6.1.2.1 Edition 06.11Product brochure · GB

www.kromschroeder.com

• For monitoring and controlling central safety functions in multiple burner systems on industrial furnaces

• Checking of the valves and system for tightness using a valve proving system

• Safe recording of the furnace chamber temperature on high temperature equipment by a temperature monitor or temperature limiter

• Easy commissioning and maintenance thanks to Manual operating mode

• Long service life due to replaceable load module for fail-safe outputs

• UL, CSA, FM and AGA approvals in preparation.• Certified for systems up to SIL 3 and compliant with PL e

Protective system control FCU 500

2 · FCU 500 · Edition 06.11

ApplicationThe protective system control FCU 500 is de-signed for the monitoring and controlling of central safety functions in multiple burner sys-tems on an industrial furnace. The FCU can be used centrally to control several zones or in the individual zones as protective system and capacity control. If the centrally checked safety requirements (e.g. pre-purge, flow de-tector and pressure switch scan) have been met, the FCU 500 issues the start enable signal to the burner control units.

The FCU is optionally available with inte-grated safety temperature monitor or safety temperature limiter, integrated tightness con-trol and with an interface for controlling the capacity of actuators supplied by different manufacturers (e.g. Kromschröder, Honey-well (RBW), Maxon) or a frequency converter interface.

Using the BCSoft program, the parameters can be read from the FCU via the optionally available opto-adapter and changed. The parameters are saved on the burner chip card which can simply be removed, e.g. when replacing the unit, and inserted again.

An integrated Manual mode allows manual activation of the burner control units and set-ting of the butterfly valve position.

The fail-safe outputs, e.g. for fan, butterfly valve and valves for protecting the furnace, are activated via a plug-in load module. When the maximum number of operating cycles has been reached, it can simply be replaced.

The FCU can be installed on a DIN rail in the control cabinet. The plug-in connection terminal strips make it easier to install and remove the FCU.

An optional operator-control unit OCU can be connected to the FCU. The program status or fault messages can be visualized via the OCU. In Manual mode, the operator-control unit can be used to proceed through the se-quence of operating steps. The OCU is fitted to the outside of the control cabinet door.

Legend

Ready for operation

Safety interlocks (Limits)

DI Digital input

Ignition transformer

Gas valve

Air valve

Air/gas ratio control valve

Burner

P Purge

Controlled air flow

Flame signal

Burner operating signal

ϑ Burner start-up signalPZ Pressure switch for tightness

control (TC)PZH Pressure switch for maximum

pressurePZL Pressure switch for minimum

pressurePDZ Differential pressure switch

M Control element with butterfly valve

TC Tightness control>750°C High temperature operation

pe/2 Half the inlet pressure

Thanks to the opera-tor-control unit OCU, display functions and operation of the FCU can be relocated to the control cabinet door.

FCU 500 with plug-in connection terminals

Once the plug-in load module has been removed, the burner chip card and fuses are accessible.

FCU 500 · Edition 06.11 · 3

M

PZL PZH PZ

PZL PDZ

TE

M

BCU 460..L

BCU 460..L

FCU 500..F0

µC P

DG DG DGVG VAS

VAS

VCG

VCG

VR..L

VR..LDG DG

DGmin DGmax49 15 131450

45

47 4858 STW

>750°

pe/2ϑ 1

2

3

DLmin DLPurge

FCU 500..F1

µC

P

DG DG DGVG VAS

VCG

VCG

DGmin DGmax49 15 131450

53

45

47 4858 STW

pe/2

M

PZL PZH PZ

PZL PDZ

TE

BCU 460..L

BCU 460..L

M

M

TC

90°�0°0°�90°

5455

VAS

DGDG

>750°

ϑ 1

2

3

DLmin DLPurge

ON/OFF rotary impulse control for burners up to 360 kWFor processes which require a control range of more than 1:10 and/or those which require heavy circulation of the furnace atmosphere to ensure a uniform temperature, e.g. heat treatment furnaces operating at low and medium temperatures in the metallurgical industry.

