BCS 6000B BURNER CONTROL SYSTEM
Contents
1. HAUCK MANUFACTURING CO P O Box 90 Lebanon PA 17042 0090 717 272 3051 Fax 717 273 9882 4 03 www hauckburner com BCS 6000B 9 Page 2 BCS6000B 9 A GENERAL INFORMATION The Hauck Burner Control System BCS provides burner management and temperature control for a single pilot ignited burner firing on natural gas or oil The spark ignited gas fired pilot is interrupted after the main burner flame has been established Flame supervision is provided by a Honeywell RM7890A1015 flame relay combined with a R7849A1023 amplifier module and C7027A UV detector s This panel includes special provisions for adjustable valve characterization in order to reduce stack emissions Reference section F VALVE CHARACTERIZATION for details A Programmable Logic Controller PLC supervises burner operation and provides three process control loops for material temperature stack temperature dryer draft The PLC is coupled to a touchscreen display to supply the operator with system status and fault annunciation Two Honeywell UDC1000 series instruments are provided for temperature indication and over temperature protection The thermocouple of the MATERIAL CONTROL instrument is positioned to read the temperature of the material as it exits the dryer while the STACK TEMPERATURE instrument s thermocouple senses the temperature of the exhaust gases The UDC1000 instruments display the process temperature and provide temperature inputs to the Programmabl2. BCS 6000B BURNER CONTROL SYSTEM Section Table of Contents Page A General Information 2 B Receiving and Inspection 2 C Drawings and Supplemental Literature 3 D Installation 3 E Adjustments and Final Checkout 5 F Electronic Valve Characterization 8 G Operation 9 H Troubleshooting 11 Appendix A Operator Interface Screens 14 Appendix B Configuration Record 18 Appendix C Recommended Spare Parts 19 Appendix D DL250 Programmable Controller 20 Appendix E UDC 1000 Temperature Instrument 22 Appendix F Exhaust Fan Flow Limit Installation 24 Appendix G Stack Thermocouple Installation 25 Appendix H Material Thermocouple Installation 26 Appendix Draft Transmitter Adjustments 28 Attachments Applicable Hauck Drawings INSTRUCTIONS These instructions are intended to serve as guidelines covering the installation operation and maintenance of Hauck equipment While every attempt has been made to ensure completeness unforeseen or unspecified applications details and variations may preclude covering every possible contingency WARNING TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY DO NOT USE OR OPERATE ANY EQUIPMENT OR COMPONENT WITH ANY PARTS REMOVED OR ANY PARTS NOT APPROVED BY THE MANUFACTURER Should further information be required or desired or should particular problems arise which are not covered sufficiently for the purchaser s purpose contact Hauck Mfg Co
3. 1 4 Littlefuse 312010 400429 1 Module CPU Automation Direct D2 250 with operating program installed 62311 1 Battery Automation Direct D2 BAT 1 58481 1 Module 8 point AC input Automation Direct D2 08NA 1 58479 1 Module 8 point relay output Automation Direct D2 08TR 63319 1 Module 8 point voltage input Automation Direct F2 08AD 2 300181 1 Operator interface touch screen Automation Direct EZ S8C F 43508 1 Material thermocouple Hauck TC100A J 43868 1 Stack thermocouple Hauck TC200A J Page 21 BCS6000B 9 APPENDIX D DL250 PROGRAMMABLE CONTROLLER VENDOR BASE CPU BATTERY SLOT 0 Input Wire 1 g 01 24V OV SLOT 1 Input Wire X20 X21 X22 X23 X24 X25 X26 X27 COM SLOT 2 Input Wire X30 X31 X32 X33 X34 X35 X36 X37 COM Automation Direct 800 633 0405 9 Slot base Hauck part number 58484 Automation Direct model number D2 09B Central processing unit Hauck part number 400429 Automation Direct model number D2 250 Hauck part number 62311 Automation Direct model number D2 BAT 1 8 Point analog voltage input module Hauck part number 63319 Automation Direct model number F2 08AD 2 Function 92 0 5Vdc Material temperature from UDC1000 instrument 93 0 5Vdc Stack temperature from UDC1000 instrument 94 1 5Vdc from dryer draft transmitter 91 0 5Vdc flame signal from RM7890A flame relay 83 0 5Vdc fuel control motor position 85 0 5Vde air control motor p
4. 3 input 0 and the high gas pressure switch power on terminal 17 LOW OIL or LP PRESSURE Monitor slot 3 input 5 Verify that the manual shutoff valve is open and that the low pressure switch is made power on terminal 17 LOW OIL TEMPERATURE Monitor slot 2 input 2 For heavy oil systems verify that the oil heater is operating and the oil temperature switch is made power on terminal 18 HIGH STACK TEMPERATURE Monitor slot 2 input 3 Check for power on terminals 25 and 26 Observe the display and OUT indicator of the stack temperature instrument A full scale reading 842 F or 450 C indicates an open TC or broken wire REPLACE SCREEN BATTERY Indicates low touchscreen battery voltage Replacement batteries are available from Automation Direct part no EZ BAT Consult the EZTouch Hardware User Manual for battery replacement instructions REPLACE PLC BATTERY Indicates low PLC battery voltage The battery compartment is located in the CPU A replacement battery is available from Hauck part no 62311 or Automation Direct part no D2 BAT 1 The control motor and excess fuel faults all indicate possible problems with the burner control motors or the position feedback circuits Silence the alarm horn and make note of the motor position values displayed on the MOTOR CALIBRATION screen then press the ALARM SILENCE button a second time to reset the fault Shut off the burner verify that all control m
