INSTRUCTIONS - Hauck Manufacturing
Contents
1. eeeeeee es 24 Appendix F Exhaust Fan Flow Limit Installation ceeeeeeee 26 Appendix G Stack Thermocouple Installation c eceeeeeeeeee es 27 Appendix H Material Thermocouple Installation eeeeeeees 28 Appendix Draft Transmitter Adjustments eeeeeeeeeeeeeeeeees 31 Appendix J Flame Supervision and Safety Component Check List 33 Attachments Applicable Thermix Drawings These instructions are intended to serve as guidelines covering the installation operation and maintenance of Thermix 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 Thermix Inc or Hauck Mfg Co THERMIX INC 7400 St Francois Ph 514 695 0681 Fax 514 695 1513 BCS 6000C 9 2 04 Project R3930 Page 2 BCS6000C CSA 9 A GENERAL INFORMATION The Thermix Hauck Burner Control System BCS provides burner management and temperature control of a single pilot ignited burner firing on natural gas oil or liquid propane2. LP The spark ignited gas fired pilot is interrupted after the main burner flame has been established Flame supervision is provided by a Honeywell RM7800 series flame relay combined with an amplifier module and one or two ultra violet UV flame detectors 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 UDC120L series instruments are provided for temperature indication and over temperature protection The thermocouple of the MATERIAL TEMPERATURE 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 UDC120L instruments display the process temperature and provide temperature inputs to the PLC which 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 high stack and material temperature alarms which drive the burner to low fire if their alarm setpo
3. Dryer Discharge Chute IMPORTANT A small clearance of 1 25mm 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 thermocouple 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 reading 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 Project R3930 Page 30 BCS6000C CSA 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 mat
4. PURGE SETPOINT 0 50 WC LOW FIRE SETPOINT 0 25 WC HIGH FIRE SETPOINT 0 35 WC SETPOINT TRANSFER DELAY 1 0 SEC REDUCE DRAFTBY 0 WC IF DRAFT DROPS BELOW 0 WC MORE THAN 10 TIMES BIAS POINTS Firing Light Low 1 2 3 4 5 6 7 8 9 10 Mode Off Fire 10 20 30 40 50 60 70 80 9 100 Gas 5 0 5 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 100 0 Oil or LP 3 0 0 5 0 10 0 15 0 25 0 35 0 45 0 55 0 65 0 77 0 100 0 Project R3930 Page 21 BCS6000C CSA 9 APPENDIX C RECOMMENDED SPARE PARTS e 1 THSCR Ag Omron Timer e 1 beror Kromschroder Airflow switch o 1 DCt20L1 7001000 Honeywell High Limit amp Temperature controler PO ee reo e a Project R3930 Page 22 BCS6000C CSA 9 APPENDIX D DL250 PROGRAMMABLE CONTROLLER BASE 9 Slot Base w 8 I O Modules Part No D2 09B CPU Central Processing Unit Part No D2 250 BATTERY CPU 3V Battery Part No D2 BAT SLOT 0 8 Point Analog Voltage Input Module Part No F2 08AD 2 Input Wire Function 1 92 0 5Vdc Material temperature from UDC120L instrument 93 0 5Vdc Stack temperature from UDC120L instrument 3 94 1 5Vdc from dryer draft transmitter 4 91 0 5Vdc flame signal from the flame relay 5 83 0 5Vdc Gas control motor position 6 85 0 5Vdc Air control motor position 7 84 0 5Vdc Oil LP control motor positio
5. THERMILX Combustion Systems sre INSTRUCTIONS BCS 6000C CSA BURNER CONTROL SYSTEM Thermix Project No Lee These instructions are intended for use only by experienced qualified combustion start up personnel Adjustment of this equipment and its components by unqualified personnel can result in fire explosion severe personal injury or even death Table of Contents Subject Page A General Information ccesccicsvcccaseenterecescseeiederseseyecuvetiearsesipeciaseusehddecs 2 B Receiving and Inspection ssessssssesrerrsrrsrrrrsrrsrrrerrrrrrrerrrrrrre 3 C Drawings and Supplemental Literature ssneeneseeneseenrr esner eee eee 3 D Installation ene coca 8b Gai ctes bunt autos atnaieeecesoreileeeatbancideet 3 E Adjustments and Final Checkout cceeeeeeeeeeeeeeeeeeeeeeeeeeenees 5 F Electronic Valve Characterization ccccceeeeeeeeeeeeeeeeeeeeeaeaeaees 9 G Operatore ti r EEEE AE DE a ERORE 10 H MPO MINE SO CTING soto ete n desiunAaecee catncesexsbeay devi veaed ldo ee veaGsvemeciceadeet age 13 Appendix A Operator Interface SCreens cceceeeee ee ee eeeeeee eee ees 16 Appendix B Configuration Record cceceeeeeeeeeeeeeeeeeeeeeaeaees 20 Appendix C Recommended Spare Parts e eeeeeeeee tenes ee ee eee 21 Appendix D DL250 Programmable Controller c eeeeeeeeeee eee 22 Appendix E UDC 120L Temperature Instrument
6. a LOW OIL or LP PRESSURE message will appear HIGH OIL or LP PRESSURE Oil or LP fired systems only gt Remove the cover of the oil or LP pressure switch Make note of the high pressure switch setting then lower the setting so that it is less than the normal operating pressure gt Start the oil or LP supply pump and attempt to start the burner gt The high pressure switch should trip the alarm will sound and a HIGH OIL or LP PRESSURE message will appear gt Return the pressure switch to its original setting and replace the switch cover Project R3930 Page 35 BCS6000C CSA 9 LOW and HIGH OIL TEMPERATURE Heavy Oil fired systems only gt Shut off the exhaust fan and combustion air burner blower gt Set the multi meter to read continuity and verify that continuity exist between control panel terminals 17D and 18 gt Make note of the low oil temperature switch setpoint then raise the setting above the current oil temperature and verify that continuity is lost between terminals 17D and 18 gt Return the switch to its original setting and verify that continuity is re established gt Make note of the high oil temperature switch setpoint then lower the setting below the current oil temperature and verify that continuity is lost between terminals 17D and 18 gt Return the switch to its original setting and verify that continuity is re established HIGH STACK TEMPERATURE LIMIT gt With all limits c
