Fibre Optic System D-LL 703/704

Transcription

1 English 03/2005 Fibre Optic System D-LL 703/704 with Compact Flame Scanner D-LX 700 Preliminary Manual DURAG GmbH Kollaustraße 105 D Hamburg Tel Fax Internet:

2 ! Important Notice! Flame monitors are safety relevant devices which shall ensure a safe operation of furnaces. Please read this manual carefully before setting the flame monitor into operation. The adjustment of flame monitors shall be carried out only by trained staff. Therefore, DURAG offers suitable courses. Flame Monitors are certified devices. Any modifications will result in a loss of such certification. Repairs should be made only by the manufacturer or its representatives.

3 D-LX 700 Table of Contents 1. General Information Block Diagram Functional Description Self-Check Fault Error Codes of the 1 st CPU: Installation Start-Up Programming the Flame Scanner Setting the Flame Recognition Threshold Flame Recognition Thresholds as a Function of the Rocker Switch Setting Setting the Amplification D-ZS Digital Display Unit Safety Time Integrated Flame Scanner Infrared Flame Scanner Selection Criteria for the D-LX 700 Compact Flame Scanner Options Technical Data Technical Data of the Compact Flame Scanner Technical Data and Configuration of Inputs and Outputs D-LX 700 Dimensional Drawing D-LX 700 Wiring Diagram General Information about the D-LL 703 Fibre Optic System Mounting the D-LL 703/704 Fibre Optic System Installing the fibre optic system in tilting burner applications Purge and Cooling Air Purge and cooling air for the D-LL 703 fibre optic system Purge and cooling air for the D-LL 704 fibre optic system Technical Data D-LL 703/ Model Overview for the D-LL 703 series Model Overview for the D-LL 704 series Mounting and disassembling the D-LL 703 fibre optic system D-LL 703 Materials List Uninstalling the fibre optic connector of the D-LL Mounting the fibre optic conductor of the D-LL Mounting and disassembling the D-LL 704 fibre optic system Materials list for the D-LL 704 series Disassembly of the fibre optic conductor of the D-LL Mounting the fibre optic conductor of the D-LL Dimensional Drawing of the D-LL 703/D-LE Dimensional Drawing of the D-LL Installation Drawing of the D-LL Optional Accessory Devices and Spare Parts Dimensional Drawing of the D-ZS 702/703 mounting flange Dimensional Drawing of the D-ZS 704 welded flange Spare parts list for the D-LL 703/

4 D-LX 700 Illustrations (Fig. 1) D-LX 700 block diagram...2 (Fig. 2) D-LX 700 with D-ZS (Fig. 3) Location of fuses...5 (Fig. 4) Flame recognition thresholds as function of the rocker switch setting...8 (Fig. 5) Dimensional drawing: D-LX (Fig. 6) Wiring diagram: D-LX 700 -P...14 (Fig. 7) Cable and Shielding...15 (Fig. 8) Power supply and error suppression...15 (Fig. 9) Laying the outer carrier tube of the D-LL (Fig. 10) Changes in the flame viewing range in tilting burner applications...18 (Fig. 11) Graph of purge and cooling air volumes for the D-LL (Fig. 12) Graph of purge and cooling air volume for the D-LL (Fig. 13) Outer carrier tube D-OC (Fig. 14) Inner carrier tube D-IC (Fig. 15) Mounting the D-IC 703 optic holder...23 (Fig. 16) Fibre optic bundle D-FO (Fig. 16) (Fig. 17) Mounting the flame scanner end of the D-LL 703 fibre optics...24 Aligning the fibre optic bundle and the guide tube...25 (Fig. 18) Disassembly of the scanner-side D-LL 704 fibre optic bundle...26 (Fig. 19) Assembly and disassembly of the D-LL 704 fibre optic bundle...26 (Fig. 20) Installation and assembly of the D-LL 704 cooling and purge air connections...27 (Fig. 21) Dimensional drawing of the D-LL (Fig. 22) Dimensional drawing of the D-LL 704 fibre optic system...29 (Fig. 23) Installation Drawing of the D-LL (Fig. 24) Dimensional drawing of mounting flange D-ZS (Fig. 25) Dimensional drawing of welding flange D-ZS (Fig. 26) Spare parts for the D-LL 703/ Tables (Table 1) Model overview D-LL (Table 2) Model overview for the D-LL 704 series...22 (Table 3) D-LL 703 components list...22 (Table 4) Component list for the D-LL 704 series...25 (Table 5) Spare parts for D-LL (Table 6) Spare parts for the D-LL

5 D-LX 700 Page 1 1. General Information The D-LX 700 Compact Flame Scanner consists of a control unit and an optical flame scanner. The flame scanner is suitable for monitoring flames from a variety of fuels and combustion techniques, particularly in single burner applications. Uses for this flame scanner include remote heating stations, chemical processes or thermal flue gas combustion systems. The D-LX 700 Compact Flame Scanner offers an extremely high degree of safety and availability by using two microprocessors operating in parallel, with corresponding hardware and software. The hardware is designed to follow all EC guidelines and laws relevant to electromagnetic compatibility. Thanks to the fail-safe design of the hardware, and the software s continuous checks of all safetyrelated functions, the D-LX 700 meets the European standards EN 230 (oil) and EN 298 (gas), as well as technical guidelines for steam boilers TRD 411 to 414 and TRD 604 for intermittent, continuous and 72-hour operation. In order to accurately monitor various types of flames and combustion conditions, five different models are available, with spectral sensitivities in the UV and IR spectrums. The flame recognition threshold for the flame scanner can be programmed to one of ten different settings using a rocker switch on the front panel. The scanner s safety time, which refers to the number of seconds before the scanner will signal flame outage, is set at the factory to 1 s. Longer safety periods of 3 or 5 s may be programmed in upon request. If one chooses the most suitable compact flame scanner, positions it correctly on the sighting tube, and properly sets the threshold, one will always be able to selectively monitor single burners or even a furnace. The essential operational groups of the control unit are depicted in the D-LX 700 block diagram (fig. 1): Dual-channel microprocessor systems for control and oversight of flame monitoring functions. Integrated flame scanner with shutter drive for performing self-checks. Dynamically driven fault relay, K1; internal operating voltages and all safety-related hardware functions are monitored. Guided flame relay, K2, with self-checking circuit. Programmable flame recognition threshold LED display for indicating operational readiness, flame signal or fault (or 0-20) ma analog output for external display of flame intensity.

