Elster PFA Handbuch

6.2.1.6 Edition 03.11

Technical Information · GB

www.kromschroeder.com

• 19" module for easy transmission of activation signals and feedbacks from

burner control units via ﬁeldbus cable

• Remote maintenance and diagnostics facilities

• Saves installation and wiring costs

• Units can be exchanged during bus mode operation thanks to industrial plug

connector system

• Bus interface remains in operation when PFA is switched off (standby mode)

• Certiﬁcation for PROFIBUS DP

Field bus interface PFA

Module subrack BGT

PFA, BGT · Edition 03.11

t = To be continued

Contents

Field bus interface PFA

Module subrack BGT.............................. 1

Contents........................................2

1 Application.....................................3

1.1 Examples of application. . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.1 PFA 700 with PFU 760, staged On/Off burner control . . . . . .5

1.1.2 PFA 700 with PFU 760L, staged High/Low burner control . .5

1.1.3 PFA 710 with PFU 780, stage-controlled main burner with

alternating pilot burner..................................6

1.1.4 PFA 710 with PFU 780, stage-controlled main burner with

permanent pilot burner .................................6

2 Certiﬁcation....................................7

2.1 EC type-tested and certiﬁed . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Approval for Russia.............................7

3 Function.......................................8

3.1 Safety-related control signals . . . . . . . . . . . . . . . . . . . . . 8

3.2 Air valve......................................8

3.3 BCSoft........................................9

3.4 Conﬁguration, Master-Slave procedure . . . . . . . . . . . . 9

3.5 Addressing ...................................9

3.6 Network technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.7 Conﬁguration.................................10

3.7.1 Bus communication ...............................10

3.8 Program status ...............................12

3.9 Fault signalling ............................... 12

3.10 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.10.1 PFA 700 and BGT SA-9U/1DP700. . . . . . . . . . . . . . . . . . . . 13

3.10.2 PFA 710 and BGT SA-8U/1DP . . . . . . . . . . . . . . . . . . . . . . . 14

3.10.3 Flame control using an electrode . . . . . . . . . . . . . . . . . . . 15

3.10.4 Flame control with UV sensor UVS . . . . . . . . . . . . . . . . . . 15

3.10.5 Flame control with UV sensor for continuous operation

UVD 1 ...............................................15

4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Scanning the parameters . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 Manual operation............................. 17

4.3.1 PFA 700 .........................................18

4.3.2 PFA 710 .........................................19

5 Selection .....................................20

5.1 PFA .........................................20

5.1.1 Selection table................................... 20

5.1.2 Type code ...................................... 20

5.2 BGT.........................................20

5.2.1 Selection table .................................. 20

5.2.2 Type code...................................... 20

6 Project planning information . . . . . . . . . . . . . . . . . . . . . 21

6.1 Installation ...................................21

6.2 Old-new PFA exchange . . . . . . . . . . . . . . . . . . . . . . . . 21

6.3 Wiring.......................................22

6.3.1 Safety-related control signals . . . . . . . . . . . . . . . . . . . . . . 22

6.3.2 EMC........................................... 22

6.3.3 PROFIBUS plug connector . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.4 Manual operation.............................22

7 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.1 PROFIBUS plug connector . . . . . . . . . . . . . . . . . . . . . . . 23

7.2 Opto-adapter and BCSoft . . . . . . . . . . . . . . . . . . . . . . . 23

7.3 “Changed parameters” stickers . . . . . . . . . . . . . . . . . . 23

8 Technical data.................................24

8.1 PFA 700, PFA 710 ..............................24

8.1.1 Operating controls ............................... 24

8.2 BGT.........................................25

8.2.1 Dimensions..................................... 25

9 Legend ......................................26

Feedback ......................................27

Contact........................................27

PFA, BGT · Edition 03.11

Application

1 Application

In module subrack BGT, up to nine burner control units can be

inserted together with the PFA700, while with the PFA710, the

maximum is eight burner control units.

The BGT is provided with a backplane with screw terminals for

simple, reliable wiring.

The conventional wide-spread systems used in industrial fur-

nace and kiln construction require bridging of large distances

for signal processing.

The ﬁeld bus interface PFA is used in conjunction with the

pre-wired module subrack BGT for interworking of burner

control units PFU to industrial communication networks us-

ing PROFIBUS DP to control and monitor burners in industrial

furnaces and ﬁring systems, e.g. in the iron and steel, glass

and ceramics, or plastics and chemical industries.

As a standardized ﬁeldbus system, the PROFIBUS DP consider-

ably reduces development, installation and commissioning

costs compared to conventional wiring.

