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Burner Control CBR

Burner Control CBR (Control Box Rekumat/ Regemat) Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same. Burner Control CBR The CBR burner control box incorporates the following components:

• Microprocessor controlled flame relay • Safety relevant temperature measurement of a NiCr-Ni

dual thermocouple for release of the appropriate operating mode and for thermal supervision of FLOX operation or safety relevant inputs for release of FLOX® / flame mode (XOR signal processing)

• Air / exhaust and cooling valve control • Manual / Automatic operation • Display of information, operating and fault status

messages, in a compact metal housing The CBR controls, ignites (externally) and supervises WS gas burners REKUMAT / REGEMAT in intermittent operation (pre-configured self test < 24 hours). Signal exchange with the main process control can be achieved via Profibus DP interface or via hard wired input/output. Depending on the power supply voltage, 4 variations, which are project customized, pre-configured and tested. Technical Specifications: • Power Supply 230V AC –15% ... +10% 50/60Hz or

115V AC –15% ... +10% 50/60Hz • Electrical connection Phase correct connection and ground connection

according to electrical diagram Touch protection! Must be present for thermocouples and the UV sensor / flame rod (powerless installation and connection)

• Fuse 6,3A slow or 10A fast, integrated, replaceable • Power consumption (self) < 14VA • Power consumption (total) Max. current: 6,3A • Power consumption (safety relevant

users) Max. 5A (for all gas valves and ignition transformer for approx. 2 sec during ignition)

• Max. cable lengths to burner components 10m • Protection class IP54 • Ambient temperature -20°C ... +60°C • Storage and transportation -20°C ... +70°C • Humidity DIN 60730-1, dew/condensation formation not allowed • Dimensions 264x310x123mm (Width x Height x Depth) • Installation orientation any • Mounting On site, 4 female threads M8x1,25 (12mm deep) each

17mm from outside edge • Weight 5 ... 15kg (depending on components and cable length) • Certification EG-Construction Pattern Test Certificate

EG-Gas Device guide line (CE Nummer: 0085BT0439 / Testing basis: EU/90/396/EWG; DIN EN298) FM approved Class: 7610 (Test number PDR 3035948)

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Burner Control CBR

The burner control box has many diagnosis features for ease of commissioning or trouble shooting: Program sequence, device parameters, fault code history, operating hours counter, combustion chamber temperature (measured by dual thermocouple) or the flame signal strength can be indicated on the 7-segment display. Three LED's visualize the most important operating states: • green Flame signal strength (flashing when quality bad) • yellow FLOX- Status • red Fault (flashing) The functions of the buttons, button combinations, information, operating and fault codes are described on two labels. Labels are available in different languages and are changeable.

Code label 1

Code label 2 Each CBR is configured for its specific application and tested prior to delivery. The most important parameters can be visualized on the display (Comfort Configuration) by applying the appropriate key combinations (refer to label 1). A Password is required to change parameters (except Profibus address) and to activate manual operation. You will receive your password from our sales, service or electronics department after completing registration.

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Burner Control CBR

Comfort Configuration Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same. NOTE: All configured parameters are documented in the burner control certificate. This certificate is archived according the serial number. Please notify our electrical engineering department of any changes. All configured parameters are documented in the burner control certificate. This certificate is archived according the serial number. Please notify our electrical engineering department of any changes.

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Burner Control CBR

Electrical Connections Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same. Tools: • screw driver

• wrench • multi meter

Parts: • Burner controls CBR (ready for connecting and pre-

configured to customers specifications) • M8x1,25 screws or threaded studs (with washers and

nuts) 4x

Attention! Components under tension and high voltage! Mount the burner control unit CBR in close proximity to the burner. For mounting purposes the CBR has 4 molded nuts (female threads) incorporated into the rear of the unit - M8x1,25 (12mm deep). Select a mounting location at which the ambient temperature will not exceed 60°C . From process control, connect the power supply 230V 50/60Hz (optional 115V 50/60Hz) as well as the release signal „Safety chain“, interlocked with the application safety chain, to the control box. Make the connections according to the electrical schematics supplied by WS. All connections must be fused properly (depending on wire lengths, wire gauge, ambient temperature, and power draw). The „safety chain“ signal carries the load from the ignition transformer and the gas valves connected to the burner. Signal exchange for burner control can be hard wired (refer to electrical schematics) or it can be achieved via Profibus communications (optional).