7. bias points as shown in Figure 1 100 80 70 at pe S 60 50 a Ss gs 40 x 30 20 10 0 1 10 20 30 40 50 60 70 80 90 100 Figure 1 Example of EVC Fuel Bias Settings Project R3930 Page 10 BCS6000C CSA 9 BIAS POINT ADJUSTMENT Bias adjusting screens are accessed via the MAIN MENU Before firing the burner verify the OIL FIRING BIAS POINTS and GAS FIRING BIAS POINTS are set to the default values listed below Point Oil LP Gas Light off 3 0 0 0 Low Fire 0 0 10 0 10 5 0 15 0 20 10 0 20 0 30 15 0 30 0 40 25 0 40 0 50 35 0 50 0 60 45 0 60 0 70 55 0 70 0 80 65 0 80 0 90 77 5 90 0 100 100 100 Setup an analyzer to monitor stack or drum emissions With the burner firing in manual at approximately 10 output select the bias point setting screen Allow the analyzer readings to stabilize then increase or decrease the fuel input if required 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 30 40 50 etc or extrapolate settings by plotting them on the chart shown in Figure 2 Record the resulting settings in the Table provided in Appendix B Press the MAIN button to exit and return to normal display 100 Motor Position 10 20 30 40 50 60 70 30 90 Heat Demand Figure 2 Blank Chart for Plott
8. gt 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 gt 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 gt Set the BURNER OUTPUT LIMIT at 100 0 for normal operation This value may need to be lowered to accommodate system limitations gt Enter a LOW FIRE AIR percentage if applicable The burner will lightoff with the air motor at zero and then drive open to the low fire setting to minimize blower surge gt The LIGHTOFF TIME setting determines how long the air and fuel valves will remain in their lightoff positions before returning to their low fire settings Timing begins as soon as the main fuel valve has opened gt If the optional gas flow display and totalizer are installed set the GAS PRESSURE to match the pressure in osig 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 UDC120L instrument displays a positive or negative BIAS value may be entered for each instrument CONTROL LOOP TUNING Screen After setting and recording all par
9. will appear c The fuel control motors will drive to their light off positions 8 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 9 When the air and fuel motors have reached their light off positions and all burner low fire limit switches have closed the START pushbutton will flash and a READY TO START message will be displayed 10 Momentarily press the START pushbutton to begin the burner ignition sequence a The flame relay will be energized and a 10 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 11 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 12 Three seconds after the pilot flame has been detected a The ignition transformer will be de energized Project R3930 Page 12 13 BCS6000C CSA 9 b A MAIN FUEL VALVES ENERGIZED message will appear As soon as the main fuel valve and valve open input have been powered a Pilot timer 2T will be energized and the ten second main flame tri
10. 0 H TROUBLESHOOTING Page 13 BCS6000C CSA 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 GAS CONTROL MOTOR FAULT Indicates that the gas 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 R7 AIR CONTROL MOTOR FAULT Indicates that the air control motor has failed to respond to the motor positioning output signals of the PLC Check fuse 45 on the printed circuit board Monitor slot 4 outputs 6 and 7 and relays R8 and R9 OIL CONTROL MOTOR FAULT Indicates that the oil or LP control motor has failed to respond to the motor positioning output signals of the PLC Check fuse 47 on the printed circuit board Monitor slot 5 outputs 6 and 7 and relays R11 and R12 EXCESS FUEL FAULT The control algorithm does not normally allow the theoretical fuel motor position to be greater than the 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 ai
11. 68 Gas motor decrease relay R7 69 Air motor increase relay R8 70 Air motor decrease relay R9 8 Point Relay Output Module Part No 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 72 Oil LP motor increase relay R11 73 Oil LP motor decrease relay R12 8 Point Relay Output Module Part No D2 08TR Wire Function 200 Limits Set PB 201 Spare 202 Spare 203 Spare 204 Spare 205 Spare 206 Spare 207 Spare 8 Point Analog Input Module Part No F2 08AD 1 Wire Function 96 Spare 97 Spare 95 Spare 98 Spare 101 Spare 102 Spare 103 Spare 104 Spare Project R3930 Page 24 BCS6000C CSA 9 APPENDIX E UDC120L SERIES LIMIT INSTRUMENTS Two Honeywell UDC120L series instruments Part No 300003 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 temperature 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 MAN AT ALM key AS awe UDC 120L Instrument Front Face Display Upper Display Normally dis
12. A 9 GAS VALVE LEAK TESTING Refer to gas piping diagram for leak testing shown in Figure 1 SAFETY SHUTOFF VALVE NO 2 SAFETY SHUTOFF EQUIPMENT VALVE NO 1 BOCA X en ore ri MANUAL SHUTORT f S85 t N VALVE me em rs C C eke Fi L J n L Ka a a pe Di x X K 1 LEAK TEST LEAK TEST W7610 VALVE NO 1 VALVE NO 2 NOT TO SCALE Figure 1 Gas Piping Diagram for Leak Testing Close the manual shutoff valve downstream of Safety Shutoff Valve No 2 Open the equipment isolation valve upstream of Safety Shutoff Valve No 1 Bleed off trapped gas by opening both Leak Test Valves No 1 and No 2 Close Leak Test Valve No 2 Connect 3 16 4 8mm ID tubing to Leak Test Valve No 1 and immerse the open end of the tubing in a container of water Hold the tubing vertically 1 8 to 1 4 3 to 6 mm below the surface If bubbles appear record the leakage rate in bubbles min and refer to the IMPORTANT note at the end of this section Close Leak Test Valve No 1 and apply auxiliary power to open Safety Shutoff Valve No 1 VV VV WV Vv gt Wait several minutes so that any leakage through Safety Shutoff Valve No 2 will have time to fill the pipe between Safety Shutoff Valve No 2 and the manual shutoff valve gt Connect the tubing to Leak Test Valve No 2 and immerse the open end in water as before Open Test Valve No 2 If bubbles appear record the leakage rate in bubbles min and refer to the IMPORTANT note a
