Page is loading ...
6 Edition 03.16l
AGA
Industrial & Commercial Thermal
Technical Information · GB
• For pilot and main burners in intermittent or continuous operation
• Replace the local control cabinet
• 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
Burner control units BCU 480
BCU 480 · Edition 03.16l 2
▼ = To be continued
Contents
Burner control units BCU 480 .......................1
Contents ............................................2
1 Application ........................................5
1.1 Examples of application ........................... 7
1.1.1 Stage-controlled main burner with alternating
pilot burner ..................................................7
1.1.2 Stage-controlled main burner with permanent
pilot burner ..................................................8
1.1.3 Two-stage-controlled main burner with
permanent pilot burner......................................9
1.1.4 Modulating-controlled burner ......................10
1.1.5 BCU 480..B1 for PROFIBUS DP ......................11
1.1.6 BCU 480..D:
High temperature equipment ..............................11
2 Certification ......................................12
3 Function ..........................................13
3.1 Connection diagrams .............................13
3.1.1 BCU 480..E1.........................................13
3.1.2 BCU 480 ............................................. 14
3.1.3 BCU 480..B1..E1 ....................................15
3.1.4 BCU 480..B1.........................................16
3.1.5 BCU 460..P..E1 with industrial plug connector ......17
3.1.6 BCU 460..P with industrial plug connector . . . . . . . . . 18
3.2 BCU..P with 16-pin industrial plug connector ....19
3.3 PROFIBUS DP ................................... 20
3.3.1 Safety-related control signals.......................20
3.3.2 BCSoft................................................21
3.3.3 Configuration, MasterSlave procedure .............21
3.3.4 Addressing............................................21
3.3.5 Network technology.................................22
3.3.6 Configuration........................................22
3.3.7 Bus communication .................................22
3.4 BCU 480 program sequence .....................24
3.5 Program status and fault messages..............27
4 Parameters ...................................... 29
4.1 Scanning the parameters........................ 30
4.2 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.1 Flame signal, pilot burner ............................31
4.2.2 Flame signal, main burner............................31
4.2.3 Program status when the most recent fault
occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.2.4 Switch-off threshold of the flame amplifier..........31
4.2.5 High temperature operation in the case of BCU..
D2 or BCU..D3 ............................................. 32
4.2.6 UVS check ...........................................35
4.3 Pilot and main burner monitoring ................36
4.3.1 Permanent pilot burner...............................37
4.3.2 Interrupted pilot burner ..............................37
4.4 Behaviour in start-up position/standby ..........38
4.4.1 Flame simulation check in start-up position/
standby ....................................................38
4.4.2 Minimum burner pause time tBP ....................39
4.5 Behaviour during start-up ....................... 40
4.5.1 Safety time on start-up tSA .........................40
4.5.2 Flame proving period tFS ............................41
4.5.3 Minimum burner on time tB ..........................41
4.5.4 Burner start-up attempts ........................... 42
4.6 Behaviour during operation...................... 44
4.6.1 Safety time during operation tSB for pilot and main
burners ....................................................44
4.6.2 Fault lock-out or restart, pilot burner ...............44
4.6.3 Fault lock-out or restart, main burner...............46
4.6.4 Program status on last fault .........................47
4.7 Air valve control on BCU..L ....................... 48
4.7.1 Purge.................................................48
4.7.2 Cooling in start-up position/standby ...............48
4.7.3 Burner start ..........................................48
4.7.4 Air valve opens in the case of external activation
(not during start-up).......................................49
4.7.5 Air valve opens in the case of external activation
(even during start-up) .....................................50
4.7.6 Air valve opens with valve V2 .........................51
BCU 480 · Edition 03.16l 3
▼ = To be continued
4.7.7 Air valve opens with operating signal ................ 52
4.7.8 Low fire over-run time tKN after a controlled shut-
down .......................................................53
4.7.9 Behaviour of the air valve in the event of a fault
lock-out....................................................54
4.8 Manual mode .....................................55
4.8.1 Manual mode limited to 5 minutes..................55
5 Selection ........................................ 56
5.1 Type code .........................................56
6 Project planning information .....................57
6.1 Cable selection ...................................57