6 Page 2 D-LX Block Diagram Flame Monitor UA / UAF / IS / IG Amplifier Photo element Filter Pulse stage Pulse Shutter Flame threshold Safety time soldering field LED indicator Data compare Synchronization Current output 0 / 4-20mA Flame intensity RAZ Read back flame relay Flame ON K2 K2.2 Internal reset Power supply UB Dynamic safety circuit K1 K1.1 K1.2 ready for operation LX F1 0V UB 0V F2 Power supply L- L+ PE (Fig. 1) D-LX 700 block diagram

7 D-LX 700 Page 3 3. Functional Description The photo elements used in the integrated optical flame scanner evaluate different spectral ranges of the flame. Those scanners with semiconductor photo elements cover ranges from short-wave UV-A to infrared. The signal from the photo element passes through an amplifier with suppression of any constant (non-dynamic) emitted energy. This amplifier can be set to one of two different levels. After the amplifier, the signal runs through a high-pass filter and a pulse generation stage. The pulses generated by the integrated flame scanners, which offer a measure of the flame intensity, are transmitted to the microprocessor system and will trigger a flame ON or OFF signal, depending on the flame recognition threshold programmed in. Three features are available for the flame signal: 1) a fail-safe relay contact, K2, 2) a green LED on the front panel, and 3) a current output for display of the flame intensity. The current output is set at the factory to either 4-20 or 0-20 ma. Both operational readiness and fault status are signaled via a contact in the K1 fault relay, and either a yellow (ready) or red (fault) LED on the front panel. The DURAG D-ZS Display Unit may be plugged into the jack on the front panel. This device displays the flame intensity as a pulse signal between 0 and 4095 pulses/sec. and further aides in setting the proper flame recognition threshold. Digital Display D-ZS (only for setup) Reset Mode D-ZS Connection for D-ZS V2 D-ZS D-LX V1 Gain selection (covered by housing) Status display Reset button Flame threshold adjustment (Fig. 2) D-LX 700 with D-ZS 087

8 Page 4 D-LX Self-Check The D-LX 700 Compact Flame Scanner is fail-safe and self-checking, in accordance with European EN standards for flame scanning equipment. After power-up, the flame scanner performs a selfcheck, which is constantly performed during continuous operation. If employed for continuous operation, any component failure that jeopardizes the safety-related functions of a scanner must trigger an error shutdown. The D-LX 700 is therefore equipped with a dual-channel microprocessor system. This system controls all functions and self-checks, and monitors all safety-related timing sequences. Input and output status is independently checked and compared by the microprocessors. Only if they agree is operation allowed to continue. If the controller signals flame ON, the integrated flame scanner is automatically monitored. This occurs every second for 0.2 s via the activation of a shutter. The shutter is a transistor separating the photo element from the electronics. The interruption of the photocurrent simulates the outage of a flame and must result in a drop in the flame signal that was present during the 0.8 s that the scanner was monitoring the flame. If a hardware problem causes too little a decrease in the flame signal, an error shutdown will occur after eight such cycles, that is, after eight seconds. If the flame ON signal is stopped, the integrated flame scanner is also no longer checked. 5. Fault If the internal self-check recognizes an error in the safety-related software and hardware components, an error shutdown and internal lockout must be triggered. The relays for the flame, operational readiness and fault signals are released, and the red LED on the front panel will begin blinking. The contact from K1 signals the present fault. The red LED blinks 5 times by itself. After that, the yellow LED will also begin blinking with the red. The number of times that the yellow LED blinks corresponds to the type of error, which allows the operator to precisely analyze the source of the fault. The following error sources can be signaled: 5.1. Error Codes of the 1 st CPU: Error Code Yellow LED Blinks Source of Error Possible Cause of the Error 1. 1 x Synchronization defective / faulty microprocessor circuit 2. 2 x 2 nd CPU 2 nd CPU is indicating an error (no display of its own) 3. 3 x FOS cycle defective cycle generation / faulty acknowledgment 4. 4 x Flame signal relay defective drive / faulty acknowledgment 5. 5 x Flame signal contact defective / faulty acknowledgment of the contact position 6. 6 x Status signal relay defective drive / faulty acknowledgment 7. 7 x Flame comparison faulty transmission of flame data 8. 8 x Flame recognition threshold push button switch on front panel pressed by unauthorized personnel 9. 9 x Safety time unauthorized change in the soldering field x PROM test defective / faulty microprocessor circuit x RAM test defective / faulty microprocessor circuit x Flag test defective / faulty microprocessor circuit x CPU test defective / faulty microprocessor circuit

