shut-down during operation
via ϑ signal
If the flame fails during operation, either
an immediate fault lock-out or a restart
00 If min. burner on time tB occurs. This procedure can be set via the
has elapsed: optical interface (parameter 12, “Burner
operation signalling
contact opens, restart”).
V1 and V2 close,
min. burner pause time tBP
starts to elapse (P21)

BCU 460, BCU 465 · Edition 07.12 38

Function

3.5 BCU 465 program sequence

Switch on BCU 465
Normal start-up
If an “old” fault is still being signalled
In the event of fault signal: reset after switching on, it will be necessary
to reset this first.
Safety interlock (Limits) When the safety interlocks are closed,
the BCU reverts to start-up position
00 Start-up position/Standby and conducts a self-test. If it does not
determine a malfunction of the internal
A0 The air valve can be electronic circuitry or of the flame sensor,
opened for cooling. the burner can be started.
The flame simulation check is conducted
00 If parameter P15 = 1: during start-up position or after applying
flame simulation check the start-up signal (ϑ), depending on
parameter 15.
01 Start-up with ϑ signal After a safety shut-down, first the pre-
ventilation time after safety shut-down
Wait until min. burner pause time elapses (parameters 39 – 41). Then the
tBP has elapsed (P21) min. burner pause time tBP runs. The
If parameter P06 = 1: verification of air BCU now opens valve V1 and ignites the
“no flow” state check burner. The ignition time tZ is constant.
▼
A1 Pre-ventilation time after
safety shut-down running (P39–41)
01 Min. burner pause time tBP
running once again (P21)

If parameter P15 = 0:
flame simulation check

BCU 460, BCU 465 · Edition 07.12 39

A1 Pre-ventilation time tVL running (P37)
If parameter P15 = 0:
flame simulation check

Function > BCU 465 program sequence

If both flame and air flow are detected
during the safety time tSA, the flame prov-
A1 Pre-ventilation time tVL running (P37)
ing period tFS starts after this safety time
has elapsed. Valve V2 opens and the op-
eration signalling contact between ter-
A2 Safety time tSA running (P22), minals 16 and 17 closes. This completes
ignition in process, start-up. An adjustable min. burner on
V1 opens and
time tB ensures that the burner burns
min. burner on time tB starts to elapse (P20)
for a defined period even if the start-up
signal (ϑ) is switched off beforehand.
If parameter P30 = 1:
air valve opens with V1 The burner can also be started manually
with the aid of the switch on the BCU.
Voltage must be applied continuously
If no flame detected or air flow decreases: to terminals 1, 4 and 5 in order for this
max. 3 start-up attempts
or fault lock-out to occur.
The BCU can also be operated in Manual
A3 Flame proving period tFS mode for start-up.
running (P23)
▼
In the event of flame failure or air flow failure:
fault lock-out

A4 Operation signalling contact closes and

V2 opens

In the event of flame failure or air flow failure:

restart
or fault lock-out

BCU 460, BCU 465 · Edition 07.12 40

Function > BCU 465 program sequence
Start-up without flame signal/without
air flow
A4 If no flame or no air flow is detected dur-
Controlled shut-down
via ϑ signal ing start-up, either a fault lock-out occurs
or up to two further start-up attempts
occur. The required functions and, if ap-
A0 If min. burner on time tB has elapsed:
the operation signalling contact opens and plicable, the number of start-up attempts
V1 and V2 close must be specified when ordering (pa-
rameter 10, “Burner start-up attempts”).
Post-ventilation time tNL running (P38) Behaviour in the event of flame failure/
min. burner pause time tBP starts to elapse (P21)
air flow failure during operation
If the flame or air flow fails during opera-
tion, either an immediate fault lock-out or
a restart occurs. This procedure can be
set via the optical interface (parameter
12, “Burner restart”).

BCU 460, BCU 465 · Edition 07.12 41

Function

3.6 Program status and fault messages

BCU 465T..B1
BCU 460..B1
BCU 465..B1
BCU 465T
BCU 460
BCU 465
Program status DISPLAY Fault message (flashing)

BCU switched off – –   

Start-up position/Standby 00      
Purge P0      
Waiting time/Pause time 1 Flame simulation      
Safety time on start-up 2 Start-up without flame signal      
Flame proving period 3 Flame failure during flame proving period      
Normal operation 4 Flame failure during operation      
10 Too many remote resets      
Air valve A      
Pre-ventilation A1    
Post-ventilation A0    
Cooling A0      
0 Air pressure switch “no flow” state    
P No air flow during purge    
POC (proof-of-closure) 0 Fault Position indicator during start-up  
POC (proof-of-closure) 1 Valve not closed  
POC (proof-of-closure) X Fault Position indicator in position X  
X No air flow in position X    
High temperature operation . .      
P Bus fault   

BCU 460, BCU 465 · Edition 07.12 42

Function > Program status and fault messages

BCU 465T..B1
BCU 460..B1
BCU 465..B1
BCU 465T
BCU 460
BCU 465
Program status DISPLAY Fault message (flashing)

30 EEPROM data change, NFS*   

31 EEPROM data change, FS*   
32 Undervoltage in power pack   
33 Faulty parameterization   
Bus module fault   
51 Safety interlock failure      
52 Permanent remote reset      
53 Timing cycle too short      
In manual mode, two dots will blink on the display in program status 01– 04 .
* FS = input/output, safety circuit, NFS = input/output, control system.

BCU 460, BCU 465 · Edition 07.12 43

4 Parameters
Factory BCU 460 BCU 465 BCU 465T
Description Parameter Value range default Adjustable* (BCU (BCU (BCU
setting 460..B1) 465..B1) 465T..B1)
Burner flame signal 01 0 – 99 μA   
Program status when the most recent fault occurred 03 x0 – x8   
Burner switch-off threshold 04 1 – 20 µA 1 µA    
Air flow monitoring during purging 06 0; 1 1 **
Air flow monitoring during operation 07 0; 1 1 **
Air flow monitoring, delayed 08 0; 1 0 **
Position indicator check input 09 0; 1 1 **
Burner start-up attempts 10 1 – 3 1 ** ** **
Burner restart 12 0; 1 0    
Safety time during operation for V1 and V2 tSB 14 1; 2 s 1s ** ** **
Flame simulation check in start-up position/standby 15 0; 1 1    
Minimum burner on time tB 20 tSA – 25 s tSA    
Minimum burner pause time tBP 21 0 – 250 s 0s    
Burner safety time on start-up tSA 22 3; 5; 10 s ** ** **
Burner flame proving period tFS 23 0 – 25 s 0s    
Air valve control 30 0; 1; 2; 3 0    
Air valve can be activated externally on start-up 31 0; 1 0    
Air vale closed/can be activated in the event of mal- 32 0; 1 1    
function
High temperature operation 33 2; 3 ** ** **
Manual mode limited to 5 minutes 34 0; 1 1    
UVS check (1 x in 24 hours) 35 0; 1 0    
Low fire over-run time tKN 36 0; 5; 15; 25 s 0s ** ** **

BCU 460, BCU 465 · Edition 07.12 44

Parameters

Factory BCU 460 BCU 465 BCU 465T

Description Parameter Value range default Adjustable* (BCU (BCU (BCU
setting 460..B1) 465..B1) 465T..B1)
Pre-ventilation time tVL 37 0 – 250 s 0s   
Post-ventilation time tNL 38 0 – 3 s 0s   
Pre-ventilation time after safety shut-down 39 0 – 250 s 0s ** **
Pre-ventilation for restart/start-up attempts 40 0; 1 1 ** **
Pre-ventilation after reset 41 0; 1 1 ** **

 = standard,  = available.
* Adjustable using BCSoft software and a PC opto-adapter
** Please quote in your order
0 = Function inactive,
1 = Function active.