Connections from the CBR to the electrical components of the burner are pre-wired and pre-assembled according to customer specifications. Please refer to the electrical schematics. Please note, that NiCr-Ni dual thermocouples and the UV sensor must not be attached (changed) with power ON. Danger of electrocution if phases of power supply are not connected correctly!

Prior to commissioning, all electrical connections and signal exchange must be verified by trained electricians in accordance to local codes and regulations.

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Burner Control CBR

A FLOX

® burner without the safety relevant temperature

acquisition via a NiCr-Ni dual thermocouple for release of FLOX mode, must utilize the safety relevant inputs for release of FLOX/Flame modes (XOR signal processing). Input signals must are to be determined and activated by fail safe temperature supervision. FLOX mode may only be activated at the FLOX input terminal if the furnace temperature is > 850°C via an active signal (230V AC L1 or optional 115V AC L1). The input of the Flame release terminal must be deactivated. A drop in temperature below the FLOX release threshold, the FLOX release signal must be deactivated and the Flame release signal must be activated. Switch over must occur within one second, otherwise a fault shut-off will occur (F 57)

Prior to activating FLOX ® mode, the FLOX/Flame switching logic, especially the electrical connections, must be validated by trained personnel. Validation to be performed with the gas supply turned off. Incorrect implementation can result in EXPLOSION!

Electrical connects are made directly inside the CBR terminal section (remove power and lock out). As an option, the CBR can be supplied with an industrial connector for power supply and input/output signals. Profibus is optional and the interface is provided in form of a Profibus connector (9 pin sub-D) The CBR is pre-wired and tested at our facility. A project specific electrical schematic is included inside every CBR.

Prior to commissioning, wire termination and controls must be verified and tested diligently by trained professionals, in accordance to local regulations.

NOTE: all parameter settings are documented on the burner test data certificate. This certificate is

archived according to WS serial numbers. Please notify our electrical engineering department of any changes made.

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Burner Control CBR

Profibus DP with CBR Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same. Burner control CBR with Profibus (functional schematic)

SPS,PLC,CPE

L1,N,PE

BUS

(FLOX GWS)

CBR

BUS X2: X2: BUS X2: BUS

Power supply, Safety chain, (FLOX/Flame)

Bus wire

1 2 3

CBR CBR

A maximum of 126 devices my be connected to a Profibus DP system (master and slaves). Each device receives an individually defined address. The address can be entered into the CBR via the push buttons on the front panel. The address range is from 0 to 126 (CBR delivered with invalid address 127!). All devices are connected in a bus fashion (in line). Each individual line segment can have as many as 32 participants (masters and slaves). A bus terminator must be placed at the beginning and end of each segment. Termination can be achieved via the switch within each Profibus connector. To maintain fault free bus operation, each terminated device must have power connected. Repeaters (boosters) must be used for more than 32 devices or to extend the range of the bus network. It is recommended to utilize shielded 2 wire cable (for example Lapp Unitronic –Best.-Nr. 2170-220T or Siemens –Best.-Nr.6XV1830-OEH10) to protect the network against electromagnetic interference. The shield must be connected on both ends, good conductivity of the shield is paramount. Do not switch the data lines A and B. Furthermore, keep Profibus cables as far away from other highly radiating cables (for example, high voltage cables, frequency converters, VFD, etc.) Ascertain that the power potential level is compensated between various masters and slaves (uniform potential) (Refer to Aufbaurichtlinien/ EMV-Maßnahmen im Fachbuch: “Profibus-DP/DPV1“ – Hüthig-Verlag – ISBN 3-7785-2781-9).