The use of a standard bus system offers massive beneﬁts com-

pared to manufacturer-speciﬁc bespoke solutions. Time-tested

hardware components, standardized connection methods

and a series of tools of bus diagnostics and optimization are

available on the market from a whole range of manufacturers.

The widespread use of the system ensures that the planning

and service personnel are very familiar with how the system

operates and how to handle it and can therefore operate the

system efﬁciently.

PFA 700 with BGT SA-9U/1DP700

For interworking of up to nine burner control units PFU 760

for directly ignited burners to communication networks using

PROFIBUS DP. The PFA700 is plugged into the module subrack

with printed-circuit board and rear terminal strip, together with

the burner control units.

PFA 710 with BGT SA-8U/1DP710

For interworking of up to eight burner control units PFU780

for pilot and main burners to communication networks using

PROFIBUS DP. The PFA710 is plugged into the module subrack

with printed-circuit board and rear terminal strip, together with

the burner control units.

PFA, BGT · Edition 03.11

Application

Bogie hearth forging furnace in the metallurgical industry

Walking beam furnace with overhead ﬁring

Intermittent shuttle kiln in the ceramics industry

PFA, BGT · Edition 03.11

Application

1.1 Examples of application

1.1.1 PFA 700 with PFU 760, staged On/Off burner control

L1, N, PE

BUS

PFU 760

PFA 700

BUS

VR..R

VAG

TZI

PLC

The burner can be started with reduced capacity.

A UV sensor monitors the ﬂame signal from the burner. UV

sensor UVD 1 is used for continuous operation, UV sensor UVS

for intermittent operation.

1.1.2 PFA 700 with PFU 760L, staged High/Low burner

control

VR..R

TZI

GIK..B

VAS..N

L1, N, PE

BUS

PFU 760L

PFA 700

BUS

PLC

The burner starts at low-ﬁre rate. When the operating state is

reached, the PFU 760L advises the control unit. The PLC can

now pulse the air valve in order to control the burner capacity.

PFA, BGT · Edition 03.11

Application

1.1.3 PFA 710 with PFU 780, stage-controlled main burner

with alternating pilot burner

VR..L

VAG

ϑ1

ϑ2

02–0402–04 06–08 06–08

VBY

TZI

L1, N, PE

BUS

PFU 780

PFA 710

BUS

PLC

Control: main burner ON/OFF

The main burner can be started with reduced capacity after

the operating signal from the pilot burner has been detected.

The pilot burner is switched off automatically after the main

burner has started up. When the main burner is switched off,

the pilot burner automatically switches on again.

A UV sensor monitors the ﬂame signal from pilot and main

burners. UV sensor UVD 1 is used for continuous operation,

UV sensor UVS for intermittent operation.

1.1.4 PFA 710 with PFU 780, stage-controlled main burner

with permanent pilot burner

VR..R

VAG

VBY

TZI

0402–04 06–08 06–08 04

ϑ1

ϑ2

L1, N, PE

BUS

PFU 780

PFA 710

BUS

PLC

Control: main burner ON/OFF

The main burner can be started with reduced capacity after

the operating signal from the pilot burner has been detected.

Pilot and main burners can be operated simultaneously. Both

are ionization-controlled independently.

Control: main burner High/Low

The main burner starts at low-ﬁre rate. When the operating

state is reached, the PFU780L advises the control unit. The

PLC can now pulse the air valve in order to control the capacity

of the main burner.

PFA, BGT · Edition 03.11

2 Certiﬁcation

2.1 EC type-tested and certiﬁed

– Low Voltage Directive (2006/95/EC) in conjunction with EN

60730,

– Electromagnetic Compatibility Directive (2004/108/EC) in

conjunction with the relevant standards relating to radia-

tion.

2.2 Approval for Russia

Certiﬁed by Gosstandart pursuant to GOST-R.

PFA, BGT · Edition 03.11

3 Function

L1, N, PE

BUS

…

PFU

PFA

BUS

…

PFU

PFA

BUS

PROFIBUS-DP

PLC

The ﬁeld bus interface PFA 700 integrates up to nine burner

control units PFU 760 into industrial communication networks

using PROFIBUS DP. The PFA 700 is plugged into the pre-wired

module subrack BGT SA-9U/1DP700, together with the burner

control units.

The ﬁeld bus interface PFA 710 integrates up to eight burner

control units PFU 780 into industrial communication networks

using PROFIBUS DP. The PFA710 is plugged into the pre-wired

module subrack BGTSA-8U/1DP710, together with the burner

control units.

