BFI Automation 3001S User manual

Original Operating Instructions
Flame Amplifier
Type: 3001S
Document: BA 3001S EN REV4
BFI Automation Mindermann GmbH
Ruegenstrasse 7
D-42579 Heiligenhaus Germany
Telephone [phone]
Facsimile [phone]
http://www.bfi-automation.de

ii

Content
iii
1  General aspects 1-1 
1.1Introduction 1-1
1.2Warning notes 1-2
1.3Copyright protection 1-3
1.4Disposal information 1-3
1.5Warranty 1-4
1.6Obligation of the operating company 1-5
1.7Liability disclaimer 1-6
1.8Declaration of conformity 1-7
1.9Address of the manufacturer 1-8
2  Safety 2-1 
2.1Intended use 2-1
2.2Requirements on persons 2-2
2.3Safety instructions 2-3
2.4Safety devices 2-4
2.4.1Fundamental aspects 2-4
2.4.2Safety devices on the flame amplifier 2-4
2.5Safety instructions in case of maintenance and troubleshooting 2-5
2.5.1Fundamental aspects 2-5
2.5.2Electrical / electronic devices 2-6
2.5.3Testing in keeping with the German Workplace Safety Ordinance (BetrSichV) 2-7
2.5.4Safety test 2-7
3  Technical data 3-1 
3.1General characteristic features 3-1
3.2Electrical system, mechanical system, function 3-1
3.3Weight 3-2
3.4Dimensions 3-2
3.5Adjustment and display elements 3-3
3.6Device design 3-4
3.7Block diagram 3-5
4  Transport, installation and connection 4-1 
4.1Scope of delivery 4-1
4.2Packaging 4-2
4.3Forwarding instructions 4-2
4.4Weight - flame amplifier 4-2
4.5Space requirement 4-2
4.6Installation 4-1
4.6.119”-built-in housing (rack mount installation) 4-1
4.6.219”-built-on housing (wall mount installation) 4-1
4.6.3Dimensions for 19”-built in/on housing 4-1
4.7Connection 4-4
4.7.1Electrical connection 4-4
4.7.2Terminal diagram 4-5
4.8Storage 4-6
5  Description 5-1 
5.1Functional description 5-1
5.1.1Measurement channel (M) 5-1
5.1.2Monitor channel (RM) 5-2

iv
5.1.3Evaluation channel (RF) 5-2
5.1.4Variable switch-ON threshold (hysteresis) 5-3
5.1.5Fixed switch-OFF threshold 5-3
5.1.6Pre-alarm warning 5-3
5.1.7Safety switch-OFF times 5-4
5.1.8Signal outputs 5-5
5.1.9Parallel connection of flame scanners 5-6
6  Operation of the flame amplifier 6-1 
6.1Connection of the flame amplifier 6-1
6.2Testing the flame amplifier 6-1
6.3Initial operation of the flame amplifier 6-2
6.4Factory setting of the flame amplifier 6-2
6.5Operation settings 6-3
7  Maintenance and servicing 7-1 
8  Failures 8-1 
9  Order data 9-1 
10  Accessories 10-1 

General aspects
1-1
1 General aspects
1.1 Introduction
These operating instructions are a helpful guide for ensur-
ing the successful and safe operation of the flame ampli-
fier. They contain important information on how to operate
the system safely, correctly and efficiently. Observing the
operating instructions will help to prevent hazards, reduce
costs of repair and downtimes and increase the reliability
and life of the device.
All illustrations and drawings in these operating instruc-
tions are shown for illustration purposes and are not au-
thoritative detailed designs.
The operating instructions always have to be accessible
at the device. They have to be read and applied by each
person who is required to work with/on the device.
This work may involve, for example:
operation
troubleshooting during operation
servicing
maintenance (upkeep, inspection, repair) and/or
transport
This should be confirmed by the operating company in
writing.

General aspects
1-2
1.2 Warning notes
The following warning notes are used in these operating
instructions:
This warning level indicates an imminent hazardous situa-
tion.
If the hazardous situation is not prevented, this will result
in death or severe injury.
Follow the instructions that accompany this warning to
prevent the risk of death and severe personal injury.
This warning level indicates an potentially hazardous situ-
ation.
If the hazardous situation is not prevented, this may result
in death or severe injury.
Follow the instructions that accompany this warning to
prevent the potential risk of death and severe personal in-
jury.
This warning level indicates an potentially hazardous situ-
ation.
If the hazardous situation is not prevented, this may result
in slight or moderate injuries.
Follow the instructions that accompany this warning to
prevent the injury of persons.
This warning level indicates potential damage to property.
If this situation is not prevented, it may result in damage
to property.
Follow the instructions that accompany this warning to
prevent damage to property.
A notice indicates additional information that will make the
handling of the device easier.