5. MATERIAL or STACK control to return to normal operation Verify that all low fire limit switch contacts are closed Slot 2 input 5 is ON when the burner is at 096 and OFF when the burner leaves low fire Refer to the burner operating instructions for switch adjustment Page 8 BCS6000B 9 Time and Date Setting Simultaneously press the upper left and lower left corners of the touchscreen to enter the screen setup mode then select CLOCK to access the time and date settings Use the keypad to enter the desired value then press Sec Min Hr Day Mon or Yr as applicable For example to set the month to September use the keypad to enter 9 then press Mon Use the EXIT buttons to return to normal operation F ELECTRONIC VALVE CHARACTERIZATION WARNING Adjustment of this equipment by unqualified personnel can result in fire explosion severe personal injury or even death This procedure requires the use of a stack analyzer to properly adjust air fuel ratio and optimize burner performance It is intended for qualified personnel familiar with combustion systems and the interpretation of stack emission readings Electronic Valve Characterization is designed to provide for minor adjustments to the air control valve position only The low fire start position and overall valve stroke must be set by adjustment of the valve motor linkage To facilitate burner setup and optimize emissions the BCS6000 system has been equipped with Elec
6. Stack Center over 1 3 8 dia hole Thermocouple Assy and weld Drawing showing placement of thermocouple in exhaust duct NOTE Thermocouple cables must be separated from AC power and control wiring to avoid interference and nuisance shutdowns Observe polarity when making thermocouple connections Regardless of TC type the red wire is always negative Page 27 BCS6000B 9 APPENDIX H MATERIAL THERMOCOUPLE INSTALLATION Install a Hauck Rapid Response Material Temperature Thermocouple in the material discharge chute to sense the temperature of the material leaving the dryer Wire the thermocouple to the proper terminals in the panel BRASS ADAPTER BUSHING war THERMOCOUPLE I PIPE SET SCREW COUPLING INSTALLED BY CUSTOMER DISCHARGE CHUTE Drawing showing the placement of the thermocouple and dam in the dryer discharge chute IMPORTANT A small clearance 1 maximum should be provided under the thermocouple so material will not be trapped between the thermocouple and the chute Trapped material will cause a heat loss path and the thermocouple will give erroneous readings The thermocouple should make good contact with the material but not be subject to severe abrasion caused by high velocities If the material is moving so fast that it bounces and leaves air adjacent to the thermocouple the temperature it senses will be lower than the material It may be necessary to place a dam in the chute so that the t
7. a 120Vac grounded neutral power supply for proper operation 3 Flame amplifier failure The R7849A1023 flame amplifier may need to be replaced Page 13 BCS6000B 9 MESSAGE DIAGNOSTICS Monitor slot 2 input 0 Check the exhaust fan flow switch power on EXHAUST FAN FAULT terminal 12 and the exhaust fan motor starter interlock power on terminal 13 SECONDARY AIR INTERLOCK FAULT Monitor slot 3 input 1 Verify that the burner blower is running and check the secondary air starter interlock power on terminal 14 LOW SECONDARY AIR PRESSURE Monitor slot 2 input 1 Verify that the secondary air pressure switch is made power on terminal 16 PRIMARY AIR INTERLOCK FAULT Monitor slot 3 input 2 For StarJet and EcoStar systems that use a primary air blower for atomization verify that the blower is running and check for power on terminal 15 Note that for EcoStar II systems this limit is only required when OIL or LP firing is selected LOW PRIMARY AIR PRESSURE Monitor slot 3 input 3 For StarJet and EcoStar systems verify that the primary air or compressed air pressure switch is made power on terminal 15A Note that for EcoStar II systems this limit is only required when OIL or LP firing is selected LOW GAS PRESSURE Monitor slot 3 input 4 Verify that the manual gas shutoff valve is open and that the low gas pressure switch is made power on terminal 16 HIGH GAS PRESSURE Monitor slot
8. hole to accommodate a 1 pipe coupling angled downward approximately 30 degrees Mount the draft transmitter on a vibration free support shielded from direct flame radiation The operating temperature range is 20 to 180 F Connect the transmitter manifold to the LOW pressure tap and leave the HIGH tap open to atmosphere as a reference The open tap must be shielded from wind and other disturbances and should not be in a position to collect dirt or water The manifold moisture drain should be positioned vertically down Install the flame scanner s on the burner and wire them to the appropriate terminals in the burner junction box Reference burner instructions for scanner installation details Refer to the external component wiring diagram for interconnection between the burner junction box and the BCS panel terminal strips IMPORTANT The flame scanner draft transmitter and control motor position feedback signals should be run in a separate harness from the burner junction box to the BCS control panel These cables may be run along with thermocouple cables but must be separated from all other AC power and control wiring Note that if shielded cable is used only one end of the cable shield should be grounded Use one of the ground terminals in the BCS control panel for this purpose 13 Set the purge timer 1TR for the required purge time IMPORTANT Before igniting the burner the dryer must be purged to remov
9. inputs AUTO MANUAL selection and AUTO TUNE selection Page 17 BCS6000B 9 RUN MENU Reference Section E Used to set the burner startup percentage and ramp rate for automatic temperature control Also provides for low fire drive alarms and draft setpoint inputs selection of control mode and parameters for automatic draft increase control EY w c pem pem p pm pm pP J S S te 8 t c fan X 287 10 BIAS POINT SETTINGS Reference Section F Two separate screens GAS and OIL LP are provided setup the electronic valve characterization for the air valve It provides inputs for air valve position for each of seven fuel valve positions 10 20 30 40 50 75 and 100 It also displays pertinent data to aid in burner setup Page 18 BCS6000B 9 0 SETPOINT BURNER STOPPED ER TREND Three separate trend screens provide 15 minute 4 hour and 8 hour trends of Material temperature Stack temperature Setpoint and burner firing rate Page 19 BCS6000B 9 APPENDIX B CONFIGURATION RECORD MAIN MENU SCREEN PLC PROGRAM SCREEN PROGRAM MOTOR CALIBRATION amp SETUP SCREEN MOTOR ZERO SPAN FUEL AIR BURNER OUTPUT LIMIT GAS PRESSURE OZ MATERIAL TEMPERATURE BIAS STACK TEMPERATURE BIAS DEADBAND CONTROL LOOP TUNING SCREEN MATERIAL STAC