13. BAND E BaBa RESET 98 88 RESET OPEN minzr minsr CYCLE 88 88 RATE sec 6 88 RATE sec B CLOSE E PU PU CYCLE OUTPUT i r Ti FILTER i E mam Bl MAIN FLAME ON 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 inputs AUTO MANUAL selection and AUTO TUNE selection Project R3930 Page 18 BCS6000C CSA 9 TEMPERATURE CONTROL PURGE START AT 8 8 Zz SETPOINT rane atl sa Py LOW FIRE SETPOINT HIGH FIRE SETPOINT LOW FIRE DRIVE IF STACK 58 c TRANSFER GREATER THAN DELAY LOW FIRE DRIVE IF MATERIAL 50 c GREATER THAN INCREASE DRAFT BY IF DRAFT DROPS BELOW MORE THAN BURNER STOPPED 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 GAS FIRING BIAS POINT SETTINGS 16 26 30 46 58 60 76 88 96 168 SS I 3 0 6 0 3 0 Ee gt 3a 0 1 2 3 4 5 6 8 9 18 REFERENCE GAS DP WC GAS FLOW SCFH CO ppm 02 NOX at 37 BIAS POINT SETTINGS Reference Section F Two separate screens GAS and OIL LP are provided to setup the electronic valve characterization for
14. 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 Project R3930 Page 9 BCS6000C CSA 9 F ELECTRONIC VALVE CHARACTERIZATION A 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 positions and overall valve strokes must be set by adjustment of the valve motor linkages To facilitate burner setup and optimize emissions of the EcoStar IIB burner the BCS6000 system has been equipped with Electronic Valve Characterization EVC This feature provides for creation of separate motor response curves for the air and fuel control motors Regardless of fuel selection the air control motor directly follows the heat demand output of the temperature controller For example 15 output from the temperature controller will result in the air control motor driving 15 open Meanwhile the fuel control motor will follow a separate curve established by setting ten characterization
15. NTER button will slightly increase the transmitter output and the DPS display should increase until it reads 0 00 e Ifthe DPS display reads greater than 0 00 decrease the 4 mA calibrations as follows o Press NEXT to change the lower display to A4MA i 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 e Press NEXT to step through the remaining calibration options until the lower display reads SAVE e 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 EGU USE EGU Select Engineering Units EGU SEL INH20 Lower Range Value EGU LRV 00 00 Upper Range Value EGU URV 1 00 3 00 or 5 00 Project R3930 Page 33 BCS6000C CSA 9 APPENDIX J FLAME SUPERVISION amp SAFETY COMPONENT CHECK LIST Equipment Multi meter capable of measuring Continuity and AC vol
16. OW 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 17A HIGH OIL or LP PRESSURE Monitor slot 3 input 2 and the high oil or LP pressure switch power on terminal 17B ATOMIZING AIR FAULT Monitor slot 3 input 3 Verify that the primary air interlock and pressure switch or compressed air pressure switches are made power on terminals 17C and 17D OIL TEMPERATURE FAULT Monitor slot 2 input 2 For heavy oil systems verify that the oil heater is operating and the oil temperature switches are 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 FLAME FAILURE Indicates that the flame relay has locked out due to a flame failure Check burner setup MAIN FUEL VALVE FAULT Monitor slot 2 input 6 This input must be received within 20 seconds after the pilot flame has been recognized Verify that jumper wires are installed on the control panel terminal strip between terminals 22 and 29 for gas and between terminals 30 and 44 for oil For some applications it may be necessary to remove these jumpers and connect the valve open limit switch in the main fuel valve instead Consult Hauck s Service Department f
17. ULATED FIRING RESETTABLE FIRING EnEn ESE Cc MAIN MENU 0 AGI ALARM HISTORY HELP SCREENS f CONFIGURATION _rrc rrocean soreexonrRoo SCREEN PROGRAM 59999X813 Raa TOA MOTOR BIAS POINTS CALIBRATION amp TREND SCREENS SETUP HAUCK MFG CO P 0 Box 98 Lebanon PA 17842 OIL OR LP 717 272 3051 FIRING BIAS CONTROL LOOP BCS 6000 hauckburner com POINTS TUNING x 16 13 23 BURNER STOPPED Ban co MAIN MENU SCREEN Used to access other screens Also provides language selection and 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 Project R3930 Page 17 BCS6000C CSA 9 MOTOR CALIBRATION BURNER OPERATING PARAMETERS JE 38 8 BURNER OUTPUT LIMIT z LOW FIRE AIR PERCENT FEEDBACK DEADBND ae E 8 2 E sec LIGHTOFF TIME GAS MOTOR Oz GAS PRESSURE OIL MOTOR TEMPERATURE DISPLAY FUEL FLOW amp ja m a 50 00 fie je EA a 58 88 o MOTOR CALIBRATION amp SETUP Reference Section E Used to ZERO and SPAN the burner control motors and to enter motor deadband settings Also provides numeric inputs for burner firing rate limits gas pressure correction and temperature bias settings DRAFT MATERIAL TEMPERATURE STACK pe 66 66 GAIN 46 66 GAIN 66 88 GAIN DEAD DEAD 8 81 DEAD BAND BAND
18. al for ignition time will begin The ightoff timer in the PLC will also begin its timed delay 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 After the lightoff timer has completed its delay a The burner control motors will be released to follow the temperature control output b 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 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 To terminate burner operation press the STOP pushbutton a The flame relay 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 Project R393
19. ameters 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 also be selected on this screen Manual control of the burner firing rate and exhaust damper control motors are 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 2 is equivalent to a Proportional Band setting of 50 Note that the range of the PID control loops in the BCS6000 is 1000 gt Enter a DEADBAND setting F for temperature and WC for draft for each loop This value should be as small as possible without excessive hunting by the control actuators gt 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 Therefore the smaller the setting the more frequently reset action will be repeated Project R3930 Page 7 BCS6000C CSA 9 gt 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 gt Enter CYCLE time settings seconds for the Draft control loop This loop provides duplex time proportional control outputs for the exhaust damper actua