6.1.1 Ionization cable.......................................57
6.1.2 Ignition cable .........................................57
6.1.3 UV cable ..............................................57
6.2 Ignition electrode .................................57
6.2.1 Electrode gap ........................................57
6.2.2 Star electrodes .......................................57
6.3 Calculating the safety time tSA ...................58
6.4 Minimum burner on time .........................59
6.5 Safety interlocks (Limits) .........................59
6.6 Protection of safety-relevant outputs ............59
6.7 Emergency off ................................... 60
6.7.1 In the event of fire or electric shock .................60
6.7.2 Via the safety interlocks (limits) .....................60
6.8 Reset ............................................. 60
6.8.1 Parallel reset.........................................60
6.8.2 Permanent remote reset ............................60
6.8.3 Automatic remote reset (PLC) ......................60
6.9 Burner start ...................................... 60
6.10 Restart and start-up attempts ................. 60
6.11 Fault signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.12 Protecting the pilot burner from overload.......61
6.13 Installation ......................................61
6.14 Wiring............................................62
6.15 BCU and BCU..E1 (with and without adapted
power management)..................................62
6.16 Signal distributor board .........................62
6.17 PROFIBUS DP ...................................63
6.17.1 Safety-related control signals .....................63
6.17.2 Wiring the PROFIBUS plug connector .............63
6 . 17. 3 EMC ................................................63
6.17.4 Unit replacement...................................63
6.17.5 Status and fault messages for PROFIBUS DP .....64
6.18 Third gas valve (can be shut down) on BCU..L . 66
6.19 BCU switched off................................67
6.20 Furnace control .................................67
6.21 Mains switch ....................................67
6.22 Note on EC type-examination ..................67
6.23 SIL/PL level for thermoprocessing equipment 67
6.24 Changing parameters .......................... 68
7 Flame control .................................... 69
7.1 With ionization sensor.............................69
7.2 With UV sensor ....................................69
7.3 Via the temperature in high temperature
equipment ............................................70
8 Accessories.......................................71
8.1 High-voltage cable ...............................71
8.2 Industrial plug connector, 16-pin.................71
8.3 PROFIBUS plug connector .......................71
8.4 BCSoft ............................................72
8.4.1 Opto-adapter PCO 200 .............................72
8.4.2 Bluetooth adapter PCO 300 ........................ 72
8.5 “Changed parameters” stickers ..................72
8.6 External securing bar .............................73
8.7 Fastening set .....................................73
8.8 Radio interference suppressed electrode plugs..73
9 Technical data ....................................74
9.1 BCU..B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
9.2 PROFIBUS DP ....................................75
9.3 Safety-specific characteristic values .............76
BCU 480 · Edition 03.16l 4
▼ = To be continued
9.4 Housing dimensions ..............................77
9.5 Operating controls................................77
9.6 Installation ........................................77
10 Legend ..........................................78
11 Glossary ........................................ 79
11.1 Waiting time tW ..................................79
11.2 Safety time on start-up tSA ......................79
11.3 Ignition time tZ ..................................79
11.4 Flame simulation/Flame simulation delay time
tLV .....................................................79
11.5 Safety time during operation tSB ............... 80
11.6 Flame signal .................................... 80
11.7 Fault lock-out ................................... 80
11.8 Safety interlocks (Limits) ....................... 80
11.9 Pilot gas valve V1 ............................... 80
11.10 Main gas valve V2 ..............................81
11.11 Continuous operation ..........................81
11.12 Air valve.........................................81
11.13 Diagnostic coverage DC........................81
11.14 Mode of operation..............................81
11.15 Safe failure fraction SFF .......................81
11.16 Probability of dangerous failure PFHD ........82
11.17 Mean time to dangerous failure MTTFd .......82
Feedback .......................................... 83
Contact............................................ 83
BCU 480 · Edition 03.16l 5
Application
1 Application
The burner control units BCU 480 control, ignite and
monitor gas burners for intermittent or continuous op-
eration. As a result of their fully electronic design, they
react quickly to various process requirements and are
therefore suitable for frequent cycling operation.