9 D-LX 700 Page 5 If the cause of the error is a defect in the integrated flame scanner, the red and green LED s will blink alternately. Pressing the reset button on the front panel of the D-LX 700 acknowledges a fault in the unit and allows flame scanning functions to continue after restart. When the reset button is pressed, all LEDs will go off. It is also possible to reset the unit by open the plug connection or by interrupting the yellow 24 V supply wire for a short moment. In this case the cover of the flame scanner doesn t have to be opened in order to get access to the reset button. If the power supply is interrupted or the reset button is pressed, the relays are released, regardless of the status of the unit (flame signal ON / OFF or fault). The flame scanning program is then restarted. 6. Installation Installation occurs according to the D-LX 700 dimensional drawings. The electrical installation must be performed in accordance with the wiring diagram in this manual, as well as any local guidelines. The location of fuses F1 and F2 can be found in the dimensional drawing. The enclosure rating of the flame scanner is IP67 if it is a model with the plug connection. F2 = Flame contact fuse No6 V2 D-ZS D-LX V1 F1 = Mains fuse No4 (Fig. 3) Location of fuses Note: To change the amplification or to replace the fuses, the electronics must be pulled from the housing. Due to the D-LX 700 s compact design, one must observe that no wires get pinched when putting the scanner back together. The housing should be closed without using excessive force.

10 Page 6 D-LX 700 To guarantee the best, most selective flame monitoring, one must determine the correct position of the scanner, since the flame must be visible to the flame scanner at all times, regardless of the load range of the burner. The 6 angle of view should always be oriented toward the root of the flame, that is, the bottom third of the flame. For optimal alignment of the flame scanner, the D-LX 700 uses a 4-20 ma (or 0-20 ma, if desired) current output which displays the flame intensity. Note: the current output leads are not galvanically separated from the internal voltage supply. To avoid having faults attributed to the flame scanner, these leads may need to be shielded. As a rule, however, shielding is not required for cable lengths below 15 ft (5 m). For high availability in the system, the power supply equipment and the flame scanner must be properly timed (power supply and maximum time for outages).! When connecting the flame scanner, all local regulations must be observed. The flame scanner is equipped with a safety screw to ensure that the scanner is firmly in place. Always be certain that the flame scanner has been mounted properly Start-Up Once mounted and connected according to the drawings and diagrams in this manual, the D-LX 700 Compact Flame Scanner is immediately ready for operation once power is supplied. 7. Programming the Flame Scanner The flame scanner is equipped with a rocker switch for adjusting the flame recognition threshold of the flame relay. This threshold may be set to one of ten levels. The scanner is also equipped with a hook switch for adjusting the amplification of the photo current to one of two different levels. The rocker switch is accessible after removing the cover plate. The hook switch is still obscured by the housing even if the cover plate has been removed, since it is only intended to be switched under special circumstances for dampening very high flame signals.

11 D-LX 700 Page Setting the Flame Recognition Threshold By setting the flame recognition threshold on the flame scanner, the operator of the combustion system determines whether the flame signal (pulse frequency) of the integrated flame scanner should generate a flame ON or flame OFF signal. This threshold is set using the push button switch on the front panel, and may be programmed to one of ten settings. After start-up, the threshold setting must be protected from unauthorized changes. Switch setting 0 is the highest threshold. The flame scanner must generate a strong flame signal in order to register flame ON. Position 9 is the lowest threshold. A weak flame signal is sufficient to trigger and maintain a flame ON signal.! The operator uses this threshold setting to determine when the flame scanner signals flame ON or OFF. The green (flame ON) LED and the 4-20 ma (or 0-20 ma) analog output for flame intensity may be used to select the proper switch position. However, use of the D-ZS Digital Display Unit is recommended. When setting the flame recognition threshold, one must always consider the possible influence of ambient light. This can play a role both in multi-burner and single burner applications. Flame OFF Setting: If the burner is shut down, the flame recognition threshold (switch-on threshold) must be set high enough that the flame scanner does not see any ambient light and reliably signals Flame OFF : the green Flame LED is not illuminated, the current in the flame intensity measurement circuit is less than 8 (or 5) ma, the fail-safe relay output to the external flame ON signal is open. Flame ON Setting: If the burner is operating, the flame signal must reliably exceed the flame recognition (shut-off) threshold and signal Flame ON : the green Flame LED is illuminated, the current in the flame intensity measurement circuit is greater than 12 (or 10) ma the fail-safe relay output to the external flame ON signal is closed. Example: The flame recognition threshold is set on site such that a flame ON signal is reliably present given sufficient flame intensity, under all load conditions. That is to say, the flame intensity current display fluctuates between 12 (or 10) and 20 ma. If the flame image deteriorates too much, the flame signal (pulse frequency) must dip below the shut-off threshold. The safety time programmed into the scanner will then begin to run. After the safety time expires, the flame OFF signal is given and the green LED goes out (flame intensity current is less than 8 (or 5) ma).! Once the scanner s alignment and flame recognition threshold have been properly determined, the D-LX 700 must reliably report if a burner is shut down or if an impermissible deterioration of the flame image occurs. Consideration must be given in order that ambient light sources do not generate faulty system status. The operator must see to it that the settings are never changed by unauthorized personnel. If the flame recognition threshold is changed, one must be aware that if the rocker switch is not pressed all the way, it is possible to have the scanner programmed to an intermediate setting, between settings 1 and 2, for example. If the switch is stuck in one of these undefined settings for more than 8 s, an error shutdown will occur.