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Burner Control CBR

Profibus interface connection: CBR burner control units have a bus connection (9 pin SUB-D) integrated into the flange plate.

To complete the connection, a Variosub-D connector (9-pin male) is available (included in orders with Profibus interface). This connector includes two cable glands with gaskets for cable diameters from 5 to 9mm, terminals for connections, termination device. The termination device can be activated from out side the plug via an integrated switch. Bus termination between the two conductors A and B is approximately 220 Ohm. A multi meter should be used to test and confirm this resistance between pins 3 and 8. The bus terminals within the connector are labeled 1A,1B,2A,2B. Make sure the same conductor colour is maintained throughout devices and that they are connected to the same label throughout. There is no applicable code pertaining to wiring colours for Profibus. It has become „semi“ standard to use green for A and red for B. Incoming connections are terminated on 1A, 1B and the outgoing connections are terminated on 2A, 2B. The shield is to be connected securely by the shield bracket. (Refer to the installation instructions of the plug manufacturer).

CBR Profibus – Data Cable Connections

1B 2A 2B

8 3 6 5 1

CBR Control box

220

green green

red

red shield shield

Incomming bus cable Outgoing bus cable to next CBR

1A

5

9 6

1

Sub - D 9-pin

Variosub Profibus - 9 -pin connector

WS T.- - Nr. 970-00-440

Note: Bus connector can be removed from the CBR without interrupting the bus.

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Burner Control CBR

Declaration of the Profibus interface: Manufacturers tag 0x3218 (UNIGATE IC-Profibus der Firma Deutschmann Automation

GmbH) ASCIC-Type VPC3+B Sync- und Freeze- Mode - is supported

(Sync- command: all outputs of addressed slaves frozen Freeze- command: freeze all inputs of addressed slaves)

Cycle time Maximum duration until response of a request telegram, depending on bus transfer rate: 9,6kBit/s – 500kBit/s → 15 Bit times 1500kBit/s → 20 Bit times 3000kBit/s → 35 Bit times 6000kBit/s → 50 Bit times 12000kBit/s → 95 Bit times

Diagnostic The Profibus module creates an external diagnosis when a fault is detected. The diagnostic information of the DP slave consists of standard data( 6 Bytes) and a user specific diagnostic number (2 Bytes): Octet 1: Bit 0 = Diag.station does not exist (set by master) Bit 1 = Diag.station not_ready: slave is not ready for data transfer Bit 2 = Diag.cfg_fault: configuration files do not correspond Bit 3 = Diag.ext_diag: slave has external diagnostic data Bit 4 = Diag.not supported: requested function not supported by slave Bit 5 = Diag.invalid_slave_response (perm. sets slave to 0) Bit 6 = Diag.prm_fault: incorrect set up (ID number etc.) Bit 7 = Diag.master_lock (set by master): slave configured by other master Octet 2: Bit 0 = Diag.prm_req: slave must be reconfigured Bit 1 = Diag.stat_diag: statistical diagnosis (Byte Diag-Bits) Bit 2 = 1 Bit 3 = Diag.wd_on: polling supervision activated Bit 4 = Diag.freeze_mode: freeze command received Bit 5 = Diag.sync_mode: Sync command received Bit 6 = reserved Bit 7 = Diag.deactivated (set by master) Octet 3: Bit 0 – Bit 6 = reserved Bit 7 = Diag.ext_overflow Octet 4: Diag.master_add: master address after configuratin (FF without configuration) Octet 5: ID number High byte Octet 6: ID number Low byte Octet 7: external diagnosis: header length Octet 8: internal UNIGATE- fault code

Parameter - supports only cyclic communication automatic Baud rate

recognition - supported

Cable length: Following table valid for cable type A per EN 50170

Baud rate (kbit/s): 9,6 19,2 45,45 93,75 187,5 500 1500 3000 6000 12000 Distance (m): 1200 1200 1200 1200 1000 400 200 100 100 100

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Burner Control CBR

Profibus configuration: When engineering a Profibus DP system, parameters and addresses must be configured for each device.