20. ch equipment will be replaced or put in proper operating condition free of all charges except transportation and the correction of any defects by repair or replacement by the seller shall constitute of all obligations and liability of the seller to the buyer under this Warranty and the Contract of Sale The seller is not responsible for damage to its products through improper installation maintenance use or attempts to operate it above its rated capacity intentionally or otherwise or for unauthorized repairs Any failure to notify the seller of unsatisfactory operation or any improper or unauthorized installation maintenance use repairs or adjustments shall terminate this warranty and shall relieve seller from any future responsibility there under Seller shall not be liable for special or consequential damages in any claim action suit or proceeding arising under this Warranty or the Contract of Sale nor shall there by any liability there under for claims of labor loss of profits or good will repairs or other expenses incidental to replacement This Warranty is given in lieu of all other warranties and guarantees of any kind which except the implied Warranty of title are expressly negative whether the same be implied created by statute or otherwise Thermix Combustion Systems Inc 7400 Chemin St Francois Ville St Laurent Qu bec H9X 1T5 Canada Ph 514 695 0681 Fx 514 695 1513 www thermix com
21. d press and hold both the START and ALARM SILENCE pushbuttons for two seconds to enter the manual bypass mode The alarm horn will chirp to indicate that the manual bypass mode has been activated gt Using the readouts of the MATERIAL and STACK temperature instruments the burner firing rate may be manually adjusted by pressing the START button to increase or the ALARM SILENCE button to decrease Each chirp of the alarm horn indicates a 1 output change gt Momentarily press the STOP pushbutton to shut off the burner and exit the manual bypass mode Project R3930 Page 16 BCS6000C CSA 9 APPENDIX A OPERATOR INTERFACE SCREENS MATERIAL W STACK TEMP MM BAGHOUSE DRAFT WC aje 1G A l l wy I DRAFT SETPOINT SETPOINT SETPOINT FLAME BURNER 0 0 B a GAS f OIL eee DECREASE BURNER CONTROL LOW FIRE DRIVE DRAFT CONTROL mmesioeeeo EJES 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 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 Indicators below the MATERIAL and STACK temperature readouts indicate which thermocouple is being used for control TIME 4a 6 Ba MIN HOURS MIN ACCUM
22. er 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 WC if dryer draft dropped below 0 10 WC more than two times within a ten second interval due to puffing Note that the Draft Control setpoint returns to its original setting when the burner is shut off TEMPERATURE CONTROL gt Select MATERIAL or STACK temperature control gt Seta START AT and RAMP AT percentage for startup If automatic temperature control is selected the burner will drive to the START AT __ setting as soon as the main flame has been established The control output will then begin to RAMP AT __ per minute until the temperature is within 10 F 5 5 C of setpoint or the output of the selected control loop is less than or equal to the ramp output The ramp will then stop and the control loop will assume control of the burner firing rate gt The burner will be forced to low fire if the stack temperature exceeds the LOW FIRE DRIVE IF STACK GREATER THAN __ F setting gt 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 co
23. erial 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 thermocouple type the red wire is always negative A WARNING This equipment is potentially dangerous with the possibility of serious personal injury and property damage Thermix Inc amp Hauck Manufacturing Company recommends periodic testing of the flame supervisory and safety component equipment in adherence to Canadian Standards Association CSA National Fire Protection Association NFPA standards and insurance underwriters requirements Testing should be performed by qualified personnel familiar with the equipment and functions of the various safety limits and interlocks Project R3930 Page 31 BCS6000C CSA 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 one or two seconds between each button press to allow the display to update ZEROING Allow the unit to warm up for at least five minutes before adjusting the transmitter zero Refer to Figure 1 and use the shutoff cocks in the transmitter manifold to isolate the transm
24. ewire 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 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 precise selection In order to extend the life of the display it has been programmed to enter a screen saver mode five minutes after the burner is stopped Simply touch the display to de activate the screen saver Project R3930 Page 6 BCS6000C CSA 9 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 2 maximum 2 5 typically set at 0 5 for fuel and 0 8 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
25. fired systems only gt Start the primary air blower only gt Set the multi meter to read continuity and verify that continuity exist between the following control panel terminals o 17Band17C 17C and 17D gt Shut off the primary air blower Continuity should disappear between terminals 17B and 17C immediately but should remain between terminals 17C and 17D for several seconds as the primary air blower coasts to a stop ATOMIZING AIR PRESSURE EcoStar IIB with compressed air atomization for Oil or LP fired systems only gt Shut off the exhaust fan and combustion air blower gt Set the multi meter to read continuity and verify that continuity exist between the following control panel terminals 17B and 17C 17C and 17D Project R3930 Page 34 BCS6000C CSA 9 gt Shut off the manual valve on the compressed air supply line then carefully loosen the pipe plug downstream of the compressed air flow meter to bleed off any residual air pressure gt Verify that continuity does not exist between the following control panel terminals 17B and 17C 17C and 17D gt Re tighten the pipe plug and open the manual valve on the compressed air supply line EXHAUST FAN LIMITS FLOW SWITCH amp MOTOR STARTER INTERLOCK gt Start the exhaust fan only Set the multi meter for AC voltage and verify that 120Vac is present between the following control panel terminals 12 and L2 o 13 and L2 gt Shu
