Krom Schroder FCU 505 Manual de usuario
DK S N P GR
➔www.docuthek.com
D GB F NL I E
TR CZ PL RUS H
© 2015 Elster GmbH · Edition 03.15
Safety
Please read and keep in a safe place
Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the opera-
tor. This unit must be installed and commissioned
in accordance with the regulations and standards
in force. These instructions can also be found at
www.docuthek.com.
Explanation of symbols
• , , , ... = Action
▷= Instruction
Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
Safety instructions
Information that is relevant for safety is indicated in
the instructions as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.
Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
Changes to edition 09.4
The following chapters have been changed:
– Replacing the protective system/furnace zone
control
– Certification
Contents
Operating instructions
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Translation from the German
Protective system control FCU 500
Furnace zone control FCU 505
Protective system control FCU 500
Furnace zone control FCU 505 ............
Contents ..............................
Safety.................................
Checking the usage .....................
Installation ............................
Replacing the protective system/furnace
zone control ...........................
Cable selection.........................
Wiring ................................4
Connection diagram ....................6
FCU 500 ..............................6
FCU 505 .............................. 7
IC 20 connected to FCU..F1 ...............8
IC 20 E connected to FCU..F1..............9
IC 40 connected to FCU..F1 ..............10
RBW valve connected to FCU..F2 .......... 11
Frequency converter connected to FCU..F2 ..12
Adjustment ...........................
Commissioning........................
Manual mode .........................4
Assistance in the event of malfunction ....5
Replacing the fuse ...................... 21
Parameters and values .................
Legend...............................4
Technical data ........................4
Designed lifetime .......................25
Logistics .............................5
Accessories ..........................5
Certification ..........................6
Contact ..............................6
Safety
Contents
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Checking the usage
The protective system control FCU 500 and furnace
zone control FCU 505 are designed for the moni-
toring and controlling of central safety functions in
multiple burner systems on an industrial furnace.
The FCU500 controls multiple zones acting as the
central protective system control. The FCU505 is
used for protective system and capacity control in
individual furnace zones.
Type code
Code Description
FCU 500
FCU 505
Protective system control
Furnace zone control
Q
W
Mains voltage: 120 V AC, 50/60 Hz
230 V AC, 50/60 Hz
C0
C1
No valve proving system
With valve proving system
F0
F1
F2
Capacity control:
none
with interface for actuator IC
with interface for RBW
H0
H1
Temperature monitoring:
none
with temperature monitoring
K0
K1
K2
Connection terminals:
none
screw terminals
spring force terminals
Part designations
3
5
2
6
8
1
7
4
LED display for program status and fault
messages
Reset/Information button
On/Off button
4Type label
5Connection for opto-adapter
6Power module, detachable
7Power module type label
8Parameter chip card
Type designation (FCU…), construction stage, input
voltage – see type label.
FCU
Installation
▷
Installation position: vertically upright, horizontal
or tilted to the left or right.
▷
The FCU mounting is designed for horizontally
aligned 35 × 7.5 mm DIN rails.
▷
If the DIN rail is aligned vertically, end clamps are
required (e.g. Clipfix 35 by Phoenix Contact) to
prevent the FCU from slipping.
▷
Install in a clean environment (e.g. a control
cabinet) with an enclosure ≥ IP 54, whereby no
condensation is permitted.
1
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Replacing the protective system/
furnace zone control
Disconnect the system from the electrical power
supply.
2
Disengage the FCU from the DIN rail.
4 5
6 Transfer the parameter values from the old FCU
to the new FCU.
▷Remove the parameter chip card from the old
FCU and insert into the new FCU.
CAUTION
Malfunction (fault message
)! The old and
new FCUs must have the same hardware confi-
guration (see type designation on type label). The
parameter chip card is not backward compatible.
If the parameter chip card has been operated in
an FCU with more recent firmware, it cannot be
used in a device with older firmware.
▷
Alternatively, the parameters values can be read
from the old FCU and then read back into the
new FCU using the separate BCSoft software,
see pages 13 (Adjustment) and 25 (Ac-
cessories).
7 Slide the power module back on.
8 Mount the FCU on the DIN rail again.
9 Reconnect the connection terminals.
0 Switch the system on again, see page 13
(Commissioning).
▷
Fault message
: Parameter chip card from
FCU construction stage B or above has been
inserted into FCU construction stage A, see also
page 15 (Assistance in the event of malfunc-
tion).
Cable selection
▷
Use cables suitable for the type of operation and
complying with local regulations.
▷
Signal and control line for screw terminals
max. 2.5mm2, for spring force terminals max.
1.5mm2.
▷
Do not route FCU cables in the same cable duct
as frequency converter cables or cables emitting
strong fields.
▷
Control lines must fulfil the requirements of
EN60204-1, Chapter12.
▷Avoid external electrical interference.
