pending pending Controlling and Monitoring of Gas, Oil and Combined Burners of any Capacity Integrated Gas Valve Proving System Separated Outputs for Gas- and Oil Fuel Valves Quick Fuel Change on the fly without Burner Shutdown Data Interface Adjustable Pre-purge Timer Integrated Flame Monitor with adjustable Treshold Approved according to EC Gas Appliance- and Pressure Equipment Directive Flame Sensor D-GF 150 D-LE 103
Application The DURAG D-GF 150 Burner Control System controls and monitors gas and oil burners of any capacity. The control functions of this system cover the tasks of prepurge, ignition and solenoid valve control, through to the enabling of the output regulation. Thanks to its flexibility, the program sequence for pre-purge, ignition, fuel supply and air supply may be adjusted to the requirements of the plant, with simultaneous consideration given to applicable guidelines. These units may be used in applications ranging from large power stations to small remote heating plants, or in chemical processes or thermal flue gas combustion systems. By employing microprocessors with corresponding software and hardware, this burner management system offers improved evaluation capability and a heightened degree of safety and availability. In combination with flame sensors from either the D-LE 103 or D-LE 603 series, the burner management system is fully suited to monitor flames of different fuels and combustion techniques, in single burner or multi-burner systems. Different UV and IR flame sensors are available to optimally adapt the flame monitoring system to local conditions. The response threshold (sensitivity) of the flame monitoring system in the burner control may be set to one of ten different levels using a rocker switch on the front panel of the burner control. General Program Sequence The types of fuels and burners found in the field require different functional sequences and safety times, which are electronically controlled and monitored by the burner control system. By observing the applicable guidelines, one may choose from the following program sequences, depending on the current operating conditions of the combustion system: Fuel gas in master burner mode Fuel gas in slave burner mode Fuel oil in master burner mode Fuel oil in slave burner mode Beside these standard functions the D-GF 150 Burner Control employs for the first time also the following new functions: Integrated gas valve proving system Separated Outputs for controlling gasand oil fuel valves Quick fuel change on the fly without burner shut-down Data Interface Program halt for burner optimisation Program Sequence in Master Burner Mode The master burner program sequence is generally the normal mode of operation. Once the program starts up, the blower motor is activated. Air pressure must build up within the next 30 seconds. This is monitored by the air pressure monitor. If air pressure is present, the air damper is moved to the "open" position. Afterward, the selected pre-purge of 30 s to a maximum of 20 min starts. Once the set prepurge period expires, the air damper is moved to the ignition position. The threesecond ignition delay period then starts. After activation of the ignition transformer, the pre-ignition period begins. Ignitionand pilot fuel valves are opened after 2 seconds, and the ignition safety time starts. If a flame was generated during the ignition safety time, the main fuel valve of the selected fuel is opened after a delay period of 5 seconds. The ignition fuel valve is closed after an overlap period. 5 seconds later, the operational state is reached and the burner control system activates regulating output. If, during operation, a controlled shutdown is triggered via the monitor chain, the system checks whether the flame in the burner is extinguished once the fuel supply is cut off. The period of time for the flame OFF signal is 10 seconds. A blower post-run of 5 seconds follows the flame OFF signal. 2 Application of the D-GF 150 Burner Control