They can be used for industrial burners of unlimited
capacity which are ignited by pilot burners. Pilot and
main burners may be modulating or stage-controlled.
The BCU 480 monitors pilot and main burners inde-
pendently. The pilot burner can burn permanently or be
switched off. The BCU is installed near the burner to be
monitored.
On industrial furnaces, the BCU reduces the load on
the central 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 when it is
restarted.
The air valve control assists the furnace control for cool-
ing, purging and capacity control tasks.
The program status, the unit parameters and the level
of the flame signal can be read directly from the unit.
The burner can be controlled manually for commission-
ing and diagnostic purposes.
If the local requirements on the burner control unit
change, the PC software “BCSoft” can be adjusted to
the unit parameters of the application by using the op-
tical interface.
The BCU unites
the function-
ally interrelated
components of
automatic burner
control unit, igni-
tion transformer,
Manual/Automatic
mode and display
of operating and
fault statuses in
a compact metal
housing.
▼
BCU 480 · Edition 03.16l 6
Application
The service personnel is supported by a convenient vis-
ualization system of the input and output signals and
the error history.
The new power management scheme reduces installa-
tion and wiring costs. The power for the valves and igni-
tion transformer is supplied via the power supply of the
BCU, protected by a replaceable fine-wire fuse.
The conventional wide-spread systems used in indus-
trial furnace and kiln construction require bridging of
large distances for signal processing. The optionally
available BCU..B1 for connection to the PROFIBUS DP
fieldbus is equipped for this purpose.
As a standardized fieldbus system, the PROFIBUS DP
considerably reduces development, installation and
commissioning costs compared to conventional wiring.
The use of a standard bus system offers massive ben-
efits compared to manufacturer-specific bespoke solu-
tions. Time-tested hardware components, standardized
connection methods and a series of tools of bus diag-
nostics and optimization are available on the market
from a whole range of manufacturers. The widespread
use of the system ensures that the planning and ser-
vice personnel are very familiar with how the system op-
erates and how to handle it and can therefore operate
the system efficiently.
Bogie hearth forg-
ing furnace in
the metallurgical
industry
Intermittent shut-
tle kiln in the ce-
ramics industry
Walking beam
furnace with over-
head firing
BCU 480 · Edition 03.16l 7
BCU 480
14 12
23
26
SPS
PLC
API
DI
L1, N, PE
P
22 4 21 18
19
16
17
28
29
24
2
1
t
1
2
A
P
5
3
DI
6
02–04 02–04 06–08 06–08
ϑ
2
ϑ
1
ϑ
1
ϑ
2
µC
VR..L
VAG
UV
VBY
2
1
Application
1.1 Examples of application
1.1.1
Stage-controlled main burner
with alternating pilot burner
Control:
Main burner ON/OFF.
The main burner can be started with
reduced capacity after the operat-
ing signal from the pilot burner has
been detected. The pilot burner is
switched off automatically after the
main burner has started up. When
the main burner is switched off, the
pilot burner automatically switches
on again. This reduces the main
burner start-up time.
A UV sensor monitors the flame sig-
nal from pilot and main burners. UV
sensor UVD 1 is used for continu-
ous operation, UV sensor UVS for
intermittent operation.
The BCU provides the cooling and
purging processes.
BCU 480 · Edition 03.16l 8
t
1
2
BCU 480
14 12
23
26
SPS
PLC
API
DI
L1, N, PE
P
22 4 21 18
19
16
17
28
29
24
2
1
A
P
5
3
DI
6
04 02–04 06–08 06–08 04
µC
ϑ
1
ϑ
2
ϑ
1
ϑ
2
VR..R
VAG
VBY
2
1
Application
1.1.2
Stage-controlled main burner
with permanent pilot burner
Control:
Main burner ON/OFF.