A GSD file is provided to simplify and standardize this engineering process. The GSD file format is standardized, so it can be read and recognized by devices of all manufacturers. Please contact our sales, service or engineering department for the GSD file applicable for your project. The steps required to access the file should be available from your automation system manual. The „Basic I/O“ version (minimum configuration) for data transfer, includes only the output byte (AB0) and the 2 input bytes (EB0 + EB1). The „Standard I/O“ version can transfer and analyze the four input bytes (EB0,EB1,EB2,EB3) as well the output byte (AB0). More information regarding the „Extended I/O“ version can be obtained upon request. The address of individual bus devices can be set via the CBR function keys (refer to Profibus Address Setting). Each CBR is delivered with the invalid address 127 preselected. However, it is still possible to operate the burner control unit in manual mode, without a valid Profibus address.

Data transfer (Bytes/Bits) from master (host) to the CBR burner control unit: Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures

however, remain principally the same. Please contact our sales or engineering department.

Following tables illustrate the data transfer between master (host) and slave (CBR).

Table 1: Output byte (Master → CBR): Bit Output byte AB0 0 Remote reset (impuls 0,5s) 1 Heat demand 2 Cooling 3 Purge 4 unused 5 Flame mode 6 unused 7 reserved

Table 2: Input bytes (CBR → Master):

Bit EB0 EB1 EB2 EB3

0 Burner operation Manual mode State/Error byte *) Main gas valve ON

1 Burner fault Delta-p switch air 1 (min)

Flame gas valve ON

2 Air valve ON Safety chain OK

Gas valve FLOX 1 ON

3 Air purge ON Excess temperature, heating

Gas valve FLOX 2 ON

4 Cooling ON Excess temperature burner head/exhaust

Delta-p switch 2 (max)/ exhaust gas thermost.

5 Flame sensed Cooling valve or air/ exhaust valve 1 ON

Delta-p switch 3

6 FLOX -mode ON Eductor valve or air/ exhaust valve 2 ON

Gas pressure switch (optional)

7 Heating stand-by Common exhaust flap ON

State/Error byte *) POC switch for main gas valve (optional)

*) see table 3

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Burner Control CBR

Tab.3: Status byte EB2 – signal reference (CBR → Master): (In dependence of Bit 1 (EB0) „burner fault“, either the operating status (State) may be analyzed at „0“ or the fault code may be analyzed at „1“

Byte (decimal)

Byte (HEX)

Display CBR

State Text

0 Fxx 0 Fault – Fault Code 1 01 00 1 Pre-purge 2 02 d3 2 Safety chain interrupted – self resetting 3 03 01 3 Test R1 (Relay SHK is tested for 5 seconds) 4 04 1 4 Watchdog loading phase 5 05 A0 5 Flame: waiting for heat demand 6 06 A1 6 Flame: false flame signal 7 07 A1 7 Flame: idle check air delta-p switch 1 8 08 H1 8 Manual mode pause 1 9 09 A1 9 Flame : air pre-purge

10 0A A1 10 Flame: Ignition on 11 0B A1 11 Flame: Ignition off 12 0C A1 12 Flame: Flame supervision 13 0D A2 13 Flame: minimum time start mode 14 0E A2 14 Flame: Start mode (max 24 h) 15 0F H2 15 Manual mode pause 2 16 10 A3 16 Flame: minimum time flame mode 17 11 A3/H3 17 Flame: Flame operation / manual mode pause 18 12 H4 18 Manual mode pause 3 19 13 A4 19 Flame: Post purge 20 14 A4 20 Flame: Post combustion duration 21 15 A4 21 Flame: Minimum pause flame mode 22 16 b0 22 FLOX: waiting for heat demand 23 17 b1 23 FLOX: idle check air delta-p switch 1 24 18 b2 24 FLOX: air pre-purge 25 19 b2 25 FLOX: Start FLOX mode 26 1A b2 26 FLOX: Minimum time FLOX mode 27 1B H6 27 Manual mode: Pause 4 28 1C b2 28 FLOX: Operation (max. 24h) 29 1D b4 29 FLOX: Post purge 30 1E b4 30 FLOX: Minimum pause FLOX mode 31 1F Pd 31 Air purge: Idle check air delta-p switch 1 32 20 P0 32 Air purge 33 21 d1 33 Excess temperature burner head 34 22 C0 34 Cooling (cooling air) 35 23 d2 35 Start and flame mode not released 36 24 H5 36 Manual mode: Pause 5 37 25 d4 37 False flame during restart attempt

