Flammenüberwachungsgerät F 150

Technica l Descr ip t ion F l a m e M o n i t o r i n g S y s t e m F 1 5 0

LAMTEC Leipzig GmbH & Co KG Schlesierstr. 55, D-04299 Leipzig, Telefon (+49) 03 41 / 86 32 94 00, Telefax (+49) 03 41 / 86 32 94 10

• 19”- Plug in module (3HE, 7TE) • Optical flame monitoring system for

single and multiple burner systems without high grade selectivity de-mands

• Two channel fail safe operation with

electronically self check • Digital flame frequency evaluation • 4-steps of sensitivity adjustment • Status information via LEDs • Bar graph intensity display and test

jacks for intensity 0 - 20 mA • UV- and IR-flame sensors

P ro to type proofed Reg is te red numbers DIN EN 230 for Oil operation DIN EN 298 for Gas operation 72 – hours - TRD 604 operation Prod.-Ident-No.: CE-0085AR0290

LAMTEC Leipzig GmbH & Co. KG

Technical Discription of the Flame Safeguard F150 / FFS 05 ... or FFS 06 …

Edition: 01/07 Page no.: 2

0 Scope 1 Purpose 2 Technical parameters 2.1 Parameters 2.2 Miscellaneous 3 Structure 4 Mode of operation 5 Operation conditions 6 Instructions on assembly and installation 6.1 Assembly 6.1.1 General instructions 6.1.2 FFS 05 ... and FFS 06 … Flame sensors 6.1.3 F 150 Flame monitoring device 6.2 Installation 6.2.1 External installation 6.2.2 Connecting the device 7 Instructions on commissioning and maintenance 7.1 Commissioning 7.1.1 General instructions 7.1.2 Preparatory measures 7.1.3 ”Flame out” state 7.1.4 ”Flame in” state 7.1.5 Flame failure switch-off test 7.2 Maintenance 7.2.1 General instructions 7.2.2 Instructions on troubleshooting 8 Warranty and delivery terms 9 Basic wiring diagram - F 150 / FFS 05 ... or FFS 06 Flame safeguard 10 Layout of checking and operational controls 11 Dimensioned drawings 11.1 F 150 Flame monitoring device 11.2 FFS 05 ... Flame sensors 11.3 FFS 06 … Flame sensors 12 Hook-up drawing F 150 / FFS 05 ... or FFS 06 … 12.1 19 inch casings 12.2 Panel casing (12 TE) and wll-mounted casing (12 TE) 13 Accessories 13.1 19 inch casings 13.1.1 SKT 16 Plug-in cards carrier 13.1.2 Panel casing (12 TE) 13.1.3 Wall-mounted casing (12 TE) 13.2 Adjustable holding devices of the FS 19-10, FS 20-10, FS 36 and FS 41 types for FFS 05 … 13.3 Adjustable holding device FS 60 for FFS 06 … 13.4 Junction box FG 21




0 Scope This description provides instructions on the use of the F 150 Flame Safeguard. 1 Purpose The F 150 Flame Safeguard is a safety device, and complies with the DIN EN 298 and DIN EN 230 standards. The purpose of the flame safeguard is to detect the burner flame of a furnace uninflu-enced by the conditions prevailing in the combustion chamber (such as glowing of lin-ing), and to trigger off, in case of flame rupture, a control command to cut off fuel sup-ply. This device is chiefly used in furnaces, where there are no complicated selection tasks required, e.g. in power stations, heating stations, chemical plants and wood burning plants operated from oil, gas, dust coal or mixture burners. The functioning of the F 150 Flame Safeguard is characterized by a high degree of safety, availability and ease of servicing, what is due to - a digital signal processing, - a dynamic self-check system - an appropriate number of checking and operational controls. The flame safeguard output provides a safe floating switch-over contact. 2 Technical parameters 2.1 Parameters Input values - Flame sensors Required input values produced by the flame radiation to deliver the message: ”Flame in” - spectral radiation range = 260 ... 400 nm (FFS 05 UV1, FFS 05 UV1 Ex, FFS 05 UV-1 Ex II, FFS 06 UV-1) - spectral radiation range = 210 ... 380 nm (FFS 05 UV2, FFS 05 UV2 Ex, FFS 05 UV-1 Ex II, FFS 06 UV-2) - spectral radiation range = 850 ... 1200 nm (FFS 05-1, FFS 05-1 Ex, FFS 05-1 Ex II) - spectral radiation range = 1200 ... 2800 nm (FFS 05, FFS 05 Ex, FFS 05 Ex II, FFS 06) - Pulsation frequency ok. 10...90 Hz