10. K DRAFT GAIN DEADBAND RESET RATE XXXXXXXX OPEN CYCLE XXXXXXXX XXXXXXXX CLOSE CYCLE XXXXXXXX XXXXXXXX SETPOINT XXXXXXXX RUN MENU SCREEN START AT RAMP AT LOW FIRE DRIVE IF STACK GREATER THAN LOW FIRE DRIVE IF MATERIAL GREATER THAN WC PURGE SETPOINT 96 THEN PER MIN LOW FIRE SETPOINT HIGH FIRE SETPOINT SETPOINT TRANSFER DELAY REDUCE DRAFTBY WC IF DRAFT DROPS BELOW MORE THAN BIAS POINTS TIMES WC WC sec WC Firing Mode Settings 10 20 30 40 50 75 Gas Air At Oil or LP Air At 100 APPENDIX C RECOMMENDED SPARE PARTS Page 20 BCS6000B 9 PART NO QTY DESCRIPTION 56648 1 Flame relay Honeywell RM7890A1015 56650 1 Amplifier Honeywell R7849A1023 20579 2 Scanner Honeywell C7027A1049 58485 4 Relay SPDT Idec RH1B U AC120V 17292 1 Relay 3PDT P amp B KUP 14A35 or equal 46311 1 Relay solid state Crydom 1210 w 6 8k resistors 61961 1 Timer DPDT Purge ATC 407B 100 F3K 300340 1 Timer 10 second N C delay on make SSAC TIS4 4B 1 10 61818 1 Power supply 24Vdc Automation Direct FA 24PS 53763 1 Regulator 5Vdc MC7805ACT 58762 5 Fuse 2A 1 4 x 1 1 4 Buss MDA 2 58763 5 Fuse 5A 1 4 x 1 1 4 Buss MDA 5 55167 5 Fuse 7A 1 4 x 1 1 4 Buss MDA 7 48044 5 Fuse 10A 1 4 x 1
11. Therefore the smaller the setting the more frequently reset action will be repeated Enter a RATE setting seconds if desired for Material and Stack control Note that Rate tends to de stabilize the control and may be left at zero Enter CYCLE time settings seconds for the Draft control loop Note that this loop provides duplex time proportional control outputs for the exhaust damper actuator and has separate Open and Close cycle times similar to the DPS instrument it replaces AUTOTUNE The Material Stack and Draft control PID loops are equipped with an AUTO TUNE button Please note the following before initiating the auto tune procedure gt The process should be stabilized and operating under normal conditions before beginning the auto tune procedure Do not change material feed rate mix or setpoint while auto tune is in progress Only one loop at a time may be tuned The loop must be in AUTO Theloop will be cycled between 10096 and 096 three times during the course of the auto tune procedure Obviously this will cause significant swings in temperature and or dryer draft gt Auto tune may be interrupted if necessary by placing the control loop in manual Theresulting GAIN RESET and RATE parameters GAIN only for draft control will be automatically updated when the sequence is completed RUN MENU Screen After all loop tuning settings have been recorded return to the MAIN MENU then press RUN MENU t
12. U USE EGU Select Engineering Units EGU SEL INH2O Lower Range Value EGU LRV 00 00 Upper Range Value EGU URV 1 00 3 00 or 5 00
13. after powering the instrument hold the SET UP and A keys simultaneously for approximately 5 seconds to enter the configuration mode inPt will appear in the lower display and 1418 should appear in the upper display Use the SET UP key to step through the configuration parameters and the and V keys to change values if necessary The upper display will flash after a value has been Page 24 BCS6000B 9 changed and the RESET key must be pressed to accept the change Momentarily press the SET UP and A keys again to exit the configuration mode Fahrenheit Centigrade Type J Type K Type J Type K Lower Upper Upper Upper Upper Display Display Display Display Display inPt 1418 6727 1417 6726 CtrL Hi Hi Hi Hi ALA1 P hi P hi P hi P hi ALA2 nonE nonE nonE nonE A1 d USE2 USE2 USE2 USE2 rEcP USES USES USE3 USE3 CJC EnAb EnAb EnAb EnAb Loc read only read only read only read only CHANGING THE SET POINT Press the SET UP and A keys simultaneously 0 will appear in the upper display and ULoc will appear in the lower display Press SET UP key one time to display SP in the lower display and the current setpoint value in the upper display Use the and keys to change the setpoint CAUTION The STACK alarm setpoint is factory set at 400 F 204 C If the system is equipped with a fabric dust collector baghouse consult the manufacturer for recommended baghouse temperature limitatio
14. and Earth ground Wire the fuel valves valve position limit switches and fuel pressure limit switches as shown on the external component wiring diagram Install the exhaust fan flow limit switch in the dryer exhaust duct as shown in Appendix F Wire the normally open contact of the exhaust flow limit to the appropriate terminals in either the burner junction box or the BCS control panel Install the stack temperature thermocouple in the dryer exhaust duct to sense exhaust gas temperature See Appendix G for installation instructions Install a Hauck Rapid Response material temperature thermocouple in the material discharge chute to sense the temperature of the material leaving the dryer See Appendix H for recommended installation Connect the thermocouples to the appropriate terminals in the BCS control panel using thermocouple cable of the same type as the Material and Stack thermocouples 10 11 12 Page 4 BCS6000B 9 IMPORTANT Thermocouple cables must be separated from AC power and control wiring to avoid interference and nuisance shutdowns Observe polarity when making thermocouple connections Regardless of thermocouple type the red wire is always negative A pressure tap for the dryer draft transmitter should be located in the 10 o clock or 2 o clock position on the dryer breech Locate the tap midway between the outer edge of the breeching and the outer edge of the combustion chamber or shell Cut a