26. flow switch is an interlock which requires the exhauster to be operating prior to ignition of the burner Project R3930 Page 28 BCS6000C CSA 9 APPENDIX G STACK THERMOCOUPLE INSTALLATION Install a Hauck stack temperature thermocouple in the dryer exhaust duct to sense exhaust gas temperatures as shown in Figure 1 Exhaust Duct Located Before Dry Dust Collector amp Exhaust Fan When two thermocouples are used with baghouse installation locate before and after baghouse l pion rei 1 3 8 Dia 1 2 Conduit Connection 1 Pipe Coupling Dryer Stack Center over 1 3 8 dia hole Thermocouple Assy and weld Figure 1 Installation 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 thermocouple type the red wire is always negative Project R3930 Page 29 BCS6000C CSA 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 as shown Figure 1 Wire the thermocouple to the proper terminals in the panel r a DOOR BRASS ADI BUSHIN So PIPE a SET SCR COUPLING NSTALLEO By CUSTOMER OAM 10 REF DISCHARGE CHUTE Figure 1 Installation of Thermocouple and Dam
27. he external component wiring diagram Project R3930 Page 4 5 BCS6000C CSA 9 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 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 2 or 10 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 hole to accommodate a 1 DN 25 pipe coupling angled downward at approximately 30 from horizontal Mount the draft transmitter
28. ing EVC Fuel Bias Settings Air Project R3930 Page 11 BCS6000C CSA 9 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 The temperature instruments touchscreen display flame relay and PLC will perform their self test procedures b The burner control motors will drive closed c The RESET indicator will come on d 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 Select MATERIAL or STACK control and verify the setpoints of both Press the LIMITS SET push button to latch limits circuit If all system limits are closed a PRESS RESET TO START PURGE will appear in the message box b The selected fuel motor will drive to its lightoff position 7 Momentarily press the LIMITS SET pushbutton to latch limits circuit and 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
29. ints are exceeded Safety Limits are latched with a dedicating latching circuit and pushbutton The panel also includes special provisions for adjustable valve characterization which can be utilized to reduce stack emissions Refer to Section F Valve Characterization for details NOTE High temperature limits will not prevent baghouse fires They will when properly installed and adjusted shut off the burner when a given temperature setpoint is exceeded Outside factors such as chemicals bag contamination or other ignition sources are beyond the control of the burner management system CAUTION The STACK alarm setpoint is factory set at 400 F 240 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 setpoint Project R3930 Page 3 BCS6000C CSA 9 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 Thermix 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 necessar
30. itter from the dryer and to open the LOW pressure tap to atmosphere PRESSURE SENSNG CONNECTOR W MOUNTING BRACKET T 1 COUPLING MCU l gt RET PRESSURE TRANSMITTER W7450 NOT TO SCALE Figure 1 Transmitter and Manifold Layout If the transmitter display does not read 0 00 IN H2O use the following procedure to zero the transmitter e Press the NEXT button one time to change the lower display to CALIB e Press ENTER to change the lower display to CAL ATO e Press ENTER and the lower display will read ATO DONE e Press NEXT to step through the remaining calibration options until the lower display reads SAVE e 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 Project R3930 Page 32 BCS6000C CSA 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 e Press the NEXT button one time to change the lower display to CALIB e Press ENTER to change the lower display to CAL ATO e Press NEXT until the lower display reads ADJ 4MA e Press ENTER and the lower display will read A 4MA aa e Ifthe 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 a o Each press of the E
31. ll 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 and verify that all control motors 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 45 and 47 on the fused terminal blocks Project R3930 Page 14 BCS6000C CSA 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 AIR PRESSURE Monitor slot 2 input 1 Verify that the secondary air pressure switch is made power on terminal 16 For EcoStar IIB burners jumper terminals 14 to 15A in the burner J Box 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 16A HIGH GAS PRESSURE Monitor slot 3 input 0 and the high gas pressure switch power on terminal 17 L