To the rear of the module subrack, there is a D-Sub socket for

connection to PROFIBUS DP and connection terminals in order

to send input and output signals to ignition transformers, gas

and air valves or UV sensors, for example, via the individual

burner control units PFU.

PROFIBUS DP

PROFIBUS is a manufacturer-independent, open ﬁeldbus stand-

ard for diverse applications.

PROFIBUS DP is a bus variant for communication between

automation systems and distributed peripherals at the ﬁeld

level, optimized for speed and low connection costs.

On PROFIBUS DP, the individual bus stations are connected

via a 2-core shielded cable as standard.

The bus system transfers the control signals for starting, re-

setting and for controlling the air valve to purge the furnace

or kiln or for cooling in start-up position and heating during

operation from the control system (PLC) to the PFA. In the op-

posite direction it sends information on the operating status.

3.1 Safety-related control signals

Control signals for the safety interlocks and digital input are

transferred independently of the bus communication by sepa-

rate cables.

3.2 Air valve

The air valves used to purge the furnace or kiln can either be

activated via the PROFIBUS or via a separate cable (to terminal

strip X10 of the BGT – at 24 V DC to terminal 12 or 13, or at

mains voltage to terminal 18).

It is possible to use the PROFIBUS to communicate that purging

is being carried out (by connecting mains voltage to terminal

17 of terminal strip X10 of the BGT).

PFA, BGT · Edition 03.11

3.3 BCSoft

The Windows software BCSoft allows extended access to

individual statistics, visualization of the process values and

the parameterization of the ﬁeld bus interface via an optical

interface. Unit parameters can be adjusted to the speciﬁc

application.

3.4 Conﬁguration, Master-Slave procedure

PROFIBUS DP is structured as a Master-Slave system. This al-

lows mono-master or multi-master systems to be implemented.

A distinction is made between three device types:

– DP Masters Class 1 (DPM1)

DPM1 devices are central controllers which exchange

data with the distributed stations (slaves) on the basis of a

deﬁned cycle. This includes, for instance, the PLC, PC, CNC

or VME systems with which the PROFIBUS DP is operated.

– DP Masters Class 2 (DPM2)

DPM2 devices are programming, project planning or

operator-control devices. They are used for conﬁguration

and commissioning of the system or for system operation

and visualization in ongoing operation.

– DP slaves

The devices which transmit input information from the

periphery to the master and which issue output informa-

tion from the master to the periphery are referred to as

“slaves”.

This also includes the PFA.

3.5 Addressing

A maximum of 126 units (masters and slaves) can be con-

nected to a PROFIBUS DP system. Each station is assigned an

individual PROFIBUS address which can be set between 0 and

126 using two code switches on the PFA board.

114 dec

Function

PFA, BGT · Edition 03.11

3.6 Network technology

All devices are connected in a bus structure (line). Up to 32

stations (masters or slaves) can be connected in a single seg-

ment. The beginning and end of each segment is ﬁtted with

an active bus terminator. Both bus terminators must have a

permanent power supply to ensure error-free operation. The

power supply for the bus terminator is provided by the PFA. The

bus terminator can be connected in the bus connection plug.

If more than 32 stations are implemented or if there is a need

to expand the network area, repeaters (ampliﬁers) must be

used to link the individual bus segments.

3.7 Conﬁguration

When planning a PROFIBUS DP system, unit-speciﬁc param-

eters of each station are to be taken into account.

To allow for simple and standardized planning, the parameters

of the PFA have been summarized in a so-called device master

data ﬁle (GSD). The ﬁle structure is standardized so that it can

be read by the planning devices of different manufacturers.

The GSD ﬁle is supplied on a CD with the PFA. The GSD ﬁle can

also be ordered at www.docuthek.com. The steps required to

copy the ﬁle are described in the instructions for the automa-

tion system.

3.7.1 Bus communication

Input/output bytes: The programmer can choose the data to

be transferred.

Input bytes

(PFA ▶ master)

Output bytes

(master ▶ PFA)

PFA 700 5 bytes 3 bytes

PFA 710 5 bytes 5 bytes

Baud rate: up to 1500 kbit/s.

The max. range per segment depends on the baud rate:

Baud rate [kbit/s] Range

[m] [ft]

93.75 1200 3937

187.5 1000 3280

500 400 1312

1500 200 656

The speciﬁed ranges may be increased by using repeaters.

No more than three repeaters should be connected in series.

The speciﬁed ranges relate to bus cable type A (two-core,

shielded and twisted), e.g.:

Siemens, Order No.: 6XV1830-0EH10, or

Lapp cable unitronic, Order No.: 2170-220T.

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