15. e Function 63 Purge relay R2 64 Run relay R3 65 Pilot scanner relay R4 66 Pilot relay R5 67 Fuel motor increase relay R6 68 Fuel motor decrease relay R7 69 Air motor increase relay R8 70 Air motor decrease relay R9 8 Point relay output module Hauck part number 58479 Automation Direct model number D2 08TR Wire Function 49 Alarm horn 20 START indicator 71 Spare relay R10 27 RESET indicator 40 Draft increase relay R13 42 Draft decrease relay R14 74 Spare relay R11 73 Spare relay R12 Optional 8 Point analog current input module Hauck part number 300344 Automation Direct model number F2 08AD 1 Function 96 4 20mA from optional gas differential pressure transmitter 97 Spare 95 Spare 98 4 20mA from optional oil or LP flow transmitter 101 Spare 102 Reserved for Hauck Service 103 Reserved for Hauck Service 104 Reserved for Hauck Service 99 24Vdc supply 81 Analog reference Page 23 BCS6000B 9 APPENDIX E UDC1000 SERIES LIMIT INSTRUMENTS Hauck part number 300003 Honeywell model DC100L 1 1 7 0 1 0 0 0 Two Honeywell UDC1000 series instruments are provided for temperature indication and over temperature protection Each instrument receives a thermocouple input and provides a 0 to 5Vdc temperature signal to the PLC The thermocouple of the MATERIAL CONTROL instrument is positioned to read the temperature of the material as it exits the dryer while the STACK TEMPERATURE instrument s thermocouple senses the t
16. e Logic Controller The PLC in turn is electronically linked to the burner control motors to automatically adjust the burner firing rate and maintain process temperature near setpoint The Operator can assign control of the burner to either thermocouple The alarm contact of the STACK TEMPERATURE instrument is used to shut down the burner if the preset high temperature limit is exceeded The PLC also provides a high stack and material temperature alarms which drive the burner to low fire if the alarm setpoints are exceeded CAUTION The STACK alarm setpoint is factory set at 400 204 C If the system is equipped with a fabric dust collector baghouse consult the manufacturer for recommended baghouse temperature limitations Refer to Appendix E for entering the desired alarm setpoints B RECEIVING AND INSPECTION Upon receipt check each item on the bill of lading and or invoice to determine that all equipment has been received Examine all parts to determine if there has been any damage in shipment If equipment is to be stored prior to installation provide a dry storage area IMPORTANT For optimum use of the BCS panel it is suggested that the drawings provided by Hauck be referred to for limit switch and valve installation and wiring In the event that a recommended switch or valve is not used it may be necessary to connect jumper wire s between appropriate terminals in the control panel or burner junction box Suc
17. e possible accumulation of combustible gases A MINIMUM OF FOUR COMPLETE AIR CHANGES MUST BE SUPPLIED Multiply the total system volume dryer baghouse and exhaust ducts in cubic feet by four Divide this value by the burner air capacity in cubic feet per minute The result will be the required purge time in minutes 14 15 16 17 18 Be sure that all equipment and components have been installed in accordance with the manufacturer s instructions Verify all wiring and tighten connections Clean all traps and filters Check all fuel and air supply lines for leaks Verify all pressure settings Page 5 BCS6000B 9 E ADJUSTMENTS and FINAL CHECKOUT Record all settings on the CONFIGURATION RECORD SHEET provided in Appendix B IMPORTANT The burner control motors incorporate a position feedback slidewire A 5 Vdc supply voltage from the panel is connected to the slidewires in order to generate 0 to 5 Vdc position feedback signals for the PLC The following control motor calibration procedure must be performed before operating the burner for the first time RECALIBRATE ANNUALLY OR WHENEVER A CONTROL MOTOR IS SERVICED OR REPLACED The EZ S8C F touchscreen provides access to the system operating parameters Note that touching any of the numeric displays with white text on a blue background will provide a pop up keypad for numeric entry The use of a pencil eraser wooden or plastic stylus is recommended for more pr
18. e setpoints of both If all system limits are closed PRESS RESET TO START PURGE will appear in the message box Page 10 BCS6000B 9 Momentarily press the RESET button to initiate the system purge sequence a An OPENING AIR VALVE message will appear as the burner air control motor drives open b After the air control motor has opened more than 50 purge timer 1TR will be energized and begin timing and a PURGING Message will appear After the purge delay has been completed 1TR timer will actuate and a LOW FIRE DRIVE message will appear as the air control motor drives closed to prepare for pilot ignition When all motors have reached their low fire start position and the burner low fire limit switches have closed the START pushbutton will flash and a READY TO START message will be displayed Momentarily press the START pushbutton to begin the burner ignition sequence a The RM7890A flame relay will be energized and a ten second pilot trial for ignition time will begin b The ignition transformer and pilot solenoid valves will be energized and an IGNITING PILOT message will appear If a satisfactory pilot flame is detected by the UV scanner a The START pushbutton will stop flashing and remain on and a PILOT ON message will be displayed b Flame signal strength 0 5Vdc will be displayed on the flame meter Minimum acceptable signal is 0 5Vdc c Power will be supplied to the main fuel valves Th