4.1 Scanning the parameters

During operation, the 7-segment display shows the program
status, see page 42 (Program status and fault messages).
The flame signal and all following parameters of the BCU can
be scanned one after the other by repeatedly pressing the
Reset/Information button (for 2 seconds).
In the event of a fault, the BCU halts the program run, the
display blinks and it then displays the cause of the fault in
coded form.

BCU 460, BCU 465 · Edition 07.12 45

Parameters

4.2 Flame control

4.2.1 Burner flame signal
Parameter 01
Flame signal of the burner, display in µA, measuring range:
0 – 30 µA.
4.2.2 Switch-off threshold of the flame amplifier
Parameter 04
The sensitivity at which the burner control unit still detects a
flame can be set between 1 and 20 µA.
Example: in the case of UV control with the UV sensor UVS,
the signal of the burner to be monitored is influenced by other
burners.
The set value can be incremented in parameter 04 so that only
the flame of the system’s “own” burner is detected.
The measured flame signal of the system’s “own” burner should
be at least 3 µA (empirical value) higher than the set switch-
off threshold.

BCU 460, BCU 465 · Edition 07.12 46

Parameters > Flame control
4.2.2 High temperature operation in the case of BCU..D2 or The voltage may be applied to the DI input (terminal 6) so as
BCU..D3 to activate High temperature operation only when the tem-
Parameter 33 perature at the furnace wall has exceeded 750°C. The BCU
Operation of firing systems at temperatures above 750°C. The then starts the burner as usual but without monitoring the
BCU features a fail-safe DI input (DI = Digital Input). This input presence of the flame.
supports the “High temperature operation” function. If firing 00 02 03 04 88
systems are operated above 750°C, the system is considered 1
5
to be a high temperature equipment (see EN 746-2). Flame 4 ϑ
6 DI
control must be in operation until the furnace wall temperature 7
has exceeded 750 °C. 9
12 V1
Frequently, flame control is dispensed with so as to achieve 14 V2
16-17
a particularly high flexibility of the installation. This means 18-19
that no incorrect flame signals, e.g. signals from a UV sensor tZ tFS t
which are interpreted as extraneous signals due to reflection tSA
of UV radiation, may lead to faults.
When the DI input is activated, the burner control unit reverts If the temperature in the furnace chamber drops below 750°C,
to this operating mode, i.e.: the BCU operates without evalu- the DI input must be disconnected from the electrical power
ation of the flame signal. The safety function of the device- supply and the furnace must then be operated with flame
internal flame control system is placed out of operation. control.
In High temperature mode, the gas valves are opened without ▼
flame control.
The precondition for this operating mode is that an external
flame supervision device ensures the presence of the flame
in fail-safe manner indirectly via the temperature. For this
purpose, we recommend a safety temperature monitor with
double thermocouple (DIN 3440). Sensor discontinuity, sensor
short-circuit, failure of a component or mains failure must set
the installation to a safe state.

BCU 460, BCU 465 · Edition 07.12 47

Parameters > Flame control > High temperature operation in the case of BCU..D2 or BCU..D3
The BCU then responds, depending on setting: Parameter 33 = 3 (BCU..D3)
Parameter 33 = 2 (BCU..D2)
04 04 88
1
04 01 02 03 04 88 5
1 4 ϑ
5 6 DI
4 ϑ 7
6 DI 9
7 12 V1
9 14 V2
12 V1 16-17
14 V2 18-19
16-17 t
18-19
t
tZ tFS The burner remains in operation and the BCU performs flame
tSA control again (recommended in the case of ionization control
tW
or UV control with UVD).
The BCU switches off the burner and restarts with flame simula- If no flame signal is present when High temperature operation
tion check (recommended in the case of UV control with UVS). is deactivated, the burner control unit performs a fault lock-out,
regardless of parameter 33.

04 04 88
1
5
4 ϑ
6 DI
7
9
12 V1
14 V2
16-17
18-19
t

Note the requirements of the Standards!

BCU 460, BCU 465 · Edition 07.12 48

Parameters > Flame control
4.2.3 UVS check
Parameter 35
An automatic restart of the burner control unit can be activated
every 24 hours via this parameter. The time starts each time
the start-up signal (ϑ) is applied.
Parameter 35 = 0: unlimited burner operation.
Parameter 35 = 1: an automatic restart is activated once
every 24 hours.
It must be ensured in this case that the program sequence
started matches the application. This parameter may be set
in this way only if the burner can restart as intended in all
operating phases.

BCU 460, BCU 465 · Edition 07.12 49

Parameters

4.3 Behaviour in start-up position/standby What is an extraneous signal?

An extraneous signal is an incorrect signal which is detected
4.3.1 Flame-simulation check in start-up position/standby as a flame signal out of sequence. If the BCU 460 or BCU 465
Parameter 15 notices such an extraneous signal during the flame simulation
This defines the instant for the flame simulation check. check, it starts the flame simulation delay time tLV for 25 s. If
the extraneous signal is discontinued during this period, the
00 01 02 . . . 88
burner can start up. Otherwise, a fault lock-out occurs. 01
V1
00 01 02 . . . 88 blinks on the display.
tW t
V1 Flame simulation check in standby position (parameter 15 = 1):
Parameter 15 = 0: The flame tW simulation checkt is conducted
00 01 88
after applying00the start-up signal (ϑ) during
02 . . . the88waiting time tW. 1
5
V1 4 ϑ
00 02 . . . 88 7
t 9
V1 12 V1
14 V2
t 16-17
18-19
Parameter 15 = 1: The flame simulation check is conducted tLV t
provided no start-up signal (ϑ) is applied (during the so-called
start-up position/standby). This allows fast start-up of the Flame simulation check on start-up (parameter 15 = 0):
burner since there is no waiting time tW.
00 01 01 88
The burner must have been switched off for at least 4 s be- 1
4 ϑ
fore start-up in order for the flame simulation check to be 7
conducted correctly. 12 V1
9
14 V2
18-19
t
tLV

The flame simulation check of the burner is active until valve

V1 is enabled.

BCU 460, BCU 465 · Edition 07.12 50

Parameters > Behaviour in start-up position/standby
4.3.2 Position indicator input on BCU 465T..O (POC)
Parameter 09
For applications in accordance with the requirements of
NFPA 86:2003 with more than 117 kW (400,000 BTU/h), two gas
solenoid valves are required, one of which is to be equipped
with a position indicator.