32. losed press the RESET button to initiate the system purge sequence gt Press the SET UP and A keys simultaneously on the STACK TEMPERATURE instrument 0 will appear in the upper display and ULoc will appear in the lower display gt Press SET UP key one time to display SP in the lower display and the current setpoint value in the upper display gt Use the W key to lower the setpoint until the limit opens and the OUT and EXCEED indicators come on gt The alarm will sound and a HIGH STACK TEMPERATURE message will appear gt Acknowledge the alarm and return the STACK TEMPERATURE limit setting to its original value then press the RESET key on the STACK instrument to reset the fault and extinguish the OUT indicator FLAME FAILURE TEST gt Start the burner and establish the low fire burner flame gt For gas fired systems simulate flame failure by closing the manual shutoff valve downstream of the safety shutoff valves or as an alternative to closing the manual valve on a gas fired system temporarily disconnect field wire 87 from the control panel terminal strip gt After approximately three seconds the Honeywell flame relay will lockout and its red ALARM indicator will be illuminated The burner will shut off the alarm will sound and a FLAME FAILURE message will be displayed gt Silence the alarm and replace wire 87 or open the manual shutoff valve to resume normal operation Project R3930 Page 36 BCS6000C CS
33. mpleted 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 MATERIAL or STACK control to return to normal operation Verify that all low fire limit switch contacts are closed i e slot 2 input 5 is ON when the burner is at 0 and OFF when the burner leaves low fire Refer to the burner operating instructions for switch adjustment TRANSMITTER ZERO Allow the unit to warm up for at least five minutes before adjusting the Transmitter Zero Use the shutoff cocks in the transmitter manifold to isolate the transmitter from the dryer and to open the LOW pressure tap to atmosphere The transmitter display and the touchscreen display of the BCS 6000 should both read 0 00 Reference Appendix for transmitter adjustments if necessary 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
34. n 8 88 1 5Vdc from optional baghouse outlet temperature transmitter 24V 99 24Vdc power supply OV 81 Analog reference SLOT 1 8 Point AC Input Module Part No D2 08NA 1 Input Wire Function X20 28 RESET pushbutton X21 23 ALARM SILENCE pushbutton X22 38 START pushbutton X23 60 OIL selected from fuel selector switch X24 36 STOP pushbutton normally closed X25 56 Flame on from flame relay X26 58 Reset required from flame relay X27 48 Spare COM L2 AC Neutral SLOT 2 8 Point AC Input Module Part No D2 08NA 1 Input Wire Function X30 13 Exhaust fan limits X31 16 Secondary air interlock X32 18 Low oil temperature X33 26 Stack temperature limit X34 54 Purge complete from 1TR timer X35 21 Low fire limit switches X36 43 Main fuel valve open X37 24 Purge air and main fuel valve closed limits COM L2 AC Neutral SLOT 3 8 Point AC Input Module Part No D2 08NA 1 Input Wire Function X40 17 High gas pressure limit X41 14 Secondary air motor starter interlock X42 17B High Oil or LP pressure X43 17D Atomizing air limits X44 16A Low gas pressure X45 17A Low oil pressure X46 75 Opt switch X47 76 Spare COM L2 AC Neutral Project R3930 Page 23 Y27 SLOT 7 Input Y xx Yxx Y xx Yxx Yxx Yxx Yxx YXx BCS6000C CSA 9 8 Point Relay Output Module Part No D2 08TR Wire Function 63 Purge relay R2 64 Run relay R3 65 Pilot scanner relay R4 66 Pilot relay R5 67 Gas motor increase relay R6
35. nimum of four complete air changes must be supplied Multiply the total system volume dryer baghouse and exhaust ducts in cubic feet meters by four Divide this value by the burner air capacity in cubic feet meters per minute The result will be the required purge time in minutes Be sure that all equipment and components have been installed in accordance with the manufacturer s instructions Verify the positions of the FUEL SELECT AIR SELECT and AUX SELECT switches on the printed circuit board The switches must be set to be compatible with the burner control motor s Select GND for medium torque actuators Honeywell M6284 or Barber Colman EA 57 Select 120V for high torque actuators Barber Colman EA 71 or EA 73 Verify all wiring and tighten connections Clean all traps and filters Check all fuel and air supply lines for leaks Verify all pressure settings IMPORTANT Periodic testing of the flame supervision components safety limits and interlocks should be conducted to insure proper operation Testing should be performed by personnel who are familiar with the equipment and the functions of the various controls See Appendix J for a checklist and procedure E ADJUSTMENTS amp 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 slid
36. on a vibration free support shielded from direct flame radiation The operating temperature range is 20 to 180 F 29 to 82 C Connect the transmitter manifold to the LOW pressure tap and leave the HIGH pressure 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 where it can 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 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 Set the purge timer 1TR for the required purge time Project R3930 Page 5 16 17 18 19 BCS6000C CSA 9 IMPORTANT Before igniting the burner the dryer must be purged to remove possible accumulation of combustible gases A mi
37. ontrol loop in manual gt The resulting GAIN and RESET parameters GAIN only for Draft control will be automatically updated when the sequence is completed gt For processes with significant dead time such as a rotary dryer it may be desirable to decrease the GAIN parameter RUN MENU Screen After all loop tuning settings have been recorded return to the MAIN MENU then press RUN MENU to 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 DRAFT CONTROL gt Enter a Draft Control PURGE SETPOINT for use during the burner purge sequence This value is normally set higher than the normal draft setpoint in order to prevent dusting as the air damper drives open for purge gt 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 gt 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 Project R3930 Page 8 BCS6000C CSA 9 gt 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 dry
38. or details 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 Project R3930 Page 15 BCS6000C CSA 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 a 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 MANUAL BYPASS In the event of a touchscreen display failure the burner firing rate may be adjusted manually by the following procedure gt Press the LIMITS SET amp RESET button to initiate system purge Wait for the START indicator to begin flashing then press START to ignite the burner gt As soon as the burner has ignite