19. ecise selection In order to extend the life of the display it has been programmed to enter a screen saver mode 5 minutes after the burner is stopped Simply touch the display to de activate the screen saver MOTOR CALIBRATION amp SETUP Screen Press the MAIN MENU key to access the menu screen then press the MOTOR CALIBRATION amp SETUP button to display the calibration screen MOTOR CALIBRATION gt The control motor DEADBAND settings determine the allowable deviation of actual control motor position from setpoint without corrective action by the motor control outputs minimum 0 596 maximum 5 095 typically set at 1 096 for fuel and 1 5 for air These parameters should be set as low as possible without causing the control motors to hunt excessively Touch the numeric displays and use the popup keypad to enter a deadband setting for each motor Press the ZERO button to drive all control motors closed for calibration and record the slidewire feedback signals Confirm that all motors have reached their low fire positions before beginning span calibration Press the SPAN button to drive the motors open and record the resulting feedback signals Verify that all motors have fully opened before pressing the OFF button to store the span values and end motor calibration BURNER OPERATING PARAMETERS Setthe BURNER OUTPUT LIMIT at 100 0926 for normal operation This value may need to be lowered to accommodate system limitations
20. emperature of the exhaust gases The alarm contact of the STACK TEMPERATURE instrument is used to shut down the burner if the preset high temperature limit is exceeded Figure 1 shows the front face of the UDC100L instrument Honeywell 325 OUT EXCEED ALM e Figure 1 Upper Display Normally displays process temperature Also displays parameter values or selections when in the set up mode Lower Display Shows value of set point Also displays function groups and parameters when in the set up mode OUT Illuminated when the alarm contact is de energized after the alarm setpoint has been exceeded EXCEED Illuminated when process temperature is greater than the alarm setpoint ALM Flashes when an abnormal condition such as a broken thermocouple exists RESET Used to reset the alarm contact and extinguish the OUT indicator after the setpoint has been exceeded Used to decrease the setpoint or configuration values Used to increase the setpoint or configuration values SET UP Used in conjunction with the key to enter the set up and configuration modes Also used to advance through the parameters CONFIGURATION The instruments are factory set for a type J thermocouple with a range of 32 to 842 degrees Fahrenheit Use the following procedure to change thermocouple type or temperature units if required Detailed information is given in the vendor literature supplied with the control panel Immediately
21. equired Make small adjustments and allow readings to settle after each change Increase the burner firing rate to approximately 20 and repeat the above adjustment procedure Continue for the 3096 4096 5096 75 and 10096 points or extrapolate settings by plotting them on the chart in Figure 2 Record the resulting settings in the table provide in Appendix B Press the MAIN button to exit and return to normal display Motor Position 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 Heat Demand Figure 2 Blank chart for plotting bias settings G PANEL OPERATION 1 Open all manual shutoff valves to supply air and fuel to the pilot and burner systems 2 Move the panel POWER switch to ON and verify that the FUEL SELECTOR switch is in the desired position a b C d The temperature instruments touchscreen display flame relay and PLC will perform their self test procedures The burner control motors will drive to their low fire position The RESET indicator will come on A BURNER STOPPED message will be displayed 3 Start the exhaust fan combustion air blower and all other equipment required for plant operation After the exhaust fan limits have closed the HELD CLOSED indicator of the draft control will disappear and the exhaust damper will be released to control dryer draft 4 Select MATERIAL or STACK control and verify th
22. gt If the optional gas flow display and totalizer is installed set the GAS PRESSURE to match the pressure in ounces measured just upstream of the gas orifice flange assembly TEMPERATURE DISPLAY gt Ifthe Material and Stack temperatures displayed on the touchscreen are significantly different from the UDC1000 instrument displays a positive or negative BIAS value may be entered for each instrument Page 6 BCS6000B 9 CONTROL LOOP TUNING Screen After setting and recording all parameters on the motor calibration amp setup screen press MAIN MENU key to return to the menu screen then select the CONTROL LOOP TUNING button to display the loop tuning screen This screen is used to enter tuning constants for each of the three PID control loops MATERIAL or STACK temperature control may be selected on this screen Manual control of the burner firing rate and exhaust damper control motors is also provided gt Enter a GAIN setting for each loop Note that Gain 100 Proportional Band or Proportional Band 100 Gain For example a Gain of 5 is equivalent to a Proportional Band setting of 2096 Enter a DEADBAND setting degrees F for temperature and inches of water column for draft for each loop This value should be as small as possible without excessive hunting by the control actuators Enter a RESET setting for the Material and Stack control loops Note that Reset is expressed in minutes per repeat rather than repeats per minute
23. h determination remains the responsibility of the Customer based upon his application accepted safe installation and operating procedures and any applicable insurance guidelines or governmental regulations Page 3 BCS6000B 9 C DRAWINGS AND SUPPLEMENTAL DATA BURNER SYSTEM StarJet Eco Star Eco Starll Tabletop Panel Assy CY7320 CY7320 CY7320 Drop in Panel Assy CY7321 CY7321 CY7321 Wiring Diagram CY7316 CY7316 CY7316 System Schematic CY7345 CY7345 CY7315 External Component Wiring CY7319 CY7317 CY7318 D INSTALLATION 1 Locate the tabletop panel on a firm support in an area that is protected from the weather and free from vibration The drop in version is designed to install in an existing enclosure Reference drawing CY7321 for required cutouts and mounting dimensions IMPORTANT Operating specifications of 32 to 131 F 0 to 55 C 30 to 95 relative humidity non condensing should be considered in selecting a suitable location for the control panel Provide 120Vac single phase grounded neutral power to the burner control panel It is recommended that the Customer provide a master disconnect switch to interrupt power service to the panel Maintain polarity as indicated on the drawings provided when connecting the main power source to the panel Install a heavy gauge No 12 AWG minimum ground wire between the panel ground connector