BCU 465T..O

12 21 14 mA

V1
V2

OCS

Parameter 09 = 1: A signal is sent to the BCU via the position

indicator on the gas solenoid valve V1 stating whether the
valve is closed or open. In standby, the switch must be closed.
During start-up and operation, the switch must be open. This
ensures that valve V1 is open or closed.

BCU 460, BCU 465 · Edition 07.12 51

Parameters > Behaviour in start-up position/standby
4.3.3 Minimum burner pause time tBP Example of application
Parameter 21
L1, N, PE
Programmable time between 0 and 250 s. DI P

PLC
04 00 01 02 03 04 88
1
5
4 ϑ DI P A
7 6 3 5 22 23 4
9
12 V1 19
18
14 V2 µC
16-17 17
18-19 16

tBP tZ tFS t BCU 460..L 12 26 9

tSA

VG..N GIK..B
An immediate restart of the burner after a controlled shut-down
is prevented by the pause time. The pause time starts when BIO
BIC
the burner is switched off. If a start-up signal (ϑ) is applied
VR..R
before expiry of this time, start-up is delayed until the end of
the pause time.
After the pause time, the burner is started if the start-up signal
(ϑ) is applied.
The minimum burner pause time tBP serves to adapt the pro-
gram sequence to the requirements of the application.
The time should be set such that the system can be moved to
ignition position, i.e. air valves or butterfly valves can be closed
and, possibly, gas can be flared off, before a restart occurs.

BCU 460, BCU 465 · Edition 07.12 52

Parameters

4.4 Behaviour during start-up 4.4.3 Flame proving period tFS

Parameter 23
4.4.1 Safety time on start-up tSA
Parameter 22 00 02 03 04 88
1
5
00 02 03 04 88 4 ϑ
1 7
5 9
4 ϑ 12 V1
7 14 V2
9 16-17
12 V1 18-19
14 V2
16-17 tZ tFS t
18-19
tSA
tZ tFS t
tSA
Programmable time between 0 and 25 s.
This indicates the safety time on start-up tSA for the burner. This time elapses before the BCU starts the next program step
so as to give the flame time to stabilize.
4.4.2 Minimum burner on time tB
Parameter 20 4.4.4 Burner start-up attempts
Parameter 10
Programmable time in the range from minimum safety time
on start-up tSA to maximum 25 s during which the burner This indicates the number of possible start-up attempts of
remains in operation. the burner.
In the case of brief activation of the start-up signal input (ϑ) In accordance with EN 746-2, a maximum of three start-ups
(e.g. with a pulse), the burner on time tB is started, and the are permitted in specific cases if the safety of the installation
burner remains in operation for at least this period. This time is not impaired. Note the requirements of the Standards!
is independent of the pre-ventilation time. If no flame is detected or, in the case of BCU 465, if the air
flow fails during start-up, either a fault lock-out occurs or up
to two further start-up attempts occur. The required functions
and, if applicable, the number of start-up attempts must be
specified when ordering.
▼

BCU 460, BCU 465 · Edition 07.12 53

Parameters > Behaviour during start-up > Burner start-up attempts
1 start-up attempt 2 – 3 start-up attempts
Parameter 10 = 1 Parameter 10 = 2 – 3

00 02 02 88 00 02 88
1 1
5 5
4 4 ϑ
7 7
9 9
12 V1 12 V1
14 V2 14 V2
16-17 16-17
18-19 18-19
tZ t tZ tZ t
t SA tSA tSA

If no flame forms or, in the case of BCU 465, if the air flow fails If several start-up attempts are set at the works and if the BCU
during start-up, a fault lock-out is performed after expiry of detects an installation fault during start-up, it closes valve V1
time tSA. The display blinks and shows the cause of the fault. after the safety time tSA has expired and attempts to start up
again. After the last programmed start-up attempt has been
completed, the burner control unit conducts a fault lock-out.
The display blinks and shows the cause of the fault.

BCU 460, BCU 465 · Edition 07.12 54

Parameters

4.5 Behaviour during operation

4.5.1 Safety time during operation tSB for V1 and V2
Parameter 14
This indicates the safety time during operation tSB for valves
V1 and V2.
The default in accordance with EN 298 is 1 s.
The BCU has also the available option of tSB of 2 s. Prolonging
the time increases the installation availability in the case of
brief-duration signal fades (e.g. fades of the flame signal or,
on BCU 465, in the case of pressure switch drop-out).
In accordance with EN 746-2, the safety time of the installation
during operation (including closing time of the valves) may
not exceed 3 s.
Note the requirements of the Standards!
4.5.2 Fault lock-out or restart
Parameter 12
This parameter determines whether the BCU starts a one-off
restart or performs an immediate fault lock-out for the burner
after an installation fault (flame failure or failure of air flow).

BCU 460, BCU 465 · Edition 07.12 55

Parameters > Behaviour during operation
4.5.3 Immediate fault lock-out after installation fault Restart following flame failure
Parameter 12 = 0: Fault lock-out after installation fault. Parameter 12 = 1: Restart after installation fault.

1x
04 04 88 04 01 02 03 04 88
1 1
5 5
4 ϑ 4 ϑ
7 7
9 9
12 V1 12 V1
14 V2 14 V2
>2 s 16-17
16-17
18-19 18-19
t tFS t
tSB tSB tZ
tW tSA

After an installation fault (flame failure or failure of air flow),

the burner control unit performs a fault lock-out within the If the BCU detects an installation fault (flame failure or failure
safety time during operation tSB. This involves disconnecting of air flow) after a minimum operating time of 2 s, the valves
the power from the gas valves and, if applicable, the ignition are closed and the operation signalling contact is opened
transformer. The fault signalling contact closes, the display within time tSB.
blinks and shows the current program status, see table on
The burner control unit now attempts to restart the burner once.
page 42 (Program status and fault messages).
If the burner does not function, a fault lock-out is performed.
See also parameter 32, page 60 (Behaviour of the air valve The display blinks and shows the cause of the fault.
after a fault lock-out).
In accordance with EN 746-2, a restart may be conducted
After a fault lock-out, the burner control unit can be reset, only if the safety of the installation is not impaired. Restart is
either with the button on the front panel or using an external recommended for burners which occasionally display unstable
button. Several burner control units can be reset in parallel behaviour during operation.
using the external button.
The precondition for a restart is that activation of the restart al-
The BCU cannot be reset by mains failure. The fault signalling lows the burner to restart as intended (in all operating phases).
contact does, however, open as soon as the mains voltage fails. In this case, it must be ensured that the program sequence
started by the BCU matches the application.

BCU 460, BCU 465 · Edition 07.12 56

Parameters > Behaviour during operation
4.5.4 Program status on last fault
Parameter 03
This indicates the program status in which the last burner
fault occurred.
Example: the unit indicates that the safety interlocks have been
interrupted with a blinking 51 .
Parameter 03 can now be used to scan in what program
status the BCU was when the fault was detected.