Input values - Flame monitoring device Output contact Switch-over contact - permissible switching voltage 230 V A.C. max.; 30 V D.C.

at least 6 V A.C./D.C. - permissible switching current 0.5 A max.

at least 1 mA - Switching capacity

for direct current 15 W max. for alternate current 250 VA max. (cos ϕ = 0.4)

Safety time ”operation” tVAus ≤ 1 sec other safety times tVAus ≤ 3 sec e.g. pursuant to TRD 413, which are factory-set Dynamic parameters Self-check clock pulse t Clock pulse abt. 3.0 sec for safety time tV of ≤ 1 sec t Clock pulse abt. 6.0 sec for safety time tV of ≤ 3 sec 2.2 Miscellaneous Self-check principle Signal processing is effected via two separate transmission channels, which are se-lected alternately. The output levels are continuously checked for antivalence. Parameter adaptation, Furnace --> Monitoring device A switch located inside the F 150 allows to set four different degrees of intensity. The flame intensity is displayed by means of the green two-stage luminescence display. The transmission range of the digital frequency evaluation allows for a signal passage of 10 and/or 30 Hz to 90 Hz. Signals with a frequency between 45 ... 55 Hz (with a nominal frequency of 50 Hz) are not transmitted.




3 Structure The Flame Safeguard consists of: a flame sensor of the FFS 05 ... or FFS 06 … type, which can be fixed optionally by us-ing one of the FS19, FS 20, FS 36, FS 41 for FFS 05 … or FS 60 for FFS 06 … adjust-able holdung devices, and a flame monitoring device of the F 150 type, which com-prises the following functional units: - digital frequency evaluation unit - self-check unit - switching amplifier - power supply unit. FFS 05 ... Flame sensor The component parts of the sensor circuitry are located on PCBs housed in a cylindrical casing, which is provided with an axial light incidence opening proof against water jets. The flame sensor satisfies the requirements of the IP 65 enclosure type. FFS 06 … Flame sensor The components of the sensor circuit are accommodated on circuit boards in a cylindri-cal casing with radial splash-water proof light inlet opening. The flame sensor meets the requirements of protective type IP 65. F 150 Flame monitoring device The component parts of the functional units are located on a PCB. Its constructional design is suitable for either the use of 19 inch sub-rack system and for such sub-assemblies that allow allocation of 19 inch components (such as Murr Electronics). The checking and operational controls are located on the front panel. The connection of the device is made on the rear side using a plug strip of the D design (see pin configura-tion). The arrangement of the checking and operational controls is illustrated in section 10. 4 Mode of operation (see section 9, basic wiring diagram) FFS 05 ... or FFS 06 Flame sensor The Flame sensor converts the pulsating burner flame radiation into electrical signals. The resulting representation signals are routed to an electronic switch-over contact, which alternately puts the signals through to the two separately working processing channels. These processing channels digitize the signals, this resulting in a conversion of the original signal type into the evaluation criterion ”Pulse length” (information carrier: flame radiation frequency). The F 150 Flame monitoring device is mounted at a distance of the the flame sensor. The connection to the flame monitoring device is made using a five-pole, statically shielded cable.




F 150 Flame monitoring device The F 150 comprises two separately working signal processing channels. The flame signals transmitted by the sensor are regenerated by the input stage of the F 150 and compared with the related reference signals, only those flame signals being processed that are within the preselected transmission range irrespective of their origi-nal amplitude. Signal transmission is effected via two separately working transmission channels. If required, the lower frequency limit can be modified between 10 Hz and 30 Hz using a switch located under the cover hood, this to be done when the F 150 is dis-connected from power. Moreover, it is possible to adapt the device to the flame intensity using a four-position selector switch for intensity remote switching-over. The selection is displayed by a two-stage luminescence row. Before switching on the output relays at the end of each signal processing channel, a safe monitoring of the antivalent switching states, as well as of the response and switch-off delay is effected at the output of the signal processing channels. Any off-limit antiva-lence faults or deviations in time delays result in an immediate switch-off (switching state ”flame out”). The switching states of the signal processing channels and the output relays are dis-played by a red and a green light emitting diode located at the front panel. There are moreover the following connections: - Auxiliary power feed - Connection of the system earth in conformity with DIN VDE 0100, part 540 - Flame sensor connection - Connection of external power circuits to a safe switch-over contact to enable the