24. hermocouple is in a relatively slow moving area next to the dam The dam must only be wide enough and high enough to create a localized area of build up where the material loses velocity BUT DOES NOT STOP FLOWING The thermocouple must not be located in a stagnant zone or erroneous temperature readings will result Because of the large number of variables involved it is impossible to set down any exact size or location of the dam that will always work Field experimentation will be necessary if good results are to be obtained It is advisable to tack weld the dam in place so that it can be easily modified if it fails to perform satisfactorily Page 28 BCS6000B 9 NOTE During normal operation the thermocouple should be rotated once a month to expose a different area of its surface to the abrasive forces of the material This procedure will increase the effective life of the thermocouple If excessive wear occurs a protective tube may be added to shield the shaft in the region of the high velocity flow NOTE Thermocouple cables must be separated from AC power and control wiring to avoid interference and nuisance shutdowns Observe polarity when making thermocouple connections Regardless of TC type the red wire is always negative Page 29 BCS6000B 9 APPENDIX I DRAFT TRANSMITTER ADJUSTMENTS The NEXT and ENTER buttons located below the Lcd display may be used to adjust or reconfigure the draft transmitter if required Wait 1 or 2 second
25. ns Press the SETUP key to step through the other setup parameters and confirm the following values Fahrenheit Centigrade Type J Type K Type J Type K Lower Upper Upper Upper Upper Display Display Display Display Display Filt 2 0 2 0 2 0 2 0 HySt 1 1 1 1 rOPH 842 1399 450 760 rOPL 32 32 0 0 diSP 1 1 1 1 h A1 841 1399 450 760 L A2 32 328 0 200 Loc 0 0 0 0 Page 25 BCS6000B 9 APPENDIX F EXHAUST FAN FLOW LIMIT SWITCH INSTALLATION Mount the exhaust fan flow switch in the dryer exhaust duct as shown below DOWNSTREAM N 4 a o s X E L1 fF HOF DOWNSTREAM Ro Ve ZU ES E STACK CY6909 Drawing showing the installation of the exhaust fan flow switch Wire the exhaust flow switch to the appropriate terminals The exhaust flow switch is an interlock which requires the exhauster to be operating prior to ignition of the burner Page 26 BCS6000B 9 APPENDIX G STACK THERMOCOUPLE INSTALLATION Install a Hauck stack temperature thermocouple in the dryer exhaust duct to sense exhaust gas temperatures Exhaust Duct Located Before Dry Dust Collector amp Exhaust Fan When two thermocouples are used with baghouse installation locate before and after baghouse Aen 1 3 8 Dia 1 2 Conduit Connection 1 Pipe Coupling Dryer
26. o display the run menu screen This screen provides control mode selection startup ramp settings for automatic temperature control low fire drive alarm settings and draft control setpoints v Page 7 BCS6000B 9 DRAFT CONTROL Enter a draft control PURGE SETPOINT for use during the burner purge sequence Set this value higher than the normal draft setpoint to prevent dusting as the air damper drives open for purge Enter LOW FIRE and HIGH FIRE SETPOINTS for draft control The draft setpoint will automatically ramp from the low fire to the high fire setpoint as the burner firing rate increases Enter a TRANSFER DELAY time in seconds to set the length of time after burner ignition is initiated that the purge setpoint remains active for draft control before transferring to the normal operating setpoint To accommodate variations in material moisture or composition and prevent nuisance shutdowns provisions are made for automatic draft setpoint increase The PLC senses puffs in the dryer drum and automatically increases dryer draft if a set number of puffs occurs within a ten second time window Set the desired increase via the INCREASE DRAFT BY WC display and enter values in the IF DRAFT DROPS BELOW WC and MORE THAN TIMES fields For example with settings of 0 02 WC 0 10 WC and 2 Times the dryer draft setpoint would be increased by 0 02 WOC if dryer draft dropped below 0 10 WC more than 2 times within a 10 second interval d
27. ors below the MATERIAL and STACK temperature readouts indicates which thermocouple is being used for control FIRING FIRING Ph 4 MIN MIN CONTRAST ENGLISH SPANISH ON 1 OFF ALARM HISTORY HELP SCREENS CONFIGURATION RAM 59166X838 R82 SCREEN PROGRAM 59999 802 R82 xS FIRING amp TREND SCREENS BIAS POINTS HAUCK MFG CO Box 98 Lebanon PA 17642 OIL or LP 717 272 3051 FIRING Bras CONTROL LOOP BCS 6888 x2 roms mee 10 21 36 BURNER STOPPED E aS MAIN MENU SCREEN Used to access other screens Also provides language selection display contrast adjustment accumulated and resettable daily firing times If the system is equipped with the fuel flow option totalized fuel usage is also displayed Record the PLC and screen program numbers that appear on this screen as they will be required if service is requested Page 16 BCS6000B 9 MOTOR CALIBRATION amp SETUP Reference Section E Used to ZERO and SPAN the burner control motors and to enter motor deadband settings Provides numeric inputs for burner firing rate limits gas pressure correction and temperature bias settings EJ E BURNER STOPPED CONTROL LOOP TUNING Reference Section E Used to set PID control loop tuning constants for the Material and Stack temperature control and Dryer Draft control Also provides temperature setpoint