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Burner Control CBR

Table 3: Error byte EB2 – signal mask (CBR → Master): (In dependence of Bit 1 (EB0) „burner fault“, either the operating status (State) may be analyzed at „0“ or the fault code may be analyzed at „1“ )

Byte (decimal)

Byte (HEX)

Display CBR

Error Text

3 03 F 03 0x03 Hardware error (high Voltage, ambient temperature)

4 04 F 04 0x04 Remote reset error (more than 5 reset attempts in last 15 minutes)

12 0C F 0C 0x0C Configuration error 17 11 F 11 0x11 Hardware error (low Voltage) 18 12 F 12 0x12 Power loss 29 1D F 1d 0x1D Processor crash (EMV interference) 87 57 F 57 0x57 Fault external FLOX/Flame selection (XOR) 88 58 F 58 0x58 Manual mode: Timeout 91 5B F 5b 0x5B Thermocouple error burner housing 92 5C F 5C 0x5C Thermocouple error combustion chamber 93 5D F 5d 0x5D Temperature logging ambient 94 5E F 5E 0x5E Temperature ambient too high 95 5F F 5F 0x5F Temperature combustion chamber too high 98 62 F 62 0x62 Fault external FLOX/Flame selection (too many cycles)

162 A2 F A2 0xA2 Safety chain input without signal

166 A6 F A6 0xA6 False flame signal at start-up or ground fault at ionisation electrode

167 A7 F A7 0xA7 no flame formation at start-up 168 A8 F A8 0xA8 Flame loss in flame mode 170 AA F AA 0xAA Idle check error air delta-p switch 1 173 AD F Ad 0xAD Gas deficiency gas delta-p switch 180 B4 F b4 0xB4 Air deficiency air delta-p switch 1 181 B5 F b5 0xB5 High pressure air delta-p switch 2 182 B6 F b6 0xB6 POC – Main gas valve (over travel test) 183 B7 F b7 0xB7 Excess temperature burner housing 184 B8 F b8 0xB8 Low pressure air delta-p switch 3

186 BA F bA 0xBA False flame signal at start-up or ground fault at ionisation electrode

187 BB F bb 0xBB Safety chain interrupted

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Burner Control CBR

Enter Profibus Address (initial commissioning) WS Delivery: 127 (invalid)

Test Profibus communication Test Profibus address Enter Profibus Address (correction): Example: change from 4 to 3

Test Profibus communication

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Burner Control CBR

Manual Operation CBR Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same. For service adjustments, emissions testing und failure diagnosis the burner can be operated in manual

mode. Prerequisites:

The power supply must be connected phase correct and all contacts of the process line permissives /safety limits are closed, so that power (same potential) is present at the „safety chain“ terminal of the CBR.

The following adjustments can be made via Comfort Configuration „Step 0“ or Parameter 10: • 0 – Automatic operation • 1 – Manual mode: Air purge • 2 – Manual mode: Heating • 3 – lock out control box (locked) These selections require a password (operator password)

Entering Password (Operator): Manual Mode Air Purge: Air purge ON Air purge OFF

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Burner Control CBR

Manual Mode Heating:

functions are dependant on the current operating mode (temperature range)

Burner in Start Mode:

Manual Mode Heating:

functions are dependant on the current operating mode (temperature range)

Burner in Flame Mode:

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Burner Control CBR

Manual Mode Heating

functions are dependant on the current operating mode (temperature range)

Burner in FLOX -Mode:

Manual Mode Timeout: Operation in manual mode is time limited. Once this time is exceeded, the CBR is automatically locked out.