”Flame in” and ”Flame out” switching states. 5 Operating conditions Auxiliary power, input + 10% Mains voltage 230 V A.C. - 15% Mains frequency 50 Hz Power consumption abt. 6 VA




Auxiliary power, output for the supply of the flame sensor Max. voltage UH2 30 V D.C. Max. permissible current consumption IH2 15 mA Continuous short-circuit current IK 30 mA Intensity measuring output Output direct current 0 ... 20 mA Maximum burden 500 Ω No-load direct voltage 18 ... 28 V Basic error ± 2% Technical stressability Operating mode continuous operation Creepage path and sparking distance in air DIN VDE 0110 Noise interference IEC 801, part 2,3,4,6 Radio interference suppression The output contacts of the flame safeguard have no radio interference suppression. The user is obliged to take the appropriate measures of radio interference suppression for the whole system. Climatic stressability Application class - FFS 05 … or FFS 06 … Temp. min. -10°C

max. +60°C relative air humidity 80% at 35°C

- F 150 Temp. min. -10°C

max. +60°C relative air humidity 80% at 35°C

Enclosure type FFS 05 ... / FFS 06 … IP 65 F 150 IP 20 It is required to obtain the protection degree of IP 40 for the built-in system by imple-menting appropriate build-in measures.




Weight FFS 05 ... 0.4 kgs FFS 06 … 0,4 kgs F 150 0.5 kgs Cable length between flame sensor and flame monitoring device Serial design FFS 05 … 3m Serial design FFS 06 … 2m On customer’s demand up to 500 m max. Warehousing conditions (in original packing) Storage place closed warehouses Air temperature - 40 ... + 70 °C Air humidity 80% max. at 35°C Transport conditions (in original packing) Type of transport in closed holds Air temperature - 40 ... + 70°C Temperature-to-humidity ratio 80% max. at 35°C Consumables n o n e 6 Instructions on assembly and installation 6.1 Assembly 6.1.1 General instructions Due to the processes occurring during combustion, there is amongst others, a pulsating portion of the flame radiation (flickering of the flame), which oscillation sequence (flame frequency) is used for monitoring. The flame sensor should be aligned in such a way - as to cover the first third of the flame in single monitoring operation - as to cover the root of the flame in the ”Flame in” state (area of high flame frequencies) only the residual radiation in the ”Flame out” state that is emitted by the marginal sec-tions of the other burner flames (area of low flame frequencies) and/or by the reflected radiation. Proper arrangement of the flame sensor is therefore a decisive precondition for a high availability and/or the possible degree of selection.




WARNING ! The sensor cable must be routed separately from mains and control cables, as well as power cables or power equipment (such as ignition lines, ignition transformer, electrical motors, contactors). Cable routing parallel to mains cables in the same cable duct is not allowed. 6.1.2 FFS 05 and FFS 06 Flame Sensor Dimensions see dimensioned drawing, item 11.2 and 11.3 Weight abt. 0.4 kgs Cable type FFS 05 stranded hook-up wire LiYCY (blue, red, green, yellow, white)

5 x 1 x 0.5 mm² (AWG 20) Cable type FFS 06 stranded hook-up wire LiYCY (blue, red, green, yellow, white,