BCU 460, BCU 465 · Edition 07.12 57

Parameters

4.6 Air valve control on BCU..L 4.6.3 Air valve opens in the case of external activation (not
Parameter 30, “Air valve control” during start-up)
Parameter 31, “Air valve can be activated externally on start-up”
00 A0 02 03 A4 88
Parameter 32, “Air valve closed/can be activated in the event 1
5
of malfunction” 4 ϑ
7
The BCU..L features an adjustable air valve control. The display 9
12 V1
shows that purging is currently being carried out with P0 . A 14 V2
indicates that the air valve is being activated for cooling or 23 A
26
heating. The BCU supports the following functions: 16-17
18-19
4.6.1 Purge tZ tFS t
In the case of multiple burner applications, burners with me- tSA
chanical combustion air supply are used. The air for combus-
tion and pre-purge is supplied by a central fan controlled by
a separate logic. This logic determines the purging time. Parameter 30 = 0: The air valve opens if it is activated exter-
The BCU..L supports centrally-controlled pre-purge or post- nally by input 23.
purge. The BCU..L is informed that purging is currently being Parameter 31 = 0: The air valve remains closed during start-up
performed by input 22. It then opens the air valve, regardless even if it is activated externally.
of the status of the other inputs (purging has priority). The These settings are required on burners on which the gas/air
display indicates P0 . ratio is controlled by a pneumatic air/gas ratio control system
For purging, the safety interlock (limits) must activate input 5 link and which also need to be started at low fire, e.g. on
and input 22 of the BCU. two-stage-controlled burners, see page 8 (BCU 460..L:
Two-stage-controlled burner). In this case, activation of the
4.6.2 Cooling in start-up position/standby
air valve during burner start via input 23 must be prevented.
The air valve can be activated externally by input 23 for cooling
in the start-up position. During activation of the air valve, the External control allows switchover between low fire and high
display shows A0 , indicating that cooling is currently being fire during operation.
carried out.
Parameters 30 and 31 determine the behaviour of the air valve
during burner start.

BCU 460, BCU 465 · Edition 07.12 58

Parameters > Air valve control on BCU..L
4.6.4 Air valve opens in the case of external activation Parameter 30 = 1: The air valve opens simultaneously with
(even during start-up) valve V1.
00 A0 00 A0 A2 A3 A4 88
It can be activated externally via input 23 for cooling the burner
1 in the start-up position/standby.
5
4 ϑ
7 4.6.6 Air valve opens with valve V2
9
12 V1
14 V2 00 A0 00 02 03 A4 88
23 A 1
26 5
16-17 4 ϑ
18-19 7
t 9
tZ tFS 12 V1
tSA 14 V2
23 A
26
16-17
Parameter 30 = 0: The air valve opens if it is activated exter- 18-19
nally by input 23. tZ tFS t
Parameter 31 = 1: The air valve can be activated even during tSA
start-up.
These settings may be selected only if the burner can start
Parameter 30 = 2: The air valve opens simultaneously with
with full air capacity.
valve V2.
4.6.5 Air valve opens with valve V1 It can be activated externally via input 23 for cooling the burner
00 A0 00 A2 A3 A4 88
in the start-up position/standby.
1
5
4 ϑ
7
9
12 V1
14 V2
23 A
26
16-17
18-19
tZ tFS t
tSA

BCU 460, BCU 465 · Edition 07.12 59

Parameters > Air valve control on BCU..L
4.6.7 Low fire over run-time tKN after a controlled shut-down L1, N, PE
Parameter 36 DI P

Value range 0, 5, 15 or 25 s PLC

This parameter is applicable to systems with pneumatic DI P A

air/gas ratio control system and On/Off control. 6 3 5 22 23 4

19
18
Parameter 36 tKN = 0: Without low fire over-run, the gas circuit µC
17
is closed immediately owing to the quick-closing gas valve in 16

BCU 460..L 12 26 9
the case of On/Off control. The air circuit closes more slowly.
The air flowing in during the closing time increases the O2
VG..N GIK..B
percentage in the combustion chamber.
BIO
Parameter 36 tKN = 5, 15 or 25 s: The air valve is closed with BIC

deactivated start-up signal (ϑ). The gas valve remains open VR..R

for tKN. This means that the burner, after deactivation of the
start-up signal (ϑ), is initially adjusted down to low fire and A4 00 88
then switched off completely. 1
5
Using the low fire over-run function reduces the O2 percentage 4 ϑ
7
in the furnace atmosphere. 9
12 V1
Flame control is still operational. 14 V2
23 A
Can be used only in the case of a pneumatic air/gas ratio 26
16-17
control system and On/Off control. 18-19
Its must be ensured that no excess gas occurs. tKN t

4.6.8 Behaviour of the air valve after a fault lock-out

Parameter 32
This determines whether the air valve can be activated in the
case of a fault lock-out.
Parameter 32 = 0: The air valve is closed in the event of a fault.
It cannot be activated externally.
Parameter 32 = 1: The air valve can be activated externally by
input 23 even during a fault, e.g. for cooling.

BCU 460, BCU 465 · Edition 07.12 60

Parameters

4.7 Extended air control with BCU 465..L Check of the HIGH signal (pressure switch contact closed)
For use on recuperative burners, the BCU 465..L features an The air must flow and a HIGH signal must be applied to the
extended air control which meets the specific requirements pressure switch during pre-purge. If the HIGH signal is not
of such burners. applied, the BCU performs a fault lock-out after expiry of the
testing time (as long as the safety time on start-up). Error mes-
4.7.1 Air flow monitoring during purging (BCU 465..L) sage: P , no air flow.
Parameter 06
This parameter determines whether the air flow is monitored
during pre-purge.
Parameter 06 = 0: The air flow is not monitored during pre-
purge.
Parameter 06 = 1: The air flow is monitored during pre-purge
(pressure switch signal at terminal 21), i.e.
Check of the LOW signal (pressure switch contact open)
No air may flow before pre-purge. A LOW signal must be ap-
plied to the pressure switch. If the LOW signal is not applied,
the BCU performs a fault lock-out after expiry of a delay time
(as long as the flame simulation delay time tLV). Error message:
0 , “no flow” state check failed.

BCU 460, BCU 465 · Edition 07.12 61

Parameters > Extended air control with BCU 465..L
4.7.2 Pre-ventilation time tVL before start-up (BCU 465..L)
Parameter 37
Value range 0 – 250 s
This can be set in 0.1 s steps in the range 0 to 10 s,
in 1 s steps in the range 10 to 250 s.
This parameter is used to determine the time during which
the air valve is already open before normal start-up. This time
may also be used for pre-purge.
Suitable for burners starting with full air capacity.
Parameter 37 > 0 up to max. 250 s:
00 A1 A2 A4 88
1
5
4 ϑ
7
9
12 V1
14 V2
23 A
26
21
16-17
18-19
tLV tZ t
tSA

After the start-up signal (ϑ) has been applied and after the
flame simulation check and “no flow” state check have been
conducted successfully, the air valve is opened. Start-up of
the burner commences as usual with no interruption of the
air after expiry of the programmable pre-ventilation time tVL.
(Parameter setting for this example sequence:
P15 = 1, P23 = 0, P30 = 1, P37 > 0), see page 44 (Param-
eters). The gas valve does not open until the pressure switch
has switched.