The main burner can be started with
reduced capacity after the operat-
ing signal from the pilot burner has
been detected. Pilot and main burn-
ers can be operated simultaneously.
This reduces the time required by
the main burner for starting up.
The BCU provides the cooling and
purging processes.
BCU 480 · Edition 03.16l 9
BCU 480
12
23
SPS
PLC
API
DI
L1, N, PE
P
22 4 21 18
19
16
17
28
29
24
2
1
A
P
5
3
DI
6
VBY
µC
ϑ
1
ϑ
2
t
1
2
04 02–04 06–08 06–08 04
ϑ
1
ϑ
2
2
1
BV
IC 40
4
7
M
14
26
50 51
VAG
VAS
Application
1.1.3 Two-stage-controlled main
burner with permanent pilot
burner
Control:
Main burner ON/OFF with ignition
via bypass.
The main burner can be started at
low-fire rate after the operating sig-
nal from the pilot burner has been
detected. When the operating state
is reached, the BCU issues the En-
able signal for the maximum burner
capacity. Pilot and main burners
can be operated simultaneously.
This reduces the time required by
the main burner for starting up.
The BCU provides the cooling and
purging processes.
BCU 480 · Edition 03.16l 10
BCU 480
14 12
SPS
PLC
API
DI
L1, N, PE
4 21 18
19
16
17
28
29
24
2
1
P
5
3
DI
6
mA
µC
ϑ
1
ϑ
2
VAG
VBY
BV+IC
M
2
1
Application
1.1.4 Modulating-controlled
burner
Control:
Main burner continuous.
The butterfly valve for air is moved
to ignition position in order to start
the main burner. The main burner
can be started at low-fire rate after
the operating signal from the pilot
burner has been detected. The con-
trol system controls the burner ca-
pacity via the butterfly valve for air
after the operating state has been
signalled. Pilot and main burners
can be operated simultaneously.
This reduces the time required by
the main burner for starting up.
BCU 480 · Edition 03.16l 11
PROFIBUS-DP
BCU 480..B
BUS
1–6
BCU 480..B
BUS
BCU 480..B
BUS
1–61–6
SPS
PLC
API
DI
L1, N, PE
P
BUS
Application
1.1.5 BCU 480..B1 for PROFIBUS DP
The bus system transfers the control
signals for starting, resetting and
for controlling the air valve from the
control system to the BCU 480..B1.
In the opposite direction, it sends op-
erating status, the level of the flame
signals and the current program
status.
Control signals that are relevant for
safety, such as the safety interlocks,
purge (optional) and digital input, are
transferred independently of the bus
communication by separate cables.
1.1.6 BCU 480..D:
High temperature equipment
Indirect flame control using the
temperature. During the start-up
process, as long as the wall temper-
ature is below auto ignition temper-
ature, the flame must be controlled
by conventional methods. When the
working temperature has exceeded
750°C, the safety temperature
monitor (STM) takes over the indi-
rect flame control.
L1
DI
BCU 480..D
DI 6
9 24
BCU 480..D
6
9 24
µC µC
STM > 750°C
BCU 480 · Edition 03.16l 12
Certification
2 Certification
Certificates – see Docuthek.
Certified to SIL and PL
For systems up to SIL 3 pursuant to EN 61508 and PL
e pursuant to ISO 13849
EU certified pursuant to
– Gas Appliances Directive (2009/142/EC) in conjunc-
tion with
EN 298:2012
Meets the requirements of the
– Low Voltage Directive (2006/95/EC),
– EMC Directive (2004/108/EC).
ANSI/CSA approved
American National Standards Institute/Canadian
Standards Association – ANSI Z21.20/CSA C22.2,
No. 199/UL 372
www.csagroup.org – Class numbers: 333501 and
333581.