With ON/OFF cyclical control, the capac-ity supplied to the process is controlled by means of a variable ratio of the operating time to the pause time. In this type of control, the burner output pulse frequency always maintains full momentum and maximum convection is obtained in the furnace cham-ber, even with regulated heating.

The pneumatic ratio control system controls the gas pressure on the burner proportion-ally to the air pressure and thus maintains a constant air/gas ratio. At the same time, it acts as an air deficiency cut-out.

The ignition and monitoring of the individual burners is ensured by burner control unit BCU 460..L.

The centrally checked safety functions such as pre-purge, tightness test, flow detector and pressure switch scan (Gasmin., Gasmax., Airmin.) are provided by the FCU 500.

Modulating burner controlFor processes that do not require heavy cir-culation in the furnace, e.g. heat treatment furnaces operating at low and medium temperatures in the metallurgical industry or aluminium smelting furnaces.

This system is suitable for processes in which infiltrated air from the switched off burners does not cause any problems. The capacity can be adjusted continuously by activating the air control valve (analogue or 3-point step signal). The pneumatic ratio control system controls the gas pressure proportionally to the air pressure and thus maintains a con-stant air/gas ratio. At the same time, it acts as an air deficiency cut-out.

The ignition and monitoring of the individual burners is ensured by a burner control unit.

The centrally checked safety functions such as pre-purge, setting the valve to ignition position via a valve control system, tightness test, flow detector and pressure switch scan (Gasmin., Gasmax., Airmin.) are provided by the FCU 500.

Examples of application

4 · FCU 500 · Edition 06.11

FCU 500..F1

µC

P

3PS

90°�

0°0°

�90

°

54 5553

FCU 500..F0

µC

P

49 15 131450

45

4758 48

pe/2

TC

PZL PZH PZ

PZL PDZ

M

BCU..LV1

BCU..LV1

BCU..LV1

BCU..LV1

M

FCU 500..F1

µC

P

3PS

90°�

0°0°

�90

°

54 5553

M

>750°

ϑ 1

2

3

Detailed information on this productwww.docuthek.com ➔ Elster KromschröderSearch term: FCU 500 Kind of document: Technical information

Contactwww.kromschroeder.com ➔ Sales

Elster GmbH Postfach 2809 · 49018 Osnabrück Strotheweg 1 · 49504 Lotte (Büren) Germany

T +49 541 1214-0 F +49 541 1214-370 info@kromschroeder.com

www.kromschroeder.com www.elster.com

We reserve the right to make technical modifications in the interests of progress.

Copyright © 2007 – 2011 Elster GroupAll rights reserved.

0325

0996

Furnace and zone controlA central FCU controls several FCUs in the individual zones. It per-forms central tasks such as scanning the safety interlocks, fan control, system leak tightness check and pre-purge.

The central FCU informs the FCUs in the zones that they should move to the purge position. The FCUs in the zones are informed by the

safety interlock input that the central FCU has issued the enable signal for the burners.

Technical dataMains voltage: FCU 500Q: 120 V AC, -15/+10%, 50/60 Hz, ±5%, FCU 500W: 230 V AC, -15/+10%, 50/60 Hz, ±5%.

Ambient temperature: -20 to +60°C (-4 to +140°F), no condensation permitted.

Enclosure: IP 20 pursuant to IEC 529.

Fuses, replaceable, F1: T 3.15A H, F2: T 5A H, pursuant to IEC 60127-2/5.

Weight: 0.7 kg.

Type codeCode DescriptionFCU 500 Protective system control series 500QW

Mains voltage: 120 V AC, 50/60 Hz230 V AC, 50/60 Hz

C0C1

Integrated tightness control or POC:none

with integrated tightness control or POC

F0F1F2

Capacity control:none

modulating with interface for actuator ICmodulating with interface for RBW

H0H1

Temperature monitoring:none

with temperature monitoring