12 Page 8 D-LX Flame Recognition Thresholds as a Function of the Rocker Switch Setting Rocker Switch Setting Beginning of Range 0/4 ma Shut-off Threshold 5/8 ma Switch-On Threshold 5/8 ma End of Range 20 ma * The flame recognition threshold is set to position 8 when delivered from the factory Pulse frequency Beginning of Range 0 / 4 ma 1000 Shut-Off Threshold 5 / 8 ma Switch-On Threshold5 / 8 ma UG End of Range 20mA Rocker Switch Setting (Fig. 4) Flame recognition thresholds as function of the rocker switch setting

13 D-LX 700 Page Setting the Amplification In most cases it is unnecessary to set the amplification of the photo element signal. However, if signal saturation should occur due to a very intense flame signal, the amplification hook switch can be moved from position V2 to position V1. The hook switch is mounted near the photo element. The housing must be removed in order to gain access to it. The four Allen screws must be loosened and the electronics insert pulled from the housing. When putting the housing back together, the housing s o-ring must be in the correct position, and the cable bundle must lie inside the housing such that the electronics can be re-inserted without using excessive force and without pinching the cable bundle. Once the housing is back in place, the Allen screws must be screwed back in D-ZS Digital Display Unit By connecting the D-ZS 087 display unit, the flame intensity can be displayed as a pulse signal, from pulses. Furthermore, the minimum and maximum values are stored, and the thresholds for the flame ON and flame OFF ranges are calculated. This allows the operator to determine the optimal threshold between ambient light (relay must remain in the OFF position) and flame (relay must remain in the ON position, even if flame intensity is minimal). 8. Safety Time The safety time is the response time of the flame scanner to the outage of the flame signal (pulse frequency of the integrated flame scanner) and the resulting shut-off of the relay contact for the flame ON signal. The D-LX 700 has a standard safety time of 1 s. Safety times of 3 and 5 s are available upon request. Should the safety time need to be changed, the following steps must be followed: 9. Integrated Flame Scanner In order that the flame scanner can be used in burner applications with the widest variety of fuels, 2 UV and 2 IR flame scanner models are available. All flame scanners with a semiconductor photo element have the same electronic shutter in common. The scanners use this shutter to perform a continuous check of the internal signal amplifier and filter. The signal amplifier can be set to one of two levels. Amplification level V2 is higher than V1 by a factor of three. The scanner comes from the factory having been set to V2.

14 Page 10 D-LX Infrared Flame Scanner The IR zone of a flame is in many cases large and, relative to UV radiation, very intense. The IR zone is easy to acquire under different angles of view, is strong in signal, and is not sensitive to absorption by gases. Compared to a UV flame scanner, however, it is more sensitive to ambient light. A silicon photo element with a spectral sensitivity of λ= 300 nm to 1100 nm is used in the D-LX 700 IS. This flame scanner detects visible light. If the flame is red or orange in color, it is visible to the scanner, on the pre-condition, however, that there is movement in the flame, i.e., the flame is dynamic. The D-LX 700 IG A employs a germanium photo element with a spectral sensitivity of λ = 780 nm to 1800 nm. The integrated flame scanner will therefore acquire the dynamic range of radiation generated by nearly all fuels. This type of flame scanner is strong in signal, but demonstrates lower selectivity due to the large IR zone. Flames whose short-wave UV radiation is absorbed by dust, water vapor or other materials can be monitored in the IR range. Applications include waste incinerators and oil-fired combustion systems. In the case of the latter, IR monitoring in the spectral range of 300 to 1100 nm is typical. IR flame scanners with a spectral sensitivity up to 1800 nm have proven themselves especially effective in applications employing measures for NO x reduction, e.g., flue gas re-circulation or systems with combination burners for gas and oil. Note: It can occur in practice that static emitters, like glowing boiler components, become modulated by combustion air currents or flue gas clouds, and work like ambient light with dynamic portions of radiation. Should this radiation lie in the range received by the scanner, i.e., in the IR spectrum, and within the normal flicker frequency range (approx. 10 to 200 Hz), an output signal will be generated by the flame scanner in the form of a pulse frequency corresponding to the intensity and dynamics of the received radiation. The flame recognition threshold (pulse threshold) of the D-LX 700 may not in this case be exceeded by the pulse frequency of the integrated flame scanner and cannot be allowed to trigger a flame ON signal (see section 6: Setting the Flame Recognition Threshold on the Flame Scanner).

15 D-LX 700 Page Selection Criteria for the D-LX 700 Compact Flame Scanner Model Spectral Suitable for Following Fuels Characteristics Range [nm] Gas Oil Coal Wood D-LX 700 UA D-LX 700 UAF D-LX 700 IS ! Monitoring of gas and oil flames; also for low-no x combustion. Monitoring of very intense gas and oil flames; also for low- NO x combustion. Monitoring of oil burners, even if additional fuels are also combusted. D-LX 700 IG Monitoring of oil and wood flames, as well as coal flames. Explanation of symbols: ++ Flame scanner is ideally suited for this fuel. + Flame scanner is well suited for this fuel. Flame scanner is conditionally suited for this fuel. The monitoring characteristics depend for the most part on the combustion technique.! Due to local regulations the flame sensor might not be approved for monitoring of gas flames. This information is based on years of experience in a great proportion of combustion systems. Variations due to differing flame behaviour, caused by special combustion techniques cannot be taken into account or excluded. Therefore, deviations from table are possible Options The D-LX 700 Compact Scanner is normally delivered with the options listed in the table below. Should other options be required, please make them known when ordering. Flame intensity current output 0-20 ma 4-20 ma Safety time 1 s 3 s 5 s Note: the options shown in the shaded areas are standard; please indicate when placing an order whether any of the other options shown are desired instead.