FM approved
Factory Mutual Research Class: 7610 “Combustion
Safeguards and Flame Sensing Systems”.
Suitable for applications pursuant to NFPA 86.
www.approvalguide.com
AGA approved
AGA
Australian Gas Association, Approval No.: 6478
http://www.aga.asn.au/product_directory
Eurasian Customs Union
The product BCU 480 meets the technical specifica-
tions of the Eurasian Customs Union.
BCU 480 · Edition 03.16l 13
L1 (L1)
N (L2)
PE
1 2 PE
N1 N1
s
s1
V1 V2 C N S M L
µC
l
N1
v1
c2
88
c1 N1
v2
V1 V2
F1
230V~
max. 2 A,
253 V
I
Z
30 31 32 33 34 35 36 37
DI
50 51
l
38
F3
(BCU 480..C)
40 41 42 43 44 45 46 47
UVS 1
2
3
P
5 6 7 8 119 10 12 13 14 15 25 26 2718 19 20 22 24
PE 7 8 9 10 24 25PE 7 89 24
Test
N1
O
I
BCU 480..E1
ϑ1ϑ2
A
23
2
1
16 17 28 2921
34
Function
3 Function
3.1 Connection diagrams
3.1.1 BCU 480..E1
For cable selection and wiring, see page 57 (Project
planning information).
For the explanation of symbols, see page 78 (Leg-
end).
BCU 480 · Edition 03.16l 14
L1 (L1)
N (L2)
PE
1 2 PE
N1 N1
s
s1
V1 V2 C N S M L
µC
l
N1
v1
c2
88
c1 N1
v2
V1 V2
F1
230V~
max. 2 A,
253 V
I
Z
30 31 32 33 34 35 36 37
DI
50 51
l
38
F3
(BCU 480..C)
40 41 42 43 44 45 46 47
UVS 1
2
3
P
5 6 7 8 119 10 12 13 14 15 25 26 2718 19 20 22 24
PE 7 8 9 10 24 25PE 7 89 24
Test
O
I
BCU 480
ϑ1ϑ2
A
23
2
1
16 17 28 2921
34
Function
3.1.2 BCU 480
For cable selection and wiring, see page 57 (Project
planning information).
For the explanation of symbols, see page 78 (Leg-
end).
BCU 480 · Edition 03.16l 15
L1 (L1)
N (L2)
PE
1 2 PE
N1 N1
s
s1
V1 V2 C N S M L
µC
l
N1
v1
c2
88
c1 N1
v2
V1 V2
F1
230V~
max. 2 A,
253 V
I
Z
30 31 32 33 34 35 36 37
DI
50 51
l
38
F3
(BCU 480..C)
40 41 42 43 44 45 46 47
UVS 1
2
3
P
5 6 7 8 119 10 12 13 14 15 25 26 2718 19 20 22 24
PE 7 8 9 10 24 25PE 7 89 24
Test BCU 480..B1..E1
O
IN1
BCU..B1/1
PROFIBUS-DP
1B1A2B2A
OFF
ON
OFF
ON
Function
3.1.3 BCU 480..B1..E1
For cable selection and wiring, see page 57 (Project
planning information).
For the explanation of symbols, see page 78 (Leg-
end).
BCU 480 · Edition 03.16l 16
L1 (L1)
N (L2)
PE
1 2 PE
N1 N1
s
s1
V1 V2 C N S M L
µC
l
N1
v1
c2
88
c1 N1
v2
V1 V2
F1
230V~
max. 2 A,
253 V
I
Z
30 31 32 33 34 35 36 37
DI
50 51
l
38
F3
(BCU 480..C)
40 41 42 43 44 45 46 47
UVS 1
2
3
P
5 6 7 8 119 10 12 13 14 15 25 26 2718 19 20 22 24
PE 7 8 9 10 24 25PE 7 89 24
Test
O
IN1
BCU 480..B1
BCU..B1/1
PROFIBUS-DP
1B1A2B2A
OFF
ON
OFF
ON
Function
3.1.4 BCU 480..B1
For cable selection and wiring, see page 57 (Project
planning information).