BCU 460, BCU 465 · Edition 07.12 62

Parameters > Extended air control with BCU 465..L
4.7.3 Air flow monitoring during operation (BCU 465..L)
Parameter 07
This parameter determines whether the air flow is monitored
during operation.
Parameter 07 = 0: The air flow is not monitored during op-
eration.
Parameter 07 = 1: The air flow is monitored during operation
(pressure switch signal at terminal 21), i.e.
Check of the LOW signal (pressure switch contact open)
before starting the program run
No air may flow before the program run is started. A LOW sig-
nal must be applied to the pressure switch. If the LOW signal
is not applied, the BCU performs a fault lock-out after expiry
of a delay time (as long as the flame simulation delay time tLV).
Error message: 0 , „no-flow” state check failed.
Check of the HIGH signal (pressure switch contact closed)
after activating the air valve
The air must flow and a HIGH signal must be applied to the
pressure switch after the air valve has been activated. If the
HIGH signal is not applied within a specified testing time (as
long as the safety time on start-up tSA), the BCU performs a fault
lock-out. Error message: , no air pressure in operating state.
If the air pressure drops during operation, the BCU conducts
either a fault lock-out (error message: 4 ) or a restart as in
the event of flame failure. Should restart fail, error message
2 is displayed.

BCU 460, BCU 465 · Edition 07.12 63

Parameters > Extended air control with BCU 465..L
4.7.4 Delayed air flow monitoring (BCU 465) 4.7.5 Post-ventilation time tNL after a controlled shut-down
Parameter 08 (BCU 465..L)
Supplementary setting for parameter 07 Parameter 38
Is the gas to be released with or without pressure switch signal? Value range 0 – 3 s
Parameter 08 = 0: Gas is released only with pressure switch
A4 A0 00 88
signal. 1
5
Parameter 08 = 1: Gas is released even without pressure switch 4 ϑ
signal. The scan is conducted after a delay time. 7
9
12 V1
14 V2
23 A
26
21
16-17
18-19
tNL t

The air valve remains open for the programmed time after the
start-up signal (ϑ) has been deactivated. The burner control
unit closes the air valve after expiry of the post-ventilation
time tNL.

BCU 460, BCU 465 · Edition 07.12 64

Parameters > Extended air control with BCU 465..L
4.7.6 Pre-ventilation time after safety shut-down (BCU 465..L) 4.7.7 Pre-ventilation for restart/start-up attempts (BCU
Parameter 39 465..L)
Value range 0 – 250 s Parameter 40
This can be set in 1 s steps. This parameter determines whether the pre-ventilation time
(parameter 39) is to run after a restart or after the start-up
This determines the time for which pre-purge is to occur after
attempts.
a safety shut-down.
Parameter 40 = 0: The pre-ventilation time is deactivated on
A1 01 A1 A2 A4 88 restart and in the case of several start-up attempts.
1
5
4 ϑ Parameter 40 = 1: The pre-ventilation time is activated in the
7 case of restart and several start-up attempts.
9
12 V1
14 V2 4.7.8 Pre-ventilation after reset (BCU 465..L)
23 A
26 Parameter 41
21
16-17 This parameter determines whether the pre-ventilation time
18-19
(parameter 39) is to run in the case of a reset after a fault
tVL tBP tVL tZ t
lock-out.
tSA
Parameter 41 = 0: The pre-ventilation time is deactivated after
a reset.
With this function, the combustion chamber can be purged after
a safety shut-down in compliance with standards, especially Parameter 41 = 1: The pre-ventilation time is activated after a
on radiant tube burners. This task is not implemented by a reset with the start-up signal (ϑ).
central control system but by the BCU 465. See also param-
eters 40 and 41.

BCU 460, BCU 465 · Edition 07.12 65

Parameters

4.8 Manual mode 4.8.1 Manual mode limited to 5 minutes

For convenient setting of the burner or analyzing faults. Parameter 34
If the Reset/Information button is pressed for 2 s during switch- Parameter 34 determines when Manual mode is terminated.
on, the BCU reverts to Manual mode. Two dots blink on the Parameter 34 = 0: Manual mode is not limited in time.
display. If this function has been selected, operation of the furnace may
In this operating mode, the burner control unit operates inde- be continued manually in the event of failure of the central
pendently of the status of the inputs (apart from the pre-purge control system.
input and the safety interlocks). Parameter 34 = 1: Manual mode ends automatically five min-
Each time after the button is pressed again, the BCU moves utes after the last time the button was pressed. The BCU then
to the next section of the program sequence and stops there. moves abruptly back to start-up position/standby.
The flame signal is indicated instead of the operating status Manual mode can always be terminated independently of
after approx. 3 s when the operating status is reached. parameter 34 by switching off the BCU.
On units with air valve control, the air valve can be opened
and closed repeatedly by pressing the button during operation.

BCU 460, BCU 465 · Edition 07.12 66

5 Selection
T -3 -5 -10 /1 /2 L 5 15 25 W R 1 2 3 8 GB1) P D2 D3 S2 – 3 A O2) U C B1 /1 E1
BCU 460                          Order example
BCU 465                           BCU 465-5/1LW3GBACE1
 = standard,  = available. 1) Not available for BCU..T. 2) Only available for BCU..T.

5.1 Type code

Code Description
BCU Burner control unit
4 Series 4
60 Standard version
65 Extended air control
3; 5; 10 Safety time on start-up tSA [s]
1; 2 Safety time during operation tSB [s]
L* Air valve control
5*; 15*; 25* Low fire over-run time [s]
W Mains voltage: 230 V AC, -15/+10%, 50/60 Hz
R 115 V AC, -15/+10%, 50/60 Hz
1* Ignition transformer: TZI 5-15/100
2* TZI 7-25/20
3* TZI 7,5-12/100
8* TZI 7,5-20/33
GB* Front film in English with additional stickers in D, F, I, NL, E
P* Industrial plug connector
D2* High temperature operation in conjunction with: … UVS
D3* ... ionization sensor or UVD
S2* – 3* Number of start-up attempts
A* Air flow monitoring
O* Position indicator feedback
U* Preparation for UV sensor for continuous operation UVD 1
C* Additional signal distribution
B1* For PROFIBUS DP
/1* 9-pin D-Sub bus plug connector
E1* Power management via phase (L1)
* If “none”, this specification is omitted. Please quote the default parameter settings when ordering.