16 Page 12 D-LX Technical Data Permissible ambient temperatures: -20 C +60 C (0 F +140 F, (other temperatures upon request) Safety time:...1 s (other times available upon request) Permissible operating modes:...intermittent and continuous operation; 72-hour operation in systems operating according to TRD 604 Enclosure rating (EN 60529):...IP67 Electrical connection:...1.5m (5 ft.) cable (8 conductor, 1 mm² / 18 gauge), T = -60 to +180 C (-80 F to 360 F) Weight:...approx. 1.8 kg (4 lb.) Technical Data of the Compact Flame Scanner Spectral sensitivity nm nm D-LX 700 UA 280 nm nm D-LX 700 UAF 300 nm nm D-LX 700 IS 780 nm nm D-LX 700 IG Flame scanner amplification:...2 levels: standard V2= V1x3, (not D-LX 700 UL) Technical Data and Configuration of Inputs and Outputs Connection to power supply...l+, L-, PE / grounded lead Power supply:...24 VDC ± 20%, approx. 5 W Fuse protection:...f1= A, semi-slow, MST 250 Current output 0 / 4-20 ma...flame intensity / 150 Ohm maximum load Flame contact...closer; active if flame is present Fault contact...closer; active if no fault is present Series connection with the flame contact as possible second shut-off path. Switching capacity of the relay contacts / fuse F2, slow, MST250: min:...10 VAC/dc, 10 ma max: VAC, 2.0 A / cosϕ=1,0 (resistive load), F2= 2A slow 1.0 A / cosϕ=0,4 (inductive load), F2= 1A slow 0.2 A / cosϕ=0,2 (inductive load), F2=0.2A slow 24 VDC, 0.5 A with spark extinc. F2=0.5A slow 110 VDC, 0.2 A with spark extinc. F2=0.2A slow 220 VDC, 0.1 A with spark extinc. F2=0.1A slow The flame scanner is constructed such that there is potential separation between the power supply (24 VDC) and the unit s internal voltage (UB = 20 VDC / 5 VDC). The current output is galvanically connected to the internal voltage. The relay contact for the flame ON signal is delivered with a fuse, F2 = 0.5 A, slow, MST250, for 24 VDC voltage switches. If connecting other switch voltages, this fuse must be exchanged accordingly.

17 D-LX 700 Page D-LX 700 Dimensional Drawing Cover LX (Fig. 5) Dimensional drawing: D-LX 700

18 Page 14 D-LX D-LX 700 Wiring Diagram F ge / YE sw / BK gn/ge GN/YE ws / WH L+ DC Mains L- Protective Earth Flame Message ON L L+ N L- PE D-NG 24/05 AC-Power Supply L1 AC Mains N Protective Earth Flame Relay K2.2 2 Ready for Operation! Fault Relay K1.2 F2 1 Contact Circuit Supply 0 / 4 20mA 5 gn / GN 0 Volt 4 gr / GR Flame Intensity Lx Not Connected Plug M2 (Fig. 6) Wiring diagram: D-LX 700 -P! The Flame-On-Message has to be supplied via fuse F2 on the Contact Circuit Supply input. Only such components are allowed to be connected to the output Read for Operation which are non-interacting. These components can be for example the coil of a relay or a magnetic switch. Then the flame relays contact is protected against contact welding in accordance with EN 298. Contacts K1.2 and K2.2 must be switched in series if the additional safety requirements for direct shut-off of the entire fuel supply are to be fulfilled. These are specified in VDE0116, paragraph /10.98 or TRD 604, pages 1 and 2 for 72-hour operation (steam boiler without constant supervision).

19 D-LX 700 Page Cable and Shielding The D-LX 700 is designed for the connection of 230 VAC via the fault contact and flame contact, while the system operates in the low-voltage 24 VDC range. If the contacts are to be used in the high-voltage 230 VAC range, either an appropriately insulated cable must be used to cover the entire distance from the flame scanner, or a distributor panel needs to be installed, with separate cables used after it. Shielding, if needed at all, is only required for the current output because the internal voltages of the flame scanner (0V and 5V) lead out from the flame scanner via this output. Recommendation: Separate 3 high-voltage conductors and a protective ground as early as possible (up to 5m) from the low-voltage line and then lay 2 or 3 separate cables over greater distances: D-LX 100 Junction box 3 wires for relay contacts (q1) no shield necessary 8 1 wire PE max. 5m Silflex cable, 8 x 1mm 2 unshielded, 230 VAC applications LX wires for 24 VDC supply (q2) shield may be necessary 2 wires current output (q3) shield necessary (Fig. 7) Cable and Shielding Diameters q1 and q3 can be determined by conditions on site. Diameter q2 must be great enough that resistance per conductor does not exceed R= 10Ω. The D-LX 700 operates then at 24V - (200mA x 2 x 10Ω) = 20V still permissible. The D-LX 700 is constructed potential free. There is no connection between power supply and grounded housing. If the flame monitor stops operation because of a flame sensor-error (red and green LEDs flash) this potential separation may be responsible for that. In that case a capacitive connection of C1= approx. 100nF or a direct connection B1 may help (but with B1 you loose the separation of potentials!) LX Boiler Viewing pipe D-LX PE B1 C1 L+ L - Power supply (Fig. 8) Power supply and error suppression