39. ot up sequence simultaneously press the A and SETUP keys OPtr will appear in the Upper Display Press the A arrow key until the Upper Display reads SEtP Press SETUP key ULoc will appear in the Lower Display Press the A arrow until Upper Display reads 10 then press the SETUP key to enter the setup mode 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 limitations Set the parameters as shown in the following table LOWER DISPLAY FACTORY DEFAULT OPTIONAL FUNCTION CONFIGURATION TYPE J TYPE K SP R min to R max 400 400 HYSt 0 1 0 1 0 1 FiLt 2 2 2 PhA1 R max 999 9 2503 AHY1 0 1 0 1 0 1 PLA2 R min 199 9 400 0 AHY2 0 1 0 1 0 1 SLoc 10 0 0 Note The instrument will remain in the setup mode for 2 minutes before returning to the run mode The A key represents increase The WV key represents decrease Project R3930 Page 27 BCS6000C CSA 9 APPENDIX F EXHAUST FAN FLOW LIMIT SWITCH INSTALLATION Mount the exhaust fan flow switch in the dryer exhaust duct as shown in Figure 1 11 2 oA ret wae ook Be La A rs BOO y rN i CY6909 uct EUTOUT DETAL NOT TO SCALE ASSEMBLY MOUNTING Figure 1 Installation of Exhaust Fan Flow Switch Wire the exhaust flow switch to the appropriate terminals The exhaust
40. plays 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 Error Fault Indications Parameter Upper Lower Description Display Display Over Range HH Normal Input gt 5 over range Under Range LL Normal Input gt 5 under range Sensor Break OPEN Normal Break in input sensor or wiring Option 1 Error ERR OPn1 Option 1 module fault Option 2 Error ERR OPn2 Option 2 module fault Option 3 Error ERR OPn3 Option 3 module fault Option A Error ERR OPnA Auxiliary Option module fault V Used to decrease the setpoint or configuration values A Used to increase the setpoint or configuration values SET UP Used in conjunction with the A key to enter the set up and configuration modes Also used to advance through the parameters Project R3930 Page 25 BCS6000C CSA 9 CONFIGURATION The instruments are factory set for a type J thermocouple with a range of 32 to 842 F 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 Simultaneously press and hold the A arrow and SETUP Keys OPtr will appear in the Upper Display Press the A arrow key until the Upper Display reads ConF then press SETUP ULoc will appear in the Lower Display Pre
41. r pressure limit exhaust damper open limit or any of SWITCHES the fuel valve proof of closure switches fails to close Monitor 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 Check the low fire alarm setting on the RUN MENU screen The HIGH a S burner will be held at low fire until stack temperature falls below the alarm setpoint HIGH MATL TEMPERATURE LOW FIRE HOLD Check the low fire alarm setting on the RUN MENU screen The burner will be held at low fire until material temperature falls below the alarm setting 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 flame relay requires a 120Vac grounded neutral power supply for proper operation 3 Flame amplifier failure The flame amplifier may need to be replaced The control motor and excess fuel faults a
42. ss the A arrow until Upper Display reads 20 then press the SETUP key to enter the configuration mode The lower display should read InPt Check the sales order for the thermocouple type Use the V A keys to change the value to the corresponding reading below J type 199 9 to 999 9 F J F Note decimal point between J amp F K type 199 9 to 999 9 F HF Note NO decimal point between H amp F Momentarily press the RESET key The symbols should stop flashing Press the SETUP key to view the other configuration parameters Use the W A keys to change parameters if required Press RESET after changes are made to accept the new values LOWER DISPLAY FACTORY DEFAULT OPTIONAL FUNCTION CONFIGURATION TYPE J TYPE K ruL Range Max 999 9 2503 rLL Range Low 199 9 400 0 OFFS 0 0 0 0 0 0 CtrL Hi Hi Hi SPuL Range Max 999 9 2503 SPLL Range Low 199 9 400 0 ALA1 P_Hi P_Hi P_Hi PhA1 Range Max 999 9 2503 AHY1 0 1 0 1 0 1 ALA2 P Lo P_Lo P_Lo PLA2 Range Low 199 9 400 0 AHY2 0 1 0 1 0 1 USE2 A1_d A1_d A1_d retP USE3 USE3 USE3 tyP3 0_10 0 5 0 5 ro3H Range Max 842 0 1399 ro3L Range Min 32 0 32 0 diSP EnAb EnAb EnAb CLoc 20 20 20 After your have completed the Configuration cycle power to reset or wait 2 minutes for the unit to reset to the run mode Project R3930 CHANGING THE SET POINT Page 26 BCS6000C CSA 9 After the instrument has completed its bo
43. t off the exhaust fan 120Vac should disappear from terminal 13 immediately but should remain on terminal 12 for several seconds as the exhaust fan coasts to a stop LOW GAS PRESSURE Gas fired systems only gt Move the FUEL SELECTOR switch to the GAS position and place the temperature control loop in manual at 0 output gt Start all equipment required for burner operation and then momentarily press the RESET button on the control panel After the purge sequence is completed press START to establish the pilot and low fire gas flame gt Close the manual valve in the main gas line to shut off the gas supply The burner should shut off the alarm will sound and a LOW GAS PRESSURE message should appear HIGH GAS PRESSURE Gas fired systems only gt Remove the cover of the high gas pressure switch make note of the switch setting then lower the setting to its minimum value gt Open the manual valve in the main gas line and attempt to restart the burner gt As soon as the main gas valves open the high gas pressure switch should trip The burner will shut off and a HIGH GAS PRESSURE message will appear gt Return the high gas pressure switch to its original setting and replace the switch cover LOW OIL or LP PRESSURE Oil or LP fired systems only gt Move the FUEL SELECTOR switch to the OIL position Shut off the oil or LP supply pump and attempt to start the burner gt The alarm should sound and