BCU 460, BCU 465 · Edition 07.12 67

6 Project planning information Only use radio interference suppressed electrode plugs (with
1 kΩ resistor) for ignition electrodes, see page 76 (Acces-
6.1 Cable selection sories).
Use mains cable suitable for the type of operation and com-
6.1.3 UV cable
plying with local regulations.
Recommended cable length: max. 50 m.
Signal and control line: max. 2.5 mm2.
Install well away from mains cables and interference from
Cable for burner ground/PE wire: 4 mm2. electro-magnetic sources.
Burner ground connector may also be located outdoors. Do not lay together with ignition cable.
Do not route BCU cables in the same cable duct as frequency
converter cables or cables emitting strong fields. 6.2 Electrode gap
Gap between electrode and burner ground:
6.1.1 Ionization cable
2 mm ± 0.5 mm.
Use unscreened high-voltage cable, see page 76 (Acces-
sories). 6.3 Star electrodes
Recommended cable length: max. 50 m. We recommend using 7.5 kV ignition transformers on burners
Lay cable individually and, if possible, not in a metal conduit. with star electrodes.
Install well away from mains cables and interference from
electro-magnetic sources.
Do not lay together with ignition cable.
6.1.2 Ignition cable
Use unscreened high-voltage cable, see page 76 (Acces-
sories).
Cable length for integrated ignition. max. 5 m (16.4 ft).
Avoid external electrical interference. The longer the ignition
cable, the lower the ignition capacity.
Lay cable individually and, if possible, not in a metal conduit.
Do not lay UV/ionization cable and ignition cable together
and lay them as far apart as possible.
Screw the ignition cable securely into the ignition transformer
and feed it out of the unit on the shortest possible route (no
loops) – use the left-hand M20 plastic cable gland.

BCU 460, BCU 465 · Edition 07.12 68

Project planning information

6.4 Calculating the safety time tSA

BCU 460, BCU 465 · Edition 07.12 69

Project planning information

6.5 Minimum burner on time 6.8 Permanent remote reset

Even if the start-up signal (ϑ) is applied only briefly, the time If a remote reset signal is permanently applied to terminal 3,
set under parameter 20 elapses before the burner control 52 flashes on the display to indicate a fault.
unit shuts down the burner or signals a fault.
The minimum burner on time tB can be extended beyond the
6.9 Overload protection
safety time tSA to max. 25 s. To protect the unit against overload by frequent cycling, the
BCU may not start up more than n times per minute. Exces-
6.6 Safety interlock (Limits) sive cycling triggers a fault message (flashing 53 ). The max.
The limiters in the safety interlock (linking of all the relevant number (n) per minute depends on the safety time tSA and the
safety control and switching equipment for the use of the ap- ignition transformer used.
plication, for example STL (safety temperature limiter), Gasmin, tSA Ignition transformer TZI Max. number n/min.
Gasmax, tightness control, pre-purge...) must isolate terminal s
5 from the voltage supply. If the safety interlock is interrupted, 3 5-15/100 6
the display shows a blinking 51 to indicate a fault. 5 5-15/100 6
10 5-15/100 3
6.7 Protection of safety-relevant outputs
3 7-25/20 3
When commissioning, do not switch the safety-relevant outputs 5 7-25/20 2
to a short-circuit. 10 7-25/20 1
Before switching on, ensure that outputs 7, 12 and 14 are not 3 7,5-12/100 6
overloaded (> 3 A), using an ohmmeter, for example. 5 7,5-12/100 4
All safety-relevant outputs of the BCU are fused with an internal, 10 7,5-12/100 2
replaceable fuse, see page 16 (Connection diagrams). This 3 7,5-20/33 4
affects the outputs for ignition, gas valve V1 and gas valve V2. 5 7,5-20/33 3
In the event that the second internal, non-replaceable fuse 10 7,5-20/33 2
for these outputs blows, the unit must be sent to the manu-
facturer for repair.

BCU 460, BCU 465 · Edition 07.12 70

Project planning information

6.10 Wiring 6.12 Signal distributor board

6.16 Note on EC type-examination

Since EN 298 (1993) does not describe all functions of the BCU,
the operator is responsible for ensuring that all parameters
and functions are matched to the respective application.

BCU 460, BCU 465 · Edition 07.12 74

7 Flame control 7.3 Via the temperature in high temperature
equipment
7.1 With ionization sensor
High temperature equipment is defined as a thermoprocessing
The BCU generates an alternating voltage (230 V AC) between
installation, in which the wall temperature of the combustion
the sensing electrode and burner ground. The flame rectifies
chamber and/or the processing chamber exceeds 750°C.
this voltage. Only the DC signal (> 1 µA) is detected by the
burner control unit. Burner control units BCU..D2 and BCU..D3 feature a spe-
cial “High temperature operation” function, see page 47
A flame cannot be simulated.
(High temperature operation in the case of BCU..D2 or
Ignition and monitoring with a single electrode is possible. BCU..D3).
7.2 With UV sensor During heating up, standard monitoring methods (ionization
or UV) must be used for flame control. When the working
A UV tube inside the UV sensor detects the ultraviolet light of
temperature has exceeded 750°C, indirect flame control can
a flame. It does not respond to sunlight, incandescent bulb
be taken over by a central monitoring device. When the DI
light or infrared radiation emitted by hot workpieces or red-
input (terminal 6) is activated, the burner control unit reverts
hot furnace walls.
to this operating mode.
In the event of incident UV radiation, the UV sensor rectifies
Important: in “High temperature operation” (HT operation), i.e.
the supplied alternating voltage. As with ionization control,
with the DI input being activated, burner control units BCU..D2
the burner control unit only detects this DC signal.
(D3) do not evaluate the flame signal. The safety function of
When using UV sensors of Type UVS, the burner control unit the burner control unit’s flame control is deactivated during
may be used for intermittent operation only. This means that this operating phase.
operation must be interrupted at least once every 24 hours.
This can be programmed by setting parameter 35 to 1.
Further information can be found in brochure UVS at
www.docuthek.com.
The burner control unit BCU..U is prepared for UV sensor UVD 1.
This enables continuous operation.
Further information can be found in TI UVD at
www.docuthek.com.

BCU 460, BCU 465 · Edition 07.12 75

8 Accessories 8.3 PROFIBUS plug connector
Variosub PROFIBUS plug connector, 9-pin, with deactivatable
8.1 High-voltage cable
bus terminator, Order No.: 74960431
FZLSi 1/7 up to 180°C,
GSD files for BCU Profibus DP on BCSoft CD-ROM, Order No.
Order No.: 04250410.
74960436, or at www.docuthek.com
FZLK 1/7 up to 80°C,
Order No.: 04250409.