pink) 6 x 1 x 0.5 mm² (AWG 20) The Flame sensor is supplied with a connection cable. The feed cable can be extended up to 500 m between flame sensor and flame monitoring device. For an extension to be installed on site, we recommend to use a separate, shielded five-core extension cable, which can be connected with the sensor feed cable using the FG 21 junction box. Connect the sensor casing to the system earth by means of the casing screw marked with the earthing sign. The cable shielding must not be used as low frequency carrying system earth connec-tion. Install an earth compensating line between the sensor casing connection and the flame monitoring device connection to system earths separated from each other by the related distance. Mount the Flame sensor to the socket piece of the scanning opening, through which the burner flame must be properly visible throughout the furnace operating range. For a se-lective monitoring, locate the scanning opening in such a way that the flame sensor covers the root of the flame to be monitored (near the burner nozzle). Note that the longer the socket piece is the more the range covered by the flame sensor is limited. The scanning opening must be sealed by an appropriate protective glass. 6.1.3. The F 150 Flame monitoring device Dimensions see dimensioned drawing, item 11.1 Install the flame monitoring device at a vibration-free location. The installation site must be easily accessible to enable easy control of the visual checking controls during fur-nace operation. When replacing the flame monitoring device, the installation of device with the same marking is required. Make sure that the maximally permissible ambient temperature of the installation site does not exceed 60°C.




6.2 Installation 6.2.1 External installation The flame safeguard ready for operation delivers the ”Flame in” and ”Flame out” state messages to a floating contact output. Further signal processing must be effected by means of a control unit adapted to the respective furnace. In order to provide for operating safety make sure when installing the output contacts that the circuitry of the radio interference suppression to be provided by the user is car-ried out in such a way that there is no risk of shorting out the contacts by defective component parts of the suppressor circuitry. 6.2.2 Connecting the device See connecting diagram, item 12, page 16 7 Instructions on commissioning and maintenance 7.1 Commissioning 7.1.1 General instructions Check the flame sensor for proper positioning. Before connecting the flame monitoring device to the auxiliary energy, check the con-nections of the terminal strip of the flame monitoring device located in the subrack on the basis of the connecting diagram. 7.1.2 Preparatory measures Set the intensity switch for the evaluation of the flame intensity accordingly Position 1: big flame = low boosting Position 2: big flame = medium boosting Position 3: small flame = high boosting Position 4: small flame = very high boosting 7.1.3 ”Flame out” state After powering on the auxiliary energy, the flame sensor becomes ready for service within 10 sec. The display should show the following: - ”Flame out” message LED ”red” light




7.1.4 ”Flame in” state In order to check the monitoring functions, temporarily install the flame sensor at the predetermined position with the furnace being in operation. When the flame burns naturally, the display should change as follows: LED ”red” goes out LED ”green” lights, while changing its intensity antivalently in the rhythme of the

clock pulse 7.1.5 Flame failure switch-off test Simulate the burning away of the flame from the nozzle or extinguishing of the flame. To this end, cut off the fuel supply to the burner monitored by the sensor. Check that after the extinguishing of the flame, the signal for closing the safety cut-off valve is triggered off within a period of TS < 1. LED ”red” lights LED ”green” is off 7.2 Maintenance 7.2.1 General instructions Clean at regular intervals the light incidence opening of the flame sensor and the related scanning opening of the furnace, the intervals depending on the actual operating condi-tions of the plant. The F 150 Flame monitoring device is maintenance-free. The maintenance cycle of the plant should include a check of the flame failure switch-off. 7.2.2 Instructions on troubleshooting The flame safeguard is a safety device. Any repair work or other changes to the device shall only be effected by the manufacturer’s specialist staff or by some other person appointed by the manufacturer. Any other person is not allowed to operate on parts in-side the device. 8 Warranty and delivery terms The manufacturer’s warranty conditions shall apply. Any changes to and operations on components of the flame sensor or the monitoring device carried out during the war-ranty period by unauthorized persons will result in a refusal of claims under warranty. Delivery complies with ordering details. The terms of services and supplies of LAMTEC Leipzig GmbH & Co. KG, as well as the general terms of delivery for products and ser-vices of the electrical industry shall apply.