Exiting Manual Mode:

(Return to automatic operation)

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Burner Control CBR

Testing the Safety Features Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same. Tools: • Screw driver

Accessories: • Digital thermometer

Salient notes:

Safety features of the thermal processing line must not circumvented or disabled. Functionality of the safety features of every burner must be validated prior to each application start-up, such as may occur after commissioning, maintenance work or extended down times.

How to:

1. Test ground connection Attention! Every burner must be connected with ground. This can be achieved via the burner control unit or directly through the system ground. It is not permissible to daisy chain ground connections from burner to burner!

2. Safety shut-down in flame mode

The following manipulations must lead to a fault shut-down of the firing burner: • interruption of the gas supply (via manual shut-off valve) • interruption of the combustion air supply (via manual shut-off valve) • removing the UV sensor head from the burner

3. Safety shut-down in FLOX- mode

The following manipulations must lead to a fault shut-down of the firing burner: • interruption of the combustion air supply (via manual shut-off valve) • removing the connector from the pressure switch (Delta-p air min.)

4. Safety relevant FLOX- release temperature Regular validation of the temperature measurements and the associated fault shut-off and alarms is required: Comparative measurement of the dual thermocouple for FLOX- release. (reference measuring point, for example inline testing port) with CBR information display:

• select information display vie + and ↵↵↵↵ • 0 = temperature in hundreds – 1 = temperature in single digits (e.g. 0 08 + 1 70 = 870°C) • ↵↵↵↵ = continue to next information display; ←←←← = exit or, timeout after 20 seconds

Interrupt the temperature measurement circuit. • dual thermocouple for FLOX- release → fault shut-off F 5C

b) burner head thermocouple → fault shut-off

P

1

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Burner Control CBR

Burner Faults Please follow all applicable safety regulations. Depicted configurations may differ from the actual scope of delivery, procedures however, remain principally the same.

Attention: Danger of electrocution!

Remove power (lockout and tag out) prior to working on electrical components.

Fault trouble shooting by authorized trained professionals! Repair attempts on the CBR will void the warranty! Improper attempts at repairs and incorrect electrical connections, for example providing power to output terminals can cause gas valves to pen and destroy the CBR – fail safe operation can no longer be guaranteed!

Attention: Danger to life and limb by electrical shock! Remove power from any electrical components prior to commencing work! Only trained, authorized professionals are permitted to perform electrical work. Repairs of the CBR are not permitted – warranty voided if attempted. Incorrect repairs or electrical connections e.g. powering outputs can open gas valves and destroy the CBR – fail safe functionality of the unit is no longer guaranteed.

Most faults can be reset, thus restarting the burner, by pressing the local reset button ↵↵↵↵ for a minimum of ¼ second, or by activating the remote reset signal. In case of reoccurring fault, avoid multiple or continuous reset attempts and determine the root, cause of the fault by trouble shooting the burner. Reset attempts are limited to five (5) per 15 minute interval. (refer to fault F 04 ) Each reset will initiate a restart, indicated by a flashing: 8 88 This is always followed by several seconds of air purge and burner a relight attempt (look at parameter). For some faults the CBR can be configured so that they do not cause a shut-off of the burner. The fault is then indicated on the CBR display. Please contact the WS service department if a fault persists and can not be reset. Power down the burner control box and close the manual gas shut-off valve. Isolate the burner from the exhaust system (i.e. Shut-off valve or blind flange). The faulting burner should be locked out and tagged out to prevent unintended activation.

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Burner Control CBR

a) Status Display

Fault Code Fault / Cause Check / Solution

P

1

Temp. Supervision (optional) e.g. Burner head temperature or exhaust temperature exceeded

An optional, measured temperature has exceeded the set limit

P

2

Flame operation locked out and FLOX temperature not yet reached

The CBR is only configured for a FLOX only burner Incorrect configuration of the CBR?