8.2 Industrial plug connector, 16-pin

Bibliography
– PROFIBUS Specification, EN 50170 Vol. 2 (version 1.0).
Order No.: 74919469 – Installation Guideline for PROFIBUS DP/FMS, available
from the Profibus User Organization (PUO).
– PROFIBUS Technology and Application, Order No.: 4.001,
available from the PUO.
– M. Popp, The New Rapid Way to PROFIBUS DP, a textbook
for system operators.
– M. Popp, PROFIBUS DP Principles, Tips and Tricks for Us-
ers.
– www.profibus.com

BCU 460, BCU 465 · Edition 07.12 76

Accessories

8.4 BCSoft 8.5 “Changed parameters” stickers

The current software can be downloaded from our Internet site Affix on the connection diagram
at http://www.docuthek.com. To do so, you need to register D-49018 Osnabrück, Germany
of the BCU following changes to
in the DOCUTHEK. Achtung, geänderte Parameter!
unit parameters set at the factory.
Die Angaben auf dem Typenschild
8.4.1 Opto-adapter gelten nicht mehr in vollem Umfang. 100 pcs,
Aktuelle Parameter direkt auslesen.
Order No.: 74921492.
Important, changed parameters!
The details on the type label are no
longer completely accurate. Read the
current parameters direct from the
unit.

Attention, paramètres modifiés !

Les informations figurant sur la plaque
signalétique ne sont plus valables
dans leur intégralité. Veuillez vous
référer directement aux paramètres
actualisés.

With USB interface, cable length 3 m, including BCSoft CD-ROM.

Order No.: 74960437.

BCU 460, BCU 465 · Edition 07.12 77

Accessories

8.6 External securing bar 8.7 Fastening set

m mm
212 m 174

230 mm
mm
185 mm

ø 4mm

Order No.: 74960414 Order No.: 74960422

8.8 Radio interference suppressed electrode plugs

Angle plug, 4 mm, interference-suppressed,
Order No. 04115308.
Straight plug, 4 mm, interference-suppressed,
Order No. 04115307.
Straight plug, 6 mm, interference-suppressed,
Order No. 04115306.

BCU 460, BCU 465 · Edition 07.12 78

9 Technical data Fail-safe inputs and outputs:
Mains voltage: All the inputs and outputs marked “ ” (see connection dia-
230 V AC, -15/+10%, 50/60 Hz, grams) may be used for safety tasks.
115 V AC, -15/+10%, 50/60 Hz Flame control with UV detector or ionization sensor.
For grounded and ungrounded mains. Flame signal for
Inherent consumption: approx. 9 VA plus inherent consump- ionization control: 1 – 28 μA,
tion of the integrated ignition transformer. UV control: 1 – 35 μA.
Voltage to inputs and valves = mains voltage. For intermittent or continuous operation.
Signal and control line: max. 2.5 mm2. Maximum length of ignition cable with integrated electronic
ignition: 5 m (16.4 ft).
Cable for burner ground/PE wire: 4 mm2.
Maximum length of ionization/UV cable: 50 m (164 ft).
Cable gland:
Fuses in unit:
5 cable glands with multiple seal inserts for cable diam-
F1: 3.15 A, slow-acting, H, pursuant to IEC 127-2/5.
eters of up to 7 mm,
Fuse for protecting the safety-relevant ignition, valve 1,
BCU..P: with 2 cable glands and an industrial chassis plug.
valve 2 and air valve outputs (terminals 7, 12, 14 and 26):
Each BCU is supplied for two cable glands with one seal
5 A, slow-acting, not replaceable.
insert each for cable diameters between 7 and 12 mm.
F3 (only for BCU.. A, BCU..C and BCU..U):
Input voltage of signal inputs: 3.15 A, slow-acting, H, pursuant to IEC 127-2/5.
115 V AC 230 V AC Operation and fault signalling contacts:
Signal “1” 80 – 126.5 160 – 253 Signalling contact for mains voltage, max. 2 A, 253 V,
Signal “0” 0 – 20 0 – 40 not internally fused.
Number of operating cycles:
Input current of signal inputs:
Relay outputs: 250,000 pursuant to EN 298,
Signal “1”: typ. 2 mA
Mains switch: 1,000,
Output current: Reset/Information button: 1,000.
max. 1 A, cos ϕ = 1, for the valve outputs (or SRC outputs),
but total current for valves and ignition transformer: max. ▼
2.5 A.

BCU 460, BCU 465 · Edition 07.12 79

Technical data
Ambient temperature:
-20 to +60°C,
no condensation permitted.
Enclosure: IP 54 pursuant to IEC 529.
Weight: approx. 5 kg depending on version.
Ignition Input Output
transformer V AC Hz* A* V mA*
TZI 5-15/100W 230 50 (60) 0.45 (0.35) 5000 15 (11)
TZI 7-25/20W 230 50 (60) 1.1 (0.8) 7000 25 (18)
TZI 7,5-12/100W 230 50 (60) 0.6 (0.45) 7500 12 (9)
TZI 7,5-20/33W 230 50 (60) 0.9 (0.7) 7500 20 (15)
TZI 5-15/100R 115 50 (60) 0.9 (0.7) 5000 15 (11)
TZI 7-25/20R 115 50 (60) 2.2 (1.6) 7000 25 (18)
TZI 7,5-12/100R 115 50 (60) 1.2 (0.9) 7500 12 (9)
TZI 7,5-20/33R 115 50 (60) 1.8 (1.35) 7500 20 (15)
* Values in ( ) apply to 60 Hz.

9.1 BCU..B1
External fuse: 12 A per zone.

9.2 PROFIBUS DP
Manufacturer ID: 0x05DB.
ASIC type: SPC3.
SYNC- and FREEZE-capable.
Baud rate detection: automatic.
Min. cycle time: 0.1 ms.
Diagnostic bytes: 6 (DP Standard).
Parameter bytes: 7 (DP Standard).

BCU 460, BCU 465 · Edition 07.12 80

Technical data

9.3 Safety-specific characteristic values

In the case of ionization
control, suitable for Safety SIL 3
Integrity Level
Diagnostic coverage DC 92.7%
Type B to EN 61508-2,
Type of subsystem
7.4.3.1.4
High demand mode pursu-
Mode of operation
ant to EN 61508-4, 3.5.12
Mean probability of danger-
1.92 x 10-8 1/h
ous failure PFHD
Mean time to dangerous
MTTFd = 1 / PFHD
failure MTTFd
Safe failure fraction SFF 98.8%
The specified values apply for the combination with ionization
electrode (sensor) and a unit of the BCU 400 series. No char-
acteristic values are available for flame control with UV sensor.
Relationship between the Performance Level (PL) and the
Safety Integrity Level (SIL)
PL SIL
a –
b 1
c 1
d 2
e 3
Pursuant to EN ISO 13849-1:2006, Table 4, the BCU can be
used up to PL e.
Max. service life under operating conditions: 20 years after
date of production.
For a glossary of terms, see page 84 (Glossary).