20 Page 16 D-LX General Information about the D-LL 703 Fibre Optic System The D-LL 703 fibre optic system consists of a fibre optic bundle including the lens system (D-FO 703), an inner carrier assembly with purge air connection and the threaded flame scanner mount (D-IC 703), and an outer carrier assembly including cooling air connection and mounting flange for welding (D-OC 703). The forward section of the D-LL 703 fibre optic system carrier components is flexible. This allows the scanner to monitor the flames of tilting burners. In these applications, the flange of the outer carrier assembly should be welded to the moving portion of the burner facing the flame. If the burner is moved up to a new location to distribute heat, the scanner will be automatically adjusted to the new flame location. Another suitable application for the fibre optic system is for installations that do not have a direct line of sight from the flame scanner to the burner flame. These fibre optic systems are available for two different spectral ranges: the UV flame scanner D-LX 703 UA/UAF is compatible with the D-LL 703 UV xx fibre optic systems, and the IR flame scanner D- LX 703 IG/IS is compatible with the D-LL 703 IR xx fibre optic system. The lens system receives the light from the flame and concentrates it through the fibre optic. The fibre optics transmits the light directly onto the photo element inside the D-LX 700 flame scanner. 12. Mounting the D-LL 703/704 Fibre Optic System To achieve optimal, selective flame monitoring, the correct position must be used to mount either the welded flange of the D-LL 703 outer carrier tube (flexible system) or the D-LL 704 unit (rigid system). The sensor must be able to view the flame at any load within the range of the burner. The flame sensor should also be positioned such that the distance to the selected flame is as short as possible, and the distance to neighbouring flames is as great as possible. The viewing angle of the flame sensor should capture the lower third of the flame (the root). When selecting the correct position, it is important to accommodate any normal flame migration, particularly for coal-fired burners. The viewing axis should not cut through the flames of any neighbouring burners. Two ½" internal threads have been provided on the fibre optic system, one as a purge air and another as a cooling air connection. Purge air must be supplied to keep the lens free of possible particulate accumulation. Therefore, the purge air should be connected to the inner carrier assembly. Only oilfree, filtered, compressed air should be used for purging. The D-LL 703 has a connection for cooling air on the outer carrier tube. Enough cooling air should be supplied to insure that the permissible ambient temperature for the fibre optics is not exceeded. If the ambient temperatures are too high in installations using the D-LL 704 system, a guide tube should be provided on site that can supply cooling air to the system. The necessary flow rate, air volume, and pressure required for the cooling air supply must be determined on a site-specific basis. These specifications depend on the ambient temperature, the length of the fibre optic system supplied, the diameter of the guide tube at the burner, and the temperature of the available cooling air. The length of the fibre optic section exposed to higher ambient temperatures must also be taken into account. For example, when a section of the fibre optic bundle is exposed to the heat from the main burner, less cooling air is required than if the entire length of the fibre optics were exposed to the heat radiating from the main burner or heated combustion air. When the ambient temperature inside the burner exceeds the permissible ambient! temperature of the fibre optic, sufficient cooling air must be supplied at all times. A failure to meet these criteria can damage to the fibre optic conductors. The welding flange on the outer guide tube of the D-LL 703 fibre optic system needs to be welded near the flame in the burner assembly, aligned so it has a clear, precise view of the flame. If possible, the combustion air supply (primary or secondary wind box) area should be used as the mounting location.! To prevent damage to the fibre optic conductors when welding the mounting flange into place, the internal support tube and fibre optics should be removed from the outer carrier tube before welding.

21 D-LX 700 Page 17 The back end of the outer carrier assembly must be secured at the burner plate, either by directly welding it into place or using the D-ZS 703 mounting flange. When the main flange is tightened, the cutting ring will form a pressure-seal with the rigid portion of the guide tube. After the outer carrier assembly is installed, the inner carrier assembly with the fibre optics can simply be reinserted into the outer carrier and secured with the hex nut. The carrier tube (both inner and outer) have specific, factory-determined length! tolerances and are to fit to each other during production. If these guide tubes are switched during installation, the mounting rings may need to be repositioned. After unscrewing the two M4 screws in the mounting ring, this ring can be moved. This ring must be positioned so that the beginning of the fibre optic holder is held against the welded flange. The outer guide tube should compress the inner carrier tube slightly to make sure that the holder for the fibre optics is kept in front of the welded flange when the tube moves. The D-ZS 703 can be used to secure the D-LL 703 fibre optic scanner to the burner plate. The mounting flange D-ZS 702 or the D-ZS 704 welded flange can be used to secure the D-LL 704. Once the internal carrier tube is installed, the mounting ring can be used to mount the flame scanner. It is important to make sure the surface of the photo element does not become damaged, since the housing does not directly protect it. Once the mounting ring is tightened into place, the setscrew should also be tightened down. When laying the flexible section of the D-LL 703 outer guide tube, the radius of any curves or bends should not be less than 300 mm. The fibre optics can withstand curves with a radius as small as 190 mm without permanent damage, but the internal guide tube will not be able to slide properly for insertion or later movement. For application with tilting burners, these guidelines should also be fulfilled so that a large enough radius for any bends is provided at all burner positions. The fibre optics should also be installed with enough slack that the burner s movements do not stretch the outer carrier tube. LE (Fig. 9) Laying the outer carrier tube of the D-LL Installing the fibre optic system in tilting burner applications When determining the installation position and angle of view of the D-LL 703 fibre optic system relative to the flame (particularly for coal flames whose combustion may occur away from the main burner), it is important that the monitored flame surface remain the same while the burner tilts. The following drawing (fig. 17) shows an example of a changing viewing range of a tilting burner. Generally, oil-fired burners are designed so that the fibre optic system can be mounted parallel to the oil-atomisation nozzle in the tilting burner head. In this location, there are no significant changes to the viewed flame range of the scanner system as the burner moves. For coal-fired burners, however, the fibre optic system must usually be built into the wind box above the burner. This causes significant changes in the portion of the flame being observed as the burner tilts.