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Wiring
▷
Do not reverse phase L1 and neutral conduc-
tor N.
▷Do not install different phases of a three-phase
current system at the inputs.
▷Do not connect voltage to the outputs.
▷
A short-circuit on the outputs causes one of the
replaceable fuses to trip.
▷
Ensure that the inputs at terminals 1 to 4 and
44 are only supplied with 24 V DC.
▷
24 V DC power supply: + at terminal 62, - at
terminal 61.
▷
Ensure that the 24 V DC outputs at terminals
41 and 42 are not connected to mains voltage.
▷Do not set the remote reset so that it operates
automatically in cycles.
▷Wire the safety circuit inputs via contacts (relay
contacts) only.
▷The unit features an output for fan control (termi-
nal58). This single-pole contact can be loaded
with a max. of 3A. The max. start-up current of
the fan motor may not exceed a value of max.
6A for 1s– use an external contactor if required.
▷
The limiters in the safety interlock (linking of all the
relevant safety control and switching equipment
for the use of the application, for example, safety
temperature limiter) must isolate terminal46 from
the voltage supply. If the safety interlock is in-
terrupted, the display shows a blinking
50
as
a warning signal and all of the FCU’s control
outputs are disconnected from the electrical
power supply.
▷
Connected control elements must be equipped
with protective circuits in accordance with the
manufacturer’s instructions. The protective circuit
prevents high voltage peaks which can cause
malfunctioning of the FCU.
▷
Functions of terminals 51, 65, 66, 67 and 68 are
dependent on parameter values:
Terminal Dependent on parameter
51 69
65 70
66 71
67 72
68 73
See page 22 (Parameters and values).
Disconnect the system from the electrical power
supply.
Before wiring the FCU, ensure that the yellow
parameter chip card has been installed in the
FCU– see page3 (Replacing the protective
system/furnace zone control).
▷
Screw terminals or spring force terminals are
available for the FCU– see page25 (Acces-
sories).
Wire as shown on the connection diagram– see
page6 (Connection diagram).
▷Ensure a good PE (ground) wire connection to
the burner control units and burners.
FCU..H
▷
Use type K NiCr-Ni, type N NiCrSi-NiSi or type S
Pt10Rh-Pt Class 1 double thermocouples only.
Thermocouple Temperature range
(°C)
Type K NiCr-Ni -40 to 1000
Type N NiCrSi-NiSi -40 to 1000
Type S Pt10Rh-Pt 0 to 1600
▷
Parameter 22 = 1: Type K double thermocouple
NiCr-Ni
▷
Parameter 22 = 2: Type N double thermocouple
NiCrSi-NiSi
▷
Parameter 22 = 3: Type S double thermocouple
Pt10Rh-Pt
▷STM:
Parameter 20 = 1: High temperature operation
with STM. Position the double thermocouple at
the coldest point in the furnace so that it can
reliably detect whether the spontaneous igni-
tion temperature (>750°C) has been exceeded.
▷STL:
Parameter 20 = 2: Maximum temperature moni-
toring using STL. Position the double thermo-
couple at the warmest point in the furnace so
that it can reliably detect whether the maximum
permitted temperature has been exceeded.
▷STL and STM:
Parameter 20 = 3: High temperature operation
with STM and maximum temperature monitor-
ing with STL. Position the double thermocouple
in the furnace in such a way that it can reliably
detect whether the spontaneous ignition tem-
perature (>750°C) has been exceeded and
also whether the maximum permitted furnace
temperature has been exceeded.
FCU..C
▷
Parameter 51 = 1: Tightness test before furnace
start-up.
▷
Parameter 51 = 2: On; tightness test after fur-
nace shut-down, after a fault lock-out or after
mains on.
▷
Parameter 51 = 3: On; tightness test before
furnace start-up and after furnace shut-down.
▷
Parameter 51 = 4: Permanent via proof of closure
function (POC).
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Safety interlock output in the case of higher
power requirement
▷
The burner start enable signal is issued to the
connected burner control units or automatic bur-
ner control units via the safety interlock output
(terminal 57).
▷
For burner control units or automatic burner
control units whose safety interlock input has
a power consumption of ≤ 2 mA, the power
(max. 0.5 A, cos ϕ= 1) of the FCU is sufficient
to directly activate them.