BCU 460, BCU 465 · Edition 07.12 81

Technical data
Die-cast aluminium housing with plug-in terminal blocks and
m (7 .87") plug-in M20 cable glands or (16-pin) plug connector for input
200 m
signals and optionally pre-assembled cables for output signals.
B
9.4 Control elements
C
A 88
A: Optical interface.
200 mm (7.87")

D B: Labelling field for individual labelling of the system com-

E ponents.
C: 2-digit 7-segment display.
D: Mains switch to isolate the BCU on two poles from the
mains.
E: Reset/Information button to reset the system after a fault
5 or to scan parameters on the display.
mm0 5
(1.9 m5
7") m
(2.1
7")
9.5 Installation
Recommended installation position: vertical (cable glands
pointing downwards).
Open the BCU and attach with four screws ∅ 4 mm or screw
m on the closed unit using the external securing bar, see page
185 m 76 (Accessories).
7.28"
Electrical connection via plug-in connection terminals (2.5 mm2)
and plug-in cable glands. The latter can be removed in order
to facilitate installation. When installing, ensure that there is
4,5 mm sufficient space to open the BCU.
163 mm
6.42"

0.177"

BCU 460, BCU 465 · Edition 07.12 82

10 Legend
88 Display Air pressure switch
tB Minimum burner on time tSA up to max. 25 s
88 Blinking display tBP Minimum burner pause time 0 – 25 s
tKN Low fire over-run time 0 s, 5 s, 15 s or 25 s
Ready tVL Pre-ventilation time 0 – 250 s
Safety interlocks (Limits) tNL Post-ventilation time 0 – 3 s
Start-up signal Input/Output, safety circuit
DI Digital input
Ignition transformer
Gas valve
Air valve
P Purge
A Ext. air valve control
Flame signal
Operating signal
Fault signal
Reset
Input signal
Output signal
Flame simulation check
tW Waiting time ≥ 2 s
tSA Safety time on start-up 3 s, 5 s or 10 s
tSB Safety time during operation < 1 s or < 2 s
tZ Ignition time 2 s, 3 s or 6 s
tLV Flame simulation delay time 25 s
tFS Flame proving period 0 – 25 s

Air pressure switch (electrical connection)

BCU 460, BCU 465 · Edition 07.12 83

11 Glossary 11.4 Flame simulation/Flame simulation delay time tLV
11.1 Waiting time tW
00 01 88
1
00 01 02 . . . 88 5
4 ϑ
V1
7
9
t 12 V1
tW 14 V2
16-17
18-19
Once the start-up signal ϑ has been applied, the waiting time
tLV t
tW starts to elapse. During this time, a self-test is conducted
00 02 . . . 88
to detect errors in internal and external circuit components. If An extraneous signal (flame simulation) is a flame signal that
no malfunction is detected, the burner will startV1up. is detected, although there should be no flame according to
t
11.2 Safety time on start-up tSA the program sequence. If such an extraneous signal is de-
tected, the flame simulation delay time tLV starts to elapse. If the
This refers to the period of time between switching on and flame simulation is discontinued during the flame simulation
switching off of the gas valve, when no flame signal is detected. delay time tLV, start-up can be initiated or operation continued.
The safety time on start-up tSA (3, 5 or 10 s) is the minimum Otherwise, a fault lock-out occurs.
operating time of the burner and burner control unit.

11.3 Ignition time tZ

If no malfunction is detected during the waiting time tW, the
ignition time tZ then starts to elapse. Voltage is supplied to the
pilot gas valve V1 and the ignition transformer and the burner
is ignited. The duration of the ignition time is either 2, 3 or 7
seconds (depending on safety time tSA selected).

BCU 460, BCU 465 · Edition 07.12 84

Glossary
11.5 Safety time during operation tSB plication, e.g. safety temperature limiter, minimum/maximum
gas pressure) must isolate input from the voltage supply.

04 04 88 11.9 Pilot gas valve V1

1
5 The start fuel flow rate for the burner is released by pilot gas
4 ϑ valve V1. It opens when the safety time on start-up tSA starts to
7
9 elapse. It remains open until the burner is switched off again
12 V1
14 V2 by a controlled shut-down or fault lock-out.
16-17
18-19
s1 11.10 Main gas valve V2(BCU 460..L) (BCU 460..C)
t Test
tSB F1
Once the safety time on start-up tSA has elapsed, the main
V1 V2 C N S L

If the flame fails during operation, the valve outputs are dis- gas valve V2 is opened. It remains open until the burner is
40 41 42 43 44
switched off or a fault is signalled.
connected within the safety time tSB. µC
88 F3
O
The default safety time during operation t in accord-

230V~
I SB N1 c1 v1 N1 v2 N1 n s
c2 l N1
ance with EN 298 is 1 second. In accordance with
1 2 3 4 5 6 PE 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 26 27 30 31 32 33 34
EN 746-2, the safety time of the installation during 7opera-
tion (including closing time of the valves) may not exceed 3 s.
Note the requirements of the Standards! max. 2 A, max. 2 A,
253 V 253 V

11.6 Flame signal

If a flame is detected, the flame detector will supply a flame
signal. A
Z I V1 V2
ϑ DI P
11.7 Fault lock-out
In the event of a fault lock-out, all valves and the ignition trans-
former are disconnected from the electrical power supply, 11.11 Continuous operation
and a fault is signalled. Resetting must take place manually The gas7burner runs
7 8 9 8 9 10 11 continuously for more than 24 hours.
following a fault lock-out.

11.8 Safety interlocks (Limits)

The limiters in the safety interlock (linking of all the relevant
safety control and switching equipment for the use of the ap-
1
UVS 2
3

BCU 460, BCU 465 · Edition 07.12 85

Glossary
11.12 Air valve 11.16 Probability of dangerous failure PFHD
The air valve can be used Value describing the likelihood of dangerous failure per hour
– for cooling, of a component for high demand mode or continuous mode.
– for purging, Unit: 1/h.
from EN 13611/A2:2011
– to control the burner capacity in ON/OFF mode and in
High/Low mode when using a pneumatic air/gas ratio 11.17 Mean time to dangerous failure MTTFd
control system. Expectation of the mean time to dangerous failure
11.13 Diagnostic coverage DC from EN ISO 13849-1:2008
Measure of the effectiveness of diagnostics, which may be
determined as the ratio between the failure rate of detected
dangerous failures and the failure rate of total dangerous
failures
NOTE: Diagnostic coverage can exist for the whole or parts
of a safety-related system. For example, diagnostic cover-
age could exist for sensors and/or logic system and/or final
elements. Unit: %.
from EN ISO 13849-1:2008
11.14 Mode of operation
High demand mode or continuous mode
Operating mode, where the frequency of demands for opera-
tion made on a safety-related system is greater than one per
year or greater than twice the proof-test frequency
from EN 61508-4:2001
11.15 Safe failure fraction SFF
Fraction of safe failures related to all failures, which are as-
sumed to appear
from EN 13611/A2:2011

BCU 460, BCU 465 · Edition 07.12 86

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Remarks

sdcdscdsc Kromschröder AG

Michael Rehkamp
[email protected]

Osnabrück

(Adobe Reader 7 or higher required)

www.adobe.com

Contact
Elster GmbH The current addresses of our international agents are
Postfach 2809 · 49018 Osnabrück available on the Internet:
Strotheweg 1 · 49504 Lotte (Büren) www.kromschroeder.de/index.php?id=718&L=1
Germany
T +49 541 1214-0
F +49 541 1214-370 We reserve the right to make technical modifications

BCU 460, BCU 465 · Edition 07.12

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