For the explanation of symbols, see page 78 (Leg-
end).
BCU 480 · Edition 03.16l 17
1
1 2 PE
N1 N1
s
s1
V1 V2 C N S M L
µC
l
N1
v1
c2
88
c1 N1
v2
V1 V2
F1
230V~
max. 2 A,
253 V
I
Z
30 31 32 33 34 35 36 37 50 51
l
38
F3
(BCU 480..P..C)
40 41 42 43 44 45 46 47
UVS 1
2
3
5 6 7 8 119 10 12 13 14 15 25 26 27
18 19 20 22 24
PE 7 8 9 10 24 25PE 7 8 9 24
23
34
2
DI
16 15 14 12 11 10 9
8 7 6 5 4 3 2 1
P A
L1 (L1)
N (L2)
PE
16 15 14 8 7 12 511 10 4 39 2 16
2
1
21
1716 28 29
ϑ1ϑ2
N1
O
I
BCU 480..P..E1
Function
3.1.5 BCU 460..P..E1 with industrial plug connector
For cable selection and wiring, see page 57 (Project
planning information).
For the explanation of symbols, see page 78 (Leg-
end).
BCU 480 · Edition 03.16l 18
1
1 2 PE
N1 N1
s
s1
V1 V2 C N S M L
µC
l
N1
v1
c2
88
c1 N1
v2
V1 V2
F1
230V~
max. 2 A,
253 V
I
Z
30 31 32 33 34 35 36 37 50 51
l
38
F3
(BCU 480..P..C)
40 41 42 43 44 45 46 47
UVS 1
2
3
5 6 7 8 119 10 12 13 14 15 25 26 27
18 19 20 22 24
PE 7 8 9 10 24 25PE 7 8 9 24
23
34
2
DI
16 15 14 12 11 10 9
8 7 6 5 4 3 2 1
P A
L1 (L1)
N (L2)
PE
16 15 14 8 7 12 511 10 4 39 2 16
2
1
21
1716 28 29
ϑ1ϑ2
O
I
BCU 480..P
Function
3.1.6 BCU 460..P with industrial plug connector
For cable selection and wiring, see page 57 (Project
planning information).
For the explanation of symbols, see page 78 (Leg-
end).
BCU 480 · Edition 03.16l 19
Function
3.2 BCU..P with 16-pin industrial plug
connector
The burner control unit BCU 480..P can be supplied
with an industrial plug connector (pursuant to VDE
0627). This 16-pin plug connector ensures fast con-
necting or disconnecting of units without any addition-
al wiring required. This simplifies replacing the unit 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 71 (Accessories).
BCU 480 · Edition 03.16l 20
SPS
PLC
API
PROFIBUS DP
BUS
1
2
3
BCU..B
BUS1– 6
DI
L1, N, PE
BCU..B
BUS1– 6
BCU..B
BUS1– 6
P
Function
3.3 PROFIBUS DP
BCU..B1 features the same scope of functions and per-
formance of a BCU® without a PROFIBUS connection.
PROFIBUS is a manufacturer-independent, open field-
bus standard for diverse applications.
PROFIBUS DP is a bus variant for communication be-
tween automation systems and distributed peripherals
at the field level, optimized for speed and low connec-
tion costs.
On PROFIBUS DP, the individual bus stations are con-
nected via a 2-core shielded cable as standard.
The bus system transfers the control signals for start-
ing, resetting and for controlling the air valve to purge
the furnace or kiln or for cooling in start-up position
and heating during 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.
3.3.1 Safety-related control signals
Signals from the safety interlocks and digital input are
transferred independently of the bus communication
by separate cables. The air valve used to purge the fur-
nace or kiln can either be activated via the PROFIBUS
or via a separate cable to terminal 22. The purging pro-
cess must be monitored by further measures, e.g. flow
monitoring.
/