P

3

Safety chain limits / permissives interrupted

Upstream combustion safety devices are not on line; Burners are not permitted to operate Check the limits and permissives

P 4

False flame signal detected by the UV sensor or ionization electrode during a restart attempt

(see fault F A6)

These faults do not cause a burner shut-off and will auto reset once conditions are within normal operating limits.

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Burner Control CBR

b) Burner faults Fault displayed on CBR by flashing red LED and following fault Code:

Fault Code Fault / Cause Check / Resolution

F A2

Safety chain limits / permissives interrupted

Upstream combustion safety devices are not on line; Burners are not permitted to operate Check the limits and permissives

F A6

False flame signal detected by ionization electrode or the UV-probe

Unusually long residual flare after burner has turned off e.g. gas valve leakage; UV-probe defective or aged; Ground connection of ionization electrode? Air purge orifices in the gas head plugged → clean Incorrect configuration of the CBR?

F A7

Flame loss during STS (no flame established during start-up)

High Voltage! Use caution when removing the spark plug cap! Automatic restart attempts will power the ignition transformer!

Check the gas and air flow volumes; Check spark plug connection; Is a spark generated, transformer OK? Is the spark visible through the sight glass? Moisture present in the brass ignition head? Remove the gas nozzle, ceramic tube, ignition rod, disc for gas lance and check; UV-probe defective? Residual air in the gas piping? Power connection (N and L1) reversed

F A8

Flame loss in start / flame operation (flame lifts off during operation)

Check the gas and air flow volumes; Compare differential pressures with those stated on burner name plate; UV-probe defective? Check flame signal; Burner internals defective With start/flame burners, switching temperature for next mode in order?

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Burner Control CBR

Fault displayed on CBR by flashing red LED and following fault Code:

Fault Display Fault / Cause Check / Resolution

F AA

Safety check delta-p air min. Delta-p switch defective; Flexible hose from pressure switch (negative side) to the measuring orifice lose or leaking; Continuous air flow while burner is off → check air switching valves

F A

P

Delta-p gas (optional delta-p switch for gas signals gas deficiency)

Delta-p switch defective; Gas flow volume adjusted too low; Threshold of delta-p switch selected too low → lower setting; Incorrect configuration of CBR

F 4

Delta-p air min. (pre-adjusted to approx. half of delta-p of nominal air flow volume) Minimum required air volume not achieved

Delta-p switch defective; Air volume flow too low; Exhaust suction not present; Flexible hose from pressure switch (positive side) to the measuring orifice lose or leaking; Threshold of delta-p switch selected too low → lower setting; Flexible hoses switched; High pressure air missing

F 5

Delta-p air 2 (optional) or . Exhaust gas thermostat (optional)

E.g. Delta-p air max.: Delta-p switch defective; Flexible hose from pressure switch box (negative side) to the measuring orifice lose or leaking; Exhaust gas suction too high; Air flow volume too high; Threshold of delta-p switch selected too low → lower setting; Exhaust gas temperature too high? Thermostat defective or connection defective?

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Burner Control CBR

Fault displayed on CBR by flashing red LED and following fault Code:

Fault Display Fault / Cause Check / Resolution

F 6

Faulty optional Proof of Closure Switch (POC)

Main gas valve is not closing; Main gas valve defective; Proof of closure switch defective; Check electrical connections. Incorrect configuration of CBR

F 8

Pressure switch air 3 (optional)

E.g. radiant tube pressure switch.: Exhaust valve not closing; Exhaust pressure (negative) deviates from pressure curve; Pressure switch defective; Threshold of delta-p switch selected too low → lower setting; Moisture in pressure switch?