28. osition 84 Spare 88 1 5Vdc from optional baghouse outlet temperature transmitter 99 24Vdc supply 81 Analog reference 8 Point AC input module Hauck part number 58481 Automation Direct model number D2 08NA 1 Function 28 RESET pushbutton 23 ALARM SILENCE pushbutton 38 START pushbutton 60 OIL selected from fuel selector switch 36 STOP pushbutton Normally closed 56 Flame on from flame relay 58 Reset required from flame relay 48 Spare L2 AC Neutral 8 Point AC input module Hauck part number 58481 Automation Direct model number D2 08NA 1 Function 13 Exhaust fan limits 16 Secondary air interlock 18 Low oil temperature 26 Stack temperature limit 54 Purge complete from 1TR timer 21 Low fire limit switches 43 Main fuel valve open 24 Purge air and main fuel valve closed limits L2 AC Neutral SLOT 3 Input Wire X40 X41 X42 X43 X44 X45 X46 X47 COM SLOT 4 Output Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17 SLOT 6 Input Wire 1 3 4 5 6 7 8 24V OV Page 22 BCS6000B 9 8 Point AC input module Hauck part number 58481 Automation Direct model number D2 08NA 1 Function 17 High gas pressure limit 14 Secondary air motor starter interlock 15 Primary air motor starter interlock 15A Primary air pressure switch 16A Low gas pressure 17A Low oil pressure 75 Opt switch 76 Spare L2 AC Neutral 8 Point relay output module Hauck part number 58479 Automation Direct model number D2 08TR Wir
29. otors drive to their ZERO and SPAN positions and that the feedback signals change smoothly as the motors drive If not check fuse 99 and verify that 5Vdc exists between terminals 82 and 81 Also check fuses 5 and 45 on the printed circuit board Page 14 BCS6000B 9 ALARM HISTORY Screen An alarm history screen is also provided for use as a troubleshooting guide From the MAIN MENU screen press ALARM HISTORY to view list of the last 99 logged events and the order in which they occurred Page up or down if necessary to view the entire list Use the LINE UP or LINE DOWN button to select a particular item then press DETAILS to view the time and date information Note that FLAME ON and BURNER STOPPED are included in the alarm list for monitoring purposes even though they are not alarm conditions The ALARM COUNT screen shows how many times each alarm has occurred Page 15 BCS6000B 9 APPENDIX A OPERATOR INTERFACE SCREENS gs 77 _ DRAFT SETPOINT DRAFT CONTROL MAIN SCREEN This screen displays overall system status and is the default screen on system power up It provides AUTO MANUAL control selection and setpoint SP inputs for the temperature control loops Note that the message box in the lower left corner of the screen appears on all screens to provide the operator with system status messages The MAIN MENU and RUN MENU buttons provide quick access to other screens Indicat
30. ree seconds after the pilot flame has been recognized a The ignition transformer will be de energized b A MAIN FUEL VALVES ENERGIZED message will appear As soon as the main fuel valve has opened and the valve open limit switch has closed a Pilot timer 2T will be energized and the 10 second main flame trial for ignition time will begin b A MAIN FLAME TRIAL FOR IGNITION message will be displayed After the trial for ignition timer has completed its delay a The pilot solenoid valves will be de energized and the pilot will go out b The burner control motors will be released from low fire c A MAIN FLAME ON message will be displayed Start material flow to the dryer If the temperature control loop is in AUTO the burner will drive to the START AT percentage then begin ramping at the RAMP AT rate set on the RUN MENU screen If MANUAL temperature control has been selected use the INC and DEC buttons to manually control the burner firing rate or press the OUTPUT display and enter the desired output value via the popup keypad Page 11 BCS6000B 9 15 Note that the burner may be forced to low fire at any time by pressing the DRIVE TO LOW FIRE button a The button will be highlighted and LOW FIRE SELECTED will appear in the message box b Press the button a second time to release the burner from low fire 16 To terminate burner operation press the STOP pushbutton a The Honeywell RM7890A flame rela
31. ress ENTER to change the lower display to CAL ATO Press NEXT until the lower display reads ADJ 4MA Press ENTER and the lower display will read A 4MA A If the DPS display reads less than 0 00 increase the 4 mA calibrations as follows o Press NEXT to change the lower display to A 4MA o Each press of the ENTER button will slightly increase the transmitter output and the DPS display should increase until it reads 0 00 If the DPS display reads greater than 0 00 decrease the 4 mA calibrations as follows o Press NEXT to change the lower display to A 4MA x o Each press of the ENTER button will now slightly decrease the transmitter output and the DPS display should decrease until it reads 0 00 Press NEXT to step through the remaining calibration options until the lower display reads SAVE Press ENTER to save the new zero calibration and exit the calibration mode Note that calibration changes can be discarded by pressing ENTER when the lower display reads CANCEL instead of SAVE CONFIGURATION PARAMETERS The transmitter has been factory configured and should not require any field modifications The following parameter settings are provided for reference only PARAMETER LOWER DISPLAY UPPER DISPLAY External Zero Not applicable EX ZERO EXZ DIS Output Direction OUT DIR FORWARD Output Mode OUTMODE LINEAR Output Failsafe OUTFAIL FAIL LO Signal Dampening DAMPING NO DAMP Display Engineering Units DISP EG
32. s between each button press to allow the display to update ZEROING Allow the unit to warm up for at least 5 minutes before adjusting the transmitter zero Reference the drawing below and use the shutoff cocks in the transmitter manifold to isolate the transmitter from the dryer and to open the LOW pressure tap to atmosphere PRESSURE SENSING CONNECTOR V 1 COUPLING PRESSURE SENSING LINE 1 4 OD STAINLESS STEEL TUBING CLOSE TO ZERO TRANSMITTER FFERENTIAL mese se TRANSMITTER SIGNAL CABLE W7450 Transmitter and Manifold Layout If the transmitter display does not read 0 00 IN H2O use the following procedure to zero the transmitter Press the NEXT button one time to change the lower display to CALIB Press ENTER to change the lower display to CAL ATO Press ENTER and the lower display will read ATO DONE Press NEXT to step through the remaining calibration options until the lower display reads SAVE Press ENTER to save the new zero calibration and exit the calibration mode Note that calibration changes can be discarded by pressing ENTER when the lower display reads CANCEL instead of SAVE Page 30 BCS6000B 9 4 MA ADJUSTMENT Verify that when the transmitter reads 0 00 the BCS 6000 touchscreen display also reads 0 00 If necessary adjust the transmitter 4 mA value using the following procedure Press the NEXT button one time to change the lower display to CALIB P