▷
In the event that a higher output current is re-
quired, the output current can be increased by
means of a contact multiplier using two contac-
tors. Design the circuit as follows:
61 62
FCU 500
5AT
FS
ASTW/
STB
+ - + -
L1
+24 V
V1 V2 V3
41 42 44 45
65
46
66
47
48
68
53 54 55 56 57 5849 50 51 52
ϑ
LDS
HT
P
90°➔0°
0°➔90°
67
13 14 15 16 17 185 6 7 8 11 123 41 2
L1
N
K1 K2
+24 V DC
k1k1
k2k2
Input BCU/IFD
STW/
STB
3.15AT
F = IN× 0.6
▷
BCU with power supply for valves and
ignition transformer via safety interlocks
(terminal 5)
N
≤ 2.5 A
N N
N
230 V AC
BCU 4xx
F1
1 2
PE 7 8 119 10 12 13 14 15
24 25 26 2718 19 20
5
50 5130 31 32 33 34 35 36 37 38
6
23
22
21
3 4
1
617 28 29
max. 2 A
253 V max. 2 A
253 V
F3
V1
L1
I
ZV2
▷
In the event that a higher output current is re-
quired, the output current can be increased by
means of a contact multiplier using three contac-
tors. Design the circuit as follows:
61 62
FCU 500
ASTW/
STB
+ - + -
+24 V
41 42 44 45
65
46
66
47
48
68
53 54 55 56 5749 50 51 52
ϑ
67
13 14 15 16 17
5 6 7 8
11 12
3 41 2
L1
N
K1 K2 K3
k3 k1
k2
k1 k3
k2
Input BCU
Terminal 5 Input BCU
Terminal 22
P
STW/
STB
F = IN× 0.6
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Connection diagram
FCU 500
▷Legend– see page24 (Legend).
61 62
FCU 500
5AT
FS
A
L1
+24 V
V1 V2 V3
41 42 44 45
65
46
66
47 48
68
53 54 55 56 57 5849 50 51 52
ϑ
N
0 V
pu
21
4pu
PZL
PZH
LDS
HT
P
90°➔0°
0°➔90°
PZL
PZ
PDZ
+24 V DC
K2 K1
k11
k21
M
67
13 14 15 16 17 1811 123 41 2
+ - + -
5 6 7 8
P69
P72
P70
P71 P73
Output
Airmin
Air
STM/
STL
Gas
min
3.15AT
0.6 x IN
IN×0.6
Gas
max
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FCU 505
▷Legend – see page 24 (Legend).
61 62
FCU 505
5AT
FS
A
L1
+24 V
V1 V2 V3
41 42 44 45
65
46
66
47 48
68
53 54 55 56 57 5849 50 51 52
N
0 V
pu
21
4pu
PZL
PZH
LDS
HT
P
90°➔0°
0°➔90°
PZL
PZ
PDZ
+24 V DC
K2 K1
k11
k21
M
67
13 14 15 16 17 1811 123 41 2
+ - + -
5 6 7 8
P69
P72
P70
P71 P73
Output
Airmin
Air
STM/
STL
Gas
min
Gas
max
3.15AT
IN× 0.6
0.6 x IN
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IC 0 connected to FCU..F
▷Parameter 40 = 1.
▷
Continuous control via three-point step controller.
61 62
FCU 500
5AT
FS
A
L1
+24 V
V1 V2 V3
41 42 44 45
65
46
66
47 48
68
53 54 55 56 57 5849 50 51 52
ϑ
LDS
HT
P
90°➔0°
0°➔90°
67
13 14 15 16 17 1811 12
3 41 2
PE
L1
N
3 2 116 67 4812 1115 13
S3 S4
S11 S10
0°
90°
M
IC 20
PE
S1S2
90°➔0°
0°➔90°
STW/
STB
+ - + -
5
6 7 8
3.15AT
Output
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IC 0 E connected to FCU..F
▷Parameter 40 = 1.
▷Continuous control via analogue input.
61 62
FCU 500
5AT
FS
A
L1
+24 V
V1 V2 V3
41 42 44 45
65
46
66
47 48
68
53 54 55 56 57 5849 50 51 52
ϑ
LDS
HT
P
90°➔0°
0°➔90°
67
13 14 15 16 17 1811 12
3 41 2
20 19 18 3 2 167 4812 11
S3 S4
S 1 0
OUT
0°
➔90°
0°
90°
90°
➔
0°
IC 20..E
S1
S2
517
+ +
IN
OK
RR
PE
A
D
A
D
R
123456
ON
µC
131516
M
PE
L1
N
STW/
STB
+ - + -
5
6 7 8
3.15AT
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IC 40 connected to FCU..F
▷Parameter 40 = 2.
▷Continuous control via analogue input.
▷Set IC 40 to operating mode 27, see operating
instructions Actuators IC 20, IC 40, IC 40S.
61 62
FCU 500
5AT
FS
A
L1
+24 V
V1 V2 V3
41 42 44 45
65
46
66
47 48
68
53 54 55 56 57 5849 50 51 52
ϑ
LDS
HT
P
90°➔0°
0°➔90°
67
13 14 15 16 17 1811 12
3 41 2
IC 40
PE
19 18 16 15 14 12 11 10 8 7 5 4 2 1
AAC
DDC
M
mA
L
N
22 21 20
R..
STW/
STB
+ - + -
5 6
7 8
3.15AT
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