44. t the end of this section IMPORTANT The fact that bubbles are present during the leak test does not necessarily mean that a safety shutoff valve is not functioning properly in the closed position Refer to the National Fire Protection Association s publication NFPA 86 for acceptable leakage rates for a given pipe size per UL ANSI CSA FM or EN standards If the acceptable bubbles min leakage rate is exceeded the safety shutoff valve is leaking and the manufacturer s instructions should be referenced for corrective action Project R3930 Page 37 BCS6000C CSA 9 WARRANTY Thermix Combustion Systems Inc hereinafter called seller warrants and guarantees to the original buyer that all equipment and parts manufactured by the seller are free from defects in material and workmanship Any pieces of equipment failing in normal service within a reasonable period of time not exceeding sixteen 16 months from the date of shipment or twelve 12 months from the date of commissioning with the exception of refractory materials will be promptly replaced without cost to the original buyer when returned to the factory of the seller If any product is found unsatisfactory under this warranty the buyer should notify the seller in writing and after receipt of shipping advice and return authorization buyer may return it directly to Thermix Combustion Systems Inc 7400 Chemin St Francois St Laurent QC CANADA carrying charges prepaid Su
45. tage 120Vac System Schematic Y7552 CAUTION The BCS 6000 control panel power must be on to perform the following checks Avoid contacting exposed wiring and terminals when checking voltage or continuity and after removing the pressure switch covers to make adjustments Replace all covers as soon as testing is completed gt Start all equipment required for burner operation except the exhaust fan Verify that 120Vac is not present between the following control panel terminals with the FUEL SELECTOR switch in the OIL GAS and OPT positions o 12 and L2 o 17A and L2 o 13 and L2 o 17B and L2 o 15 and L2 o 17D and L2 o 14 and L2 o 17C and L2 o 16 and L2 o 18 and L2 o 16A and L2 o 25 and L2 o 17 and L2 o 26 and L2 SECONDARY AIR LIMITS LOW PRESSURE SWITCH amp MOTOR STARTER INTERLOCK Note A jumper wire must be installed in the burner junction box between terminals 14 and 15A gt Leave the exhaust fan off and start the combustion air burner blower gt Set the multi meter to read continuity and verify that continuity exist between the following control panel terminals 14 and16 gt Shut off the combustion air blower Continuity should disappear between terminals 13 and 14 immediately but should remain between terminals 14 and 16 for several seconds as the secondary air blower coasts to a stop ATOMIZING AIR LIMITS EcoStar IIB with primary air blower for Oil or LP
46. the fuel valve It provides inputs for fuel valve position for lightoff and eleven air valve positions Low Fire 10 20 30 thru 100 It also displays pertinent data to aid in burner setup Project R3930 Page 19 BCS6000C CSA 9 tHATERIAL 5SETPOINT OUTPUT 15 MINUTE GE SETPOINT OUTPUT FLAME STen OPPED RAFT BURNER ST co TRENDS Four separate trend screens provide 5 minute 15 minute 4 hour and 8 hour trends of Material temperature Stack temperature Setpoint and burner firing rate Project R3930 APPENDIX B Page 20 CONFIGURATION RECORD Factory set default values are shown in parenthesis e g 7 0 MAIN MENU SCREEN PLC PROGRAM SCREEN PROGRAM MOTOR CALIBRATION amp SETUP SCREEN MOTOR ZERO SPAN DEADBAND FUEL 0 5 AIR 0 5 BURNER OUTPUT LIMIT 100 0 LOW FIRE AIR 0 0 LIGHTOFF TIME 10 GAS PRESSURE 24 0 sec OZ MATERIAL TEMPERATURE BIAS 32 0 STACK TEMPERATURE BIAS 32 0 CONTROL LOOP TUNING SCREEN MATERIAL STACK DRAFT GAIN 2 00 2 00 1 25 DEADBAND 1 1 0 10 RESET 1 00 1 00 RATE OPEN CYCLE 1 00 CLOSE CYCLE 1 00 FILTER 1 RUN MENU SCREEN START AT 30 0 THEN RAMP AT 50 0 ___ s PER MIN LOW FIRE DRIVE IF STACK GREATER THAN 380 LOW FIRE DRIVE IF MATERIAL GREATER THAN 400 BCS6000C CSA 9
47. tor and has separate Open and Close cycle times similar to the DPS instrument it replaces AUTO TUNE The Material Stack and Draft control PID loops are each equipped with an AUTO TUNE button Please note the following before initiating the auto tune procedure gt Make a note of the existing tuning parameters on the Control Loop Tuning Screen before beginning Auto Tune Factory default settings are given in the Configuration Record Sheet gt Only one loop at a time may be tuned gt The process should be 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 gt Stabilize the temperature or draft as close as possible to the setpoint in MANUAL then switch the loop to AUTO and press the AUTO TUNE button to begin gt For the Material and Stack temperature control loops burner OUTPUT must be less than 60 for the Auto Tune sequence to be preformed Auto Tune will increase burner output by 10 and calculate new gain and reset values based on the process response Auto Tune will be complete after the associated temperature has increased by approximately 40 F 4 C Consult Hauck s Service department if a larger or smaller step is required gt For Draft control the loop will be cycled between 100 and 0 three times during the course of the Auto Tune procedure gt Auto Tune may be interrupted if necessary by placing the c
48. y to connect jumper wire s between appropriate terminals in the control panel or burner junction box Such 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 C DRAWINGS AND SUPPLEMENTAL LITERATURE D INSTALLATION 1 EcoStar IIB Tabletop Panel Assembly System Schematic External Component Wiring 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 3795 drawings for required cutouts and mounting dimensions IMPORTANT Operating specifications of 32 to 131 F 0 to 55 C and 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 and Earth ground Wire the fuel valves valve position limit switches and fuel pressure limit switches as shown on t
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