Slave Burner Program Sequence The slave burner program sequence distinguishes itself in two respects from that of "master burner". After start-up, the program begins immediately with the ignition delay period, the pre-purge period, and the moving of the air dampers is omitted. The subsequent steps in the program are sequenced as in the master burner mode. In the "slave burner" program sequence, the regulation output is activated once the operational state has been reached, but it is not signalized by the standard LED. Gas Valve Proving System The D-GF150 Burner Control is equipped with a gas-valve proving system. This function is activated by means of internal hook switches. When operating with gas, the main fuel valves of the gas supply can be tested for tightness. This function requires the installation of two gas valves in series and of one gas pressure sensor between both gas valves. A section between the supply-side and the burner-side gas valve constitutes a pressure test space. This test space is first emptied via activation of the burner-side gas fuel valve. By an internal hook switch the testing time can be adjusted to either 5s or 30 s. In this period the gas pressure between the gas valves must not change. The gas, required for this test, is released into the furnace after the test. Fuel Change Over In the operating position, a quick change of the fuel is possible. For that purpose, the monitor chain inputs for gas (WKG) and oil (WKO) must be changed during operation (Ps43). For 1 second a simultaneous activation or deactivation of the fuel selection inputs is permitted. After the change of the monitor inputs, the ignition position is approached, the ignition burner is activated, the old fuel is stopped and the new fuel is started by opening the corresponding fuel valves. The change over between two valves takes place in 11s. Program Step Description Remarks Duration LEDs Standby position 1 2 3 4 5 6 7 8 Ps10 Air pressure off Air pressure must go to 0 unlimited Ps11 Stand by unlimited Ps12 Air pressure build-up Air pressure must signal 1 max 30 s Pre-purge Master Burner only! Ps20 Open air damper Go to pre-purge position max 10 min Ps21 Pre-purge Stray light test 30 s.. 20 min Ignition of Ignition Burner Ps30 Close air damper Go to ignition position max 10 min Ps31 Ignition delay Stray light test 3 s Ps32 Pre-ignition Ignition Transf. ZTR starts 2 s Ps33 OPEN IGNITION VALVE Overlap ZTR + ZMV 1. SZ 1 s Ps34 Ignition safety time, ignition burner D-GF 150 Program Sequence ZTR off 1 s Ps35 Main-valve delay Ignition flame stabilised 5 s Ignition of Main Burner Ps40 Program halt ZMV ZMV active alone unlimited Ps41 OPEN MAIN VALVE Overlap ZMV + HMV 2. SZ 1 s Ps42 Ignition safety time main burner and regulator delay ZMV off, main flame stabilised 1 s + 4 s Ps43 OPERATING POSITION Regulator release unlimited 1 Switch-off Ps50 Switch-off Remaining fuel burns 5 s (15 s*) Ps51 Flame off Flame must extinguish max 30 s *D-GF150-10 only Gas Valve Leakage Test Gas only! LED5 flashes Ps60 Emptying of the gas line Open GVB (burner side) 5 s Ps61 Test for pressure P0 Test input GDR= 0 5 s or 30 s Ps62 Filling of the gas line Open GVG (gas side) 5 s Ps63 Test for pressure P1 Test input GDR= 1 5 s or 30 s Fuel Change LED1 flashes Ps70 Close air damper Go to ignition position max 10min Ps71 Drive ignition lance in 5 s Ps72 Pre-ignition ZTR starts 5 s Ps73 Overlap ZMV + ZTR Open ZMV 5 s Ps74 Accept fuel mode Ignition burner active, main fuel valve closed. LED ist off LED flashes 5 s LED is off LED is on or off D-GF 150 Dimensions 3
Line Diagram: Gas Operation with Pre-purge (Master Burner) D-GF 150 Safety Time Start Ignitor: Safety Time Start Main Burner: Safety Time Main Burner: Analogue Output: Approvals : D-GF 150-10 Safety Time Start Ignitor: Safety Time Start Main Burner: Safety Time Main Burner: Analogue Output: Approvals : 3 s or 5 s 3 s or 5 s 1 s 0 or 4-20 ma DVGW DIN-CERTCO (UL, C-UL, FM)* 4 s or 10 s 10 s or 15 s 1 s or 3 s 4-20 ma (UL, C-UL, FM)* *pending D-GF 150 Order Information D-GF 150 Connection Diagram 4
Survey of D-LE 103 Flame Sensors Flame Sensor D-LE 103 UL-xx D-LE 103 UAF-xx D-LE 103 UA-xx Photo element Low voltage UV cell GaP with UV-filter GaP without UV-filter Spectral range (nm) 190-260 ++ + Suitable for fuels Gas Oil Coal Wood All flame sensors have been tested according to EN 230 (oil) and EN 298 (gas). They are approved for continuous operation without capacity limit and 72h operation according to TRD 604. Monitoring of gas and oil flames in single burner installations (increased viewing angle of 12 ). 280-410 O ++ Monitoring of gas and oil flames in single burner installations. 