22 Page 18 D-LX 700 Air Coal Air Coal Air Coal LE (Fig. 10) Changes in the flame viewing range in tilting burner applications

23 D-LX 700 Page Purge and Cooling Air The amount of purge and cooling air required for the fibre optic system depends on the site conditions. The purge air should protect the optical surfaces from dust deposits or contamination. A gas-fired burner will require significantly less purge air than a coal-fired burner that creates a great deal of ash Purge and cooling air for the D-LL 703 fibre optic system With purge airflow of 1.5 Nm 3 /h, the exit velocity at the optics is approximately 5 m/s. This corresponds to an air pressure at the purge air inlet of approximately 250 mbar. This purge rate is sufficient for average applications. At installations that have a higher chance of optics contamination, a purge air volume of 3 Nm 3 /h (exit velocity of 10 m/s) is recommended. This corresponds to an inlet pressure of about 500 mbar. Purge air must be oil- and dust-free. The cooling air is needed to protect the system from overheating. For an air velocity of 5 m/s in the outer carrier tube, a flow rate of approximately 12.5 Nm 3 /h is required. To achieve this flow rate, the cooling air pressure at the inlet should be about 100 mbar. With higher ambient temperatures, such as those in gas turbine applications, a cooling air volume of 25 Nm 3 /h or higher may be necessary. This volume can be achieved with a cooling air inlet pressure of approximately 500 mbar. The required air pressure at the inlet port for a given purge or cooling air volume can be determined from the following graph (fig 18). Pressure drops through the supply lines must be taken into account. The curves on this graph do not compensate for any backpressure from the combustion chamber. The supply pressure may need to be increased to achieve the same flow rate and compensate for the furnace pressures on site. LE (Fig. 11) Graph of purge and cooling air volumes for the D-LL 703

24 Page 20 D-LX Purge and cooling air for the D-LL 704 fibre optic system A flow volume of 7 Nm 3 /h will yield a flow velocity of approximately 10 m/s. This corresponds to an air inlet pressure of approximately 50 mbar at the air connection on the fibre optic system. This flow rate is sufficient for typical installations. If a higher level of particulate accumulation is expected, the airflow should be increased to 15 Nm 3 /h (flow velocity of 20 m/s). This requires an inlet pressure of approximately 250 mbar. Oil- and dust-free air must be used for the purge air supply. If the fibre optic system must be cooled due to an ambient temperature higher than the tolerances of the fibre optics, the airflow can be increased. For a flow velocity of 30 m/s, about 20 Nm 3 /h of air is needed. This can be achieved if the air supply pressure at the air inlet port is approximately 600 mbar. For higher ambient temperature applications, such as gas turbines, an additional guide tube should be supplied on site to supply adequate cooling air to the fibre optic system. The required air pressure at the inlet port for a given purge and cooling air volume can be determined from the following graph. Pressure drops through the supply lines must be taken into account. The curves on this graph do not compensate for any backpressure from the combustion chamber. The supply pressure may need to be increased to achieve the same flow rate and compensate for the furnace pressures on site. LE (Fig. 12) Graph of purge and cooling air volume for the D-LL 704

25 D-LX 700 Page Technical Data D-LL 703/704 Angle of view:... 6 Permissible ambient temperature: C to +350 C Spectral range: nm (D-LL 70x UV-type) nm (D-LL 70x IR-type) Fibre optic construction:... Fibre optic bundle, single fused end Material guiding pipe: / Weight (D-LL 703 xx 10) :...3 kg (D-LL 704 xx 10) :... 2 kg (D-LL 703 xx 15) :...4 kg (D-LL 704 xx 15) :... 3 kg (D-LL 703 xx 20) :...5 kg (D-LL 704 xx 20) :... 4 kg (D-LL 703 xx 25) :...6 kg (D-LL 704 xx 25) :... 5 kg (D-LL 703 xx 30) :...7 kg (D-LL 704 xx 30) :... 6 kg (D-LL 703 xx 35) :...8 kg (D-LL 704 xx 35) :... 7 kg (D-LL 703 xx 40) :...9 kg (D-LL 704 xx 40) :... 8 kg! A too low or the complete loss of the purge- and/or cooling destroys the fibre optic bundle and the lens. Therefore, fibre optic bundle and lens are not covered by any warranty. 15. Model Overview for the D-LL 703 series The D-LL 703 fibre optic system is available in seven different lengths and two different spectral ranges. Table 5 below shows the dimensions of the fibre optic system. A) Over-all dimension of the fibre optic system. B) Maximum length of the fibre optic system to be fitted inside the burner. C) Length of the flexible part of the fibre optic system, including welding flange. D) Length of the fibre optic system including the flame scanner electronics. For a diagram with these dimensions, please see the dimensional drawing for the D-LL 703 Model* A [mm] B [mm] C [mm] D [mm] for D-LE 703 xx-p D-LL 703 xx 10 1, ,245 D-LL 703 xx 15 1,500 1,270 1,000 1,745 D-LL 703 xx 20 2,000 1,770 1,000 2,245 D-LL 703 xx 25 2,500 2,270 1,500 2,745 D-LL 703 xx 30 3,000 2,770 1,500 3,245 D-LL 703 xx 35 3,500 3,270 2,000 3,745 D-LL 703 xx 40 4,000 3,770 2,500 4,245 xx = UV for UV spectrum fibre optic systems or IR for IR range fibre optic systems (Table 1) Model overview D-LL 703