33. slot 2 input 5 Verify that all low fire limit switches are closed CHECK LOW FIRE LIMITS 120Vac on terminal 21 when the control motors are in the low fire start position MAIN FUEL VALVE FAULT Monitor slot 2 input 6 The valve open switch in the main fuel valve must close within 20 seconds after the pilot flame has been recognized HIGH STACK TEMPERATURE LOW FIRE HOLD Check the low fire alarm setting on the RUN MENU screen The burner will be held at low fire until stack temperature falls below the alarm setpoint HIGH MATL TEMPERATURE LOW FIRE HOLD Same as above for the low fire drive material temperature alarm The burner will be held at low fire until material temperature falls below the alarm setting FLAME FAILURE Indicates that the flame relay has locked out due to a flame failure Check burner setup FLAME RELAY RESET REQUIRED Monitor slot 1 input 6 and the ALARM indicator of the Honeywell flame relay This fault normally indicates that the pilot has failed to ignite within the trial for ignition period Verify that air fuel and spark are being supplied to the pilot Other possibilities include 1 Premature flame signal If the flame meter indicates presence of a flame before the ignition sequence is started the flame relay will lockout and the RESET indicator will come on Check for fire in the dryer drum or for a failed UV scanner 2 Bad or missing ground The Honeywell RM7890 requires
34. tronic Valve Characterization EVC This feature provides for creation of a separate motor response curve for the air control motor Regardless of fuel selection the fuel control motor directly follows the heat demand output of the temperature controller For example 1596 output from the temperature controller will result in the fuel control motor driving 1596 open Meanwhile the air control motor will follow a separate curve established by setting seven characterization bias points see Figure 1 100 Pd 90 2 80 70 t e 40 e 30 e 20 10 0 Motor Position 0 10 20 30 40 50 60 70 80 90 100 Heat Demand Figure 1 Example of Air bias settings BIAS POINT ADJUSTMENT Before firing the burner place the FUEL SELECTOR switch in the OIL position and then press the MAIN MENU button followed by the OIL or LP FIRING BIAS POINTS button Match all seven air bias points to the fuel settings Press MAIN MENU again to return to the menu screen then change the fuel selection to GAS Now select the GAS FIRING BIAS POINTS button and again verify that all seven air bias points are set to match the fuel points Page 9 BCS6000B 9 Setup an analyzer to monitor stack or drum emissions With the burner firing in manual at approximately 1096 output select the bias point setting screen Allow the analyzer readings to stabilize then increase or decrease the air input if r
35. ue to puffing Note that the draft control setpoint returns to its original setting when the burner is shut off TEMPERATURE CONTROL Select MATERIAL or STACK temperature control Set a START AT and RAMP AT percentage for startup If automatic temperature control is selected the burner will drive to the START AT 96 setting as soon as the main flame has been established The control output will then begin to RAMP AT 96 per minute until the output of the selected temperature control loop is equal to or less than the ramp output The control loop will then assume control of the burner firing rate The burner will be forced to low fire if the stack temperature exceeds the LOW FIRE DRIVE IF STACK GREATER THAN F setting Likewise the burner will be forced to low fire if material temperature exceeds the LOW FIRE DRIVE IF MATERIAL GREATER THAN F setting LINKAGE SETUP After motor calibration is completed and system setup parameters have been set press the LINKAGE SETUP button to enter the linkage setup mode The fuel and air control motors will be released from low fire and respond to the output of the temperature control loop Return to the MAIN screen and place the temperature control loop in MANUAL Drive the motors as required to adjust fuel and air control valve linkages Confirm all linkage adjustments and insure that control arms and linkage rods are tight then return to the RUN MENU screen and select either
36. y and all fuel valves will be de energized b The air and fuel control motors will drive closed C A BURNER STOPPED message will be displayed and the RESET indicator will come on H TROUBLESHOOTING Page 12 BCS6000B 9 Use the HELP screens on the touch screen or refer to the following table MESSAGE DIAGNOSTICS CONTROL MOTOR CALIBRATION REQUIRED The difference between the Zero and Span feedback values of each motor must be greater than 3300 Verify that the motors travel full stroke during the motor calibration procedure FUEL CONTROL MOTOR FAULT Indicates that the fuel control motor has failed to respond to the motor positioning output signals of the PLC Check fuse 5 on the printed circuit board Also monitor slot 4 outputs 4 and 5 and relays R6 and 7 Same as above for the air control motor Check fuse 45 on the AIR CONTROL MOTOR FAULT printed circuit board Monitor slot 4 outputs 6 and 7 and relays R8 and R9 The control algorithm does not normally allow the fuel motor EXCESS FUEL FAULT position to be greater than the theoretical air position A fuel motor malfunction may cause this condition to occur CHECK PURGE AIR LIMITS amp MAIN FUEL VALVE PROOF OF CLOSURE Monitor slot 2 input 7 terminals 24 thru 24E This message appears if the purge air pressure limit exhaust damper open limit or any of SWITCHES the fuel valve proof of closure switches fails to close Monitor
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