F a

False flame signal detected by the UV-probe during start-up (similar to F A6)

Unusually long residual flare after burner has turned off e.g. gas valve leakage; UV-probe defective or aged Burner internals defective? Ground connection of Ionization electrode? Air purge orifices in the gas head plugged → clean

F

Safety interlock open (similar to F A2)

Upstream combustion safety devices are not on line; Burners are not permitted to operate Check the limits and permissives

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Burner Control CBR

c) Control and Operating Faults

Fault Display Fault / Cause Check / Resolution

F1

flashing

Bus fault

The TWI bus cable (service interface) is blocked by a defective bus client (e.g. defective Vision Box)

F2

flashing

Display fault (internal) The connected display is invalid

F3

flashing

Password fault Note: Access to device configuration levels protected by dedicated passwords

Incorrect password entered or password not confirmed by pressing reset button.

F4

Reset fault Prolonged reset signal present (> 10 seconds) or signal is already present when connecting power

F5

flashing

Input fault An attempt was made to overwrite a non changeable parameter. Button combination locked

F7

flashing

Burner (CBR) locked out (A burner may be turned off in this fashion)

The CBR is locked out Comfort Configuration “0” or parameter 10 (manual mode) is set to “3” For example after long operation in manual mode. Comfort Configuration “0” or parameter 10 must be set to “0” (automatic mode) or to manual mode (“1” or “2”)

F8

flashing

Configuration error Parameters 65 and 90 have colliding settings.

F9

flashing

Profibus fault

The connection with the Profibus master interrupted; Profibus IC defective or missing

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Burner Control CBR

Fault displayed on CBR by flashing red LED and following fault Code:

Fault Display Fault / Cause Check / Resolution

F 03

Hardware fault Ambient temperature too high; Excess power supply level in main power supply

F 04

Reset fault (Too many reset attempts. Maximum 5 resets per 15 minute interval permitted)

Wait until new reset is permitted

F 0C

Configuration error Switching intervals are smaller than the test intervals of the pressure switch or the thermocouple configuration or post air purge / post combustion < 0.5s

F 16

Communication fault TWI Bus (Service- interface)

On TWI Bus: Only add or remove client with power off

F 18

CBR powered down externally The CBR was powered down remotely via the PC software of the Vision Box.

F 1

P

Processor fault Strong EMV interference

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Burner Control CBR

Fault displayed on CBR by flashing red LED and following fault Code:

Fault Display Fault / Cause Check / Resolution

F 57

External FLOX/Flame switching fault XOR signals not present at FLOX and flame terminals → with external FLOX/flame release (without thermocouple

F 58

Timeout manual operation CBR turns to status F 58 (manual state 1 or 2) after 15 minutes of continuous operation in manual mode, After reset the box is in state F 7 (state 3). The state must then be changed back to automatic mode (state 0). See fault display F 7.

F 59

Profibus fault

The connection with the Profibus master interrupted; Profibus IC defective or missing

F 5

Temperature supervision (optional) Thermocouple fault / Burner head / exhaust gas temperature

Thermocouple not connected properly, Positive and negative leads switched; Thermocouple defective

F 5C

Combustion chamber thermocouple fault (Dual thermocouple fault)

{Phase correct connection of the CBR is essential. Otherwise power my be connected to the compensating wire – danger of electrocution!

The dual thermocouple for the CBR is defective; The temperature deviation between both elements is too large; Faulty thermocouple connection; Positive and negative leads switched; Thermocouples fail the cyclical test → ground fault or both elements are touching; influence of signal converter

F 5

P

Ambient temperature fault

The ambient temperature surrounding the CBR is too high

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Burner Control CBR

Fault displayed on CBR by flashing red LED and following fault Code:

Fault Display Fault / Cause Check / Resolution

F 5E

Ambient temperature fault The ambient temperature surrounding the CBR is too high

F 5F

Combustion chamber temperature fault (Over temperature burner)

Shut down to protect the burner against excessive ambient temperatures; Fault does not auto reset after temperature has dropped Thermocouple fault

F 62

Too frequent signal change Flame to FLOX (>3 in 30s) at the signal inputs of burners with external FLOX / flame switching

Check switching and signals

d) Internal faults Other error codes indicate CBR internal faults. If reset attempts are unsuccessful, please contact the WS Service Department.