26 Page 22 D-LX Model Overview for the D-LL 704 series The D-LL 704 fibre optic system is available in seven different lengths and two different spectral ranges. Table 6 below shows the dimensions of the fibre optic system. A) Over-all dimension of the fibre optic system. B) Maximum length of the fibre optic system to be fitted inside the burner. D) Length of the fibre optic system including the flame scanner electronics. For a diagram with these dimensions, please see the dimensional drawing (fig. 30) for the D-LL 704 Model* A [mm] B [mm] D [mm] for D-LE 704 xx-p D-LL 704 xx 10 1, ,245 D-LL 704 xx 15 1,500 1,400 1,745 D-LL 704 xx 20 2,000 1,900 2,245 D-LL 704 xx 25 2,500 2,400 2,745 D-LL 704 xx 30 3,000 2,900 3,245 D-LL 704 xx 35 3,500 3,400 3,745 D-LL 704 xx 40 4,000 3,900 4,245 (Table 2) xx = UV for UV spectrum fibre optic systems or IR for IR range fibre optic systems Model overview for the D-LL 704 series 17. Mounting and disassembling the D-LL 703 fibre optic system 17.1 D-LL 703 Materials List Item Part number Qty Description 1 LL n 1 Outer carrier tube 2 LL n 1 Inner carrier tube 3 LL n 1 End pipe Ø20x44 4 LL n 1 Mounting ring 5 LL n 1 Purge air inlet port 6 LL n 1 Hex mounting ring SW41x22 7 LL n 1 Restrictor G 1 ¼ to M18x1.5 8 LL n 1 Hexagonal union nut SW27x9 M18x1.5 9 LL n 1 Fibre optic holder Ø56x20 10 LL n 1 D-LE front piece/d LE n 1 Mounting ring D-LE/D LL n 1 Optic holder with quartz glass lens 13A wdiwflwld2,5 1* WF fibre optic bundle Ø2.5 mm, length as ordered 13B wdiuvlwld2,5 1** UV fibre optic bundle Ø2.5 mm, length as ordered 14 mor40x2 2 0-ring 40x2 Viton 15 mor17x3 1 O-ring 17x3 NBR 70 (Table 3) * Only with the D-LL 703 IR xx ** Only with the D-LL 703 UV xx D-LL 703 components list

27 D-LX 700 Page Uninstalling the fibre optic connector of the D-LL 703 If the D-LL 703 needs to be replaced or inspected, the disassembly should be conducted as follows:! Warning: the fibre optic conductors may not be stretched, crushed, or twisted. These types of stress can break or tear all or some of the glass fibres. During normal handling, the metal hose will protect the fibres against mechanical damage. 1. Unscrew the hexagonal locking ring (item 6) and pull out the complete internal carrier tube (fig. 20) from the outer guide tube (fig. 19). If the inner carrier tube does not come out easily, do not apply excessive force. The removal can be obstructed by dirt accumulation in the outer carrier tube, a bend with a radius of less than 300 mm, or a severe angle caused by the current orientation of a tilting burner. In such cases, reposition the burner, makes curves less sharp, or supply additional air to clear any built-in dirt. If the inner carrier tube remains immobile, unscrew the locking ring (item 16) in the fibre optic holder (item 9, fig. 24). This frees the fibre optics so they are secured at only one point to the front piece so they will not be damaged when the tube is pulled out. LE Item 1 Outer carrier tube Item 5 Cooling air connection (Fig. 13) Outer carrier tube D-OC 703 LE (Fig. 14) Inner carrier tube D-IC Once the inner carrier tube has been removed, the locking ring (item 16) should be unscrewed so the fibre optic strands can move freely. The end pipe (item 3) can be removed once the two 17 mm screws have been unscrewed from the inner carrier tube. The fibre optics can then be carefully removed from the inner carrier tube. 3. The optics holder is screwed to fibre optics with an M6x0.75 mm thread. If the end cover on the fibre optics comes loose while the optics holder is being unscrewed (Warning! The glass fibres are extremely fragile and may break when unscrewing this piece), the end cover should be carefully held still with a pair of forceps. The polished ends of the fibre optics can then be carefully cleaned with a soft optics cloth or replaced with new fibres. LE (Fig. 15) Mounting the D-IC 703 optic holder

28 Page 24 D-LX Mounting the fibre optic conductor of the D-LL Before installing the fibre optics, check the glass strands for damage or dirt (up to three of the glass fibres in the bundle may appear dark as a result of the process used to fuse the strands at one end). To check the condition of the optic fibres, hold the flame end to a light source and look at the other end of the fibre optic cables. If all 100 fibres appear as bright points of light, the fibres are in good condition. If more than 3 of these 100 fibres are dark (indicating broken filaments), the fibre optic bundle should not be used and needs to be replaced with another bundle of the same length. LE (Fig. 16) Fibre optic bundle D-FO Screw in the two M4x10 screws (item 17) and pull the fibre optic holder (item 9) out of the front portion of the mounting flange. Make sure that neither of the o-rings (item 14) falls out LE (Fig. 16) Mounting the flame scanner end of the D-LL 703 fibre optics 3. Screw the locking nut (item 8) onto the threads of the inner carrier tube as far as it can go. The complete scanner front face can then also be screwed onto the inner carrier tube as far as possible. 4. Insert the entire length of the fibre optics with attached holder into the inner carrier tube, until the neck of the optic holder rests against the threaded socket of the inner carrier tube. Screw in the end pipe (item 3) and use two 17 mm screws to secure it. 5. Insert the short end cover of the fibre optics into the hole bored in the fibre optic holder (item 9) until it reaches the back and secure it with the setscrew (item 16). Make sure that the inner o-rings (item 14) are lying inside the nut. 6. Turn the entire scanner front piece back onto the inner carrier tube until scanner side of the fibre optic holder is flush with the rear edge of the scanner front piece. -- Warning! When turning the scanner front flange piece, make sure the fibre optic bundle is never twisted. The best method is to carefully clamp the inner carrier tube, hold the fibre optic holder and fibres in one hand, and then turn the scanner front flange (item 10) with the other hand. After aligning the scanner front flange, secure it with the locking nut (item 8). When fastening the locking nut in place, make sure the holes in the front piece are aligned with the threaded holes in the fibre optic holder. Secure the fibre optic holder with the two M4x10 screws.