9 Basic wiring diagram - F 150 / FFS 05 ... or FFS 06 Flame safeguard




10 Layout of checking and operational controls

1 LED (green) ”Flame in” 2 LED (red) ”Flame out” 3 Intensity display 4 Intensity selector switch




11 Dimensioned drawings 11.1 F 150 Flame monitoring device




11.2 FFS 05 ... Flame sensors Light entry port Ø 22 Ø 40 ± 0,2 M4 Protective wire connection point Fm lead bending radius at least 25 Stranded hook-up wire LiYCY Type plate 5 x 1 x 0,5 mm² Shield (black) blue white red green yellow




11.3 FFS 06 … Flame sensors The Flame Sensor is to be connected according to the colour coding of F 150 terminal assignment. Notice The connecting cable has an additional measurement wire (pink) which can be used for a standard isolated analog or digital hand held multimeter (acc. to EN 61010 , input impedance >5 MΩ) to measure the signal voltage. The voltage is measured against the ground potential (blue wire) of the connecting cable to adjust the direction for an optimum of flame detection. Stranded hook-up wire LiYCY 6 x 1 x 0.5 mm²

(black, blue, red, green, white, yellow, pink)




12 Hook-up drawing F 150 / FFS 05 ... or FFS 06 … 12.1 SKT 16 Plug-in cards carrier High frequency stop filter Channel B

gn + 24 V Channel A 24 V GND Intensity signal GND clock pulse

Shielded rt casing

Channel A Channel B 0,5 A 0,5 A A4 A6 A2 A10 A12 A14 A8 A16 A20 A18 A22 A24 A26 A28 A30 A32

bk bu rd gn wh ye

M PE - + L N PE Normally- Normally- Intensity Flame sensor 230 V AC closed open measuring FFS 05 … or FFS 06 … contact contact output 12.2 Panel casing (12 TE) and wall-mounted casing (12 TE) Intensity Mains voltage Output 0...20 mA Flame sensors 230 V AC contact bk bu rd gn wh ye




13 Accessories 13.1 19 inch casings 13.1.1 SKT 16 Plug-in cards carrier

(can be fixed by screwing or install by top hat rail according to DIN EN 50022)

Dimensions W x H x D (T1) 45 x 112 x 145 (215) T1 = reducing scale with plug-in card and front panel




13.1.2 Panel casing (12 TE) Part of the switchboard: 69+0.7 x 137+1.0 Enclosure type: IP 65 (front side)




13.1.3 Wall-mounted casing (12 TE) - IP 65 enclosure type




13.2 Adjustable holding devices of the FS 19-10, FS 20-10, FS 36 and FS 41

types for Flame sensor FFS 05 … FS 19-10 (without ball-and-socket joint, with scavenging air connection)

± 5

40°

Ø270

160

75

150

54

~~~

110

89

( 5

5 )

Ø

Ø

* G2;

12

tief

½"

1"

Ø 11,5

FS 20-10 (with ball-and-socket joint)

+ 5

160

75

Scavenging air

Flame

Ball-and socket joint Insulating socket Flame Clamping ring Sensor connection Scavenging air View A

sensorClamping ring

ionconnectInsulatingsocket

252

167

+ 2

+ 5

( 92 )+ 2

38

½"

1"




FS 36 (with adjsutable clevis-type suspension device and scavenging air connection)

G1"

113

48

4530°

Ø 120

Ø 14

Ø 11,5

ca. 407

89

Ø

Ø

ca. 270 Cooling cylinder, where Demountable the flame sensor fits in flange support Scavenging air connection G 1/2” Flange outlines and bore sketch fixing 2 x MB (∅ 11,5) 1 x M 10 (∅ 14) FS 41 (with ball-and-socket joint and cooling air housing)

A

ca. 265

G1"

40°

54~

14

15

~

Cooling cylinder, where the flame sensor fits in Flame sensor View A analog FS 20-10 Scavenging air connection G 1/2”




13.3 Adjustable holding device FS 60 for FFS 06 ...

56

46

ø 25,0

5

40

ø4,5

56

56

ø 24,50

13.4 Junction box FG 21 FG 21 (Aluminium) Overall height 60

Weight: abt. 0.43 kgs Enclosure type: IP 65 Field of application: -30°C / +90°C relative air humidity 50% at 40°C 100% at 25°C (for short periods only)

79 63

52

74

A C D E FB

bk bl rd gn wt ye1 2 3 4 5 6

X1

X2

M 20 x 1,5

A...G

G

7pk

M 20 x 1,5

Ordering designations - FG 21 junction box Note: When ordering the junction box, the related sensor must be ordered as well inde-

cating the ordering designation ”FFS 05 ... or FFS 06 ... Flame senor with plug for FG 21”.

Flammenüberwachungsgerät F 150

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