190-520 + ++ O + Monitoring of oil flames in single burner installations as well as oil burners where additional fuels are burned. D-LE 103 IS-xx Si 300-1100! ++ ++ + Monitoring of oil and wood dust flames. D-LE 103 IG-xx Ge 780-1800 O ++ ++ ++ Monitoring of oil and wood dust flames as well as gas flames from pilot or main burners in single burner installations. xx = P: xx = MP: xx = CG: Axial plastic plug cable connection IP 67 / NEMA 4X Axial metal plug cable connection IP 54 / NEMA 3S Cable connection with M20x1.5 cable gland IP 65 / NEMA 4X Explanation of symbols: ++ The flame sensor is ideally suitable for this fuel considering its flame detection and flame selectivity. + The flame sensor is well suited to this fuel, although under certain conditions it may show an increased flame simulation signal. This is especially possible with combination operation (e.g. oil and gas). O The flame sensor is conditionally suited to this fuel. The monitoring characteristics depend mainly upon 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. D-LE 103 UL / UA / UAF Ultraviolet Flame Sensors These flame sensors have a spectral range of either 190 to 260 nm, 190 to 520 nm or 280 to 410 nm, depending on the model. All blue-burning flames, e.g. gas flames whose portion of visible light is low, may be monitored by these flame sensors. D-LE 103 IS / IG Infrared Flame Sensors These IR flame sensors have a spectral sensitivity of either 300 to 1100 nm or 780 to 1800 nm, depending on the model. Only those signals are processed which correspond to flame flickering. Thus flame monitoring is not influenced by ambient light, as far as constant light is concerned. Flames whose UV radiation is absorbed by dust, water vapour or other materials may be monitored in the infrared range. A waste incinerator would be an example of such an application. IR flame sensors with a sensitivity of up to 1800 nm have proven themselves in monitoring gas and oil combustion systems employing NO x reduction techniques such as flue gas recirculation. Schematic Diagram of D-LE 103 Dimensional Drawing of D-LE 103 Flame Sensors 5
150 06/2003 - All specifications subject to change without notice Änderungen vorbehalten D-GF Technical Data D-GF 150 Burner Control Mains Voltage 115/230 VAC +10%... -15% Mains Frequency 50/60 Hz ±10% Flame Intensity Current Output 0/4..20 ma / 750 Ohms Relay Outputs (max. 250 Vac/1A) Ignition Fuel Valve Pilot Fuel Valve Main Fuel Valve Gas (Supply Side) Main Fuel Valve Gas (Burner Side) Main Fuel Valve Oil Close Air Damper Open Air Damper Release Regulation Alarm Ignition Transformer The electro-mechanical relay contacts meet the requirements of the VDE 0116 for safety equipment. Semiconductor Outputs (max. 250Vac/0,1A) Ready for Operation Blower Insert Ignition Lance Flame ON Internal Flame ON External Flame ON Pre-Purge in Operation Ignition in Operation Gas Valve Leackage Test in Operation Inputs (115/230 Vac) Master Burner / Non Master Burner Mode Air Pressure Sensor Program Halt Gas Pressure Sensor External Flame Monitor Monitor Chain Gas Monitor Chain Oil Limiter Chain External Reset Feedback Signal Air Damper Open Feedback Signal Air Damper Closed Perm. Ambient Temperature -20 C to +60 C Protection (EN 60529) IP20 Weight 1.5 kg D-LE 103 Flame Sensor Supply Voltage Spectral Sensitivity (depending on type of flame sensor) 20 VDC (from Burner Control) 190-1800 nm Permissable Ambient Temperature 20 C to +60 C (0 F to 140 F) Viewing Pipe Connection G 1¼ Purge Air Connection G ½ Optical Viewing Angle 6 Protection (EN 60529): Cable Version (-CG) IP65 / NEMA 4X Standard Plug Version (-P) IP67 / NEMA 4X Metal Plug Version (-MP) IP54 / NEMA 3S Weight approx. 1.5 kg (3.3 lb.) Extensive descriptions of these units with specifications, setting instructions, dimensions and connection plans are available upon request. Available Accessories AM 150 Expansion module for the D-GF 150 Burner Control with following features: alphanumeric display, first-out annunciator, MODBUS- Interface and more D-ZS 087-20 Digital display for optimal alignment of flame sensors through pulse frequency measurement and for storing pulse peak values D-ZS 118 Optical adjustment auxiliary unit for alignment of the ball-type adjustment flange on the scanner tubes D-ZS 077-10 UV-C test light source 230 V / 50 Hz D-ZS 093 UV-A, UV-B and IR test light source 230 V / 50 Hz D-ZS 033 - I Ball-type adjustment flange for D-LE 103 D-ZS 117 - I Heat insulator with electrical disconnection D-ZS 133 - I Ball-type valve for closing the viewing pipe www.durag.de DURAG Industrie Elektronik GmbH & Co KG Kollaustr. 105 D-22453 Hamburg, Germany Tel. +49 40 554 218-0 Fax +49 40 584 154 Georg Hegwein GmbH & Co. KG Am Boschwerk 7 D-70469 Stuttgart, Germany Tel. +49 711 135 788-0 Fax+49 711 135 788-5 VEREWA Umwelt- und Prozessmesstechnik GmbH Kollaustr. 105 D-22453 Hamburg, Germany Tel. +49 40 554 218-0 Fax +49 40 584 154 ORFEUS Combustion Engineering GmbH An der Pönt 53a D-40885 Ratingen, Germany Tel. +49 2102 9974-0 Fax +49 2102 9974-41 DURAG, Inc. Southridge Business Center 1355 Mendota Heights Rd. #200 Mendota Heights, Minnesota 55120, USA Tel. +1 651 451-1710 Fax +1 651 457-7684 DURAG India 102, Sophia's Choice, St. Mark's Road, Bangalore - 560 001, India Tel. +91 80 5112 0223 Fax +91 80 5112 0224