General aspects
1-3
1.3 Copyright protection
These operating instructions have to be treated as confi-
dential. They may only be used by authorised staff. Ac-
cess by third parties may only be granted upon written
agreement of BFI Automation.
All documents are protected in keeping with the German
copyright law.
The disclosure and reproduction of documentation, in
whole or in part, as well as the exploitation and communi-
cation of its content shall not be permitted unless ex-
pressly stated otherwise. Offenders are liable for prosecu-
tion and the payment of damages.
We reserve all rights to exercise industrial property rights.
1.4 Disposal information
The flame detector is equipped with electrical and electronic
components and must be disposed separate from household
waste. Follow the local and actual regulations for waste dis-
posal.

General aspects
1-4
1.5 Warranty
Read these operating instructions carefully before op-
erating the flame amplifier !
The manufacturer is not liable for damage or operating
malfunctions that result from the operating instructions not
being observed.
The operating company has to supplement the operating
instructions with operating instructions on the basis of na-
tional regulations on accident prevention and environmen-
tal protection, including information on supervision and
notification requirements with respect to special operating
circumstances, e.g. regarding organisation of work, work-
ing processes and staff deployed.
The recognised technical rules for safe and professional
working also have to be observed in addition to the oper-
ating instructions and the regulations on accident preven-
tion applicable to the country and place of use.
The warranty shall become void, for example, in the event
of:
inappropriate use
use of impermissible equipment
incorrect connection
prior works that are not part of the supplied product or
service
non-use of original spares and accessories
conversion, if this has not been harmonised with BFI
Automation
non-performance of specified maintenance work
It is recommended that the operator of the device con-
cludes a service contract with BFI Automation. This guar-
antees that the device is regularly checked by our service
staff and ensures that any required wearing and spare
parts are available without long delivery periods.

General aspects
1-5
1.6 Obligation of the operating company
The flame amplifier may cause hazards if it is operated in-
appropriately or in an improper condition.
The operating company is under the obligation to operate
the machine in proper state only. The operating company
has to secure hazardous areas that exist between BFI de-
vices and the customer's own equipment.
The operating company has to appoint and instruct re-
sponsible staff:
Only deploy trained or instructed staff.
Clearly set out the responsibilities of the staff with re-
gard to operation, set-up, maintenance and repair.
Regularly check that staff are safety conscious and
aware of hazards and are observing the operating in-
structions.
Before starting work, staff who are assigned to work
with/on the device have to have read and understood
the operating instructions, in particular the chapter on
"Safety", as well as the relevant regulations.
The operating instructions and relevant regulations
have to be stored in such a way that they are accessi-
ble to operating and maintenance staff.
Set out who will have responsibility for device opera-
tion and ensure that this person has the authority to
overrule any unsafe instructions of third parties.
Generally valid legal and other binding regulations on ac-
cident prevention and environmental protection have to be
observed and instructed, in addition to the operating in-
structions.

General aspects
1-6
1.7 Liability disclaimer
All technical information, data and guidance on device op-
eration that are contained within these operating instruc-
tions are, to the best of our knowledge, correct at the time
of printing, taking into account our present understanding
and experience.
We reserve the right to make technical changes with re-
spect to the further development of the flame amplifier
outlined in these operating instructions. No claims can be
made based on the specifications, illustrations and de-
scriptions of these operating instructions.
We shall not be liable for damage or operating malfunc-
tions that result from operating errors, inappropriate re-
pairs or the non-observance of the operating instructions.
We expressly state that only original spare parts and ac-
cessories approved by us may be used. This also applies
to the components of other manufacturers that have been
used.
The installation or use of non-approved spare and acces-
sory parts and any unauthorized retrofits and modifica-
tions are not permitted for safety reasons and exclude any
liability by BFI Automation for consequential damages.
BFI Automation is liable for possible errors or omissions
with the exclusion of additional claims entered into in the
framework of the warranty obligations conceded to in the
contract. Claims for damages, on whatever legal basis
they may be, shall be excluded.
Translations into foreign languages are carried out in
good faith. We cannot accept any liability for translation
errors; this also applies where the translation has been
carried out or has been commissioned by us. The original
text alone shall be binding.
Descriptions and illustrations do not necessarily depict the
delivered product or a possible spare parts order. Draw-
ings and graphics are not to scale.

General aspects
1-7
1.8 Declaration of conformity

General aspects
1-8
1.9 Address of the manufacturer
BFI Automation Mindermann GmbH
Ruegenstrasse 7
D-42579 Heiligenhaus
Germany
Tel. [phone]
Fax. [phone]
E-mail: [email protected]
Internet: www.bfi-automation.de

Safety
2-1
2 Safety
2.1 Intended use
The flame amplifier shall be used exclusively to detect
flames in combination with a suitable flame scanner. The
flame scanner and flame amplifier together constitute a
complete flame monitoring system for burners with a ran-
dom capacity and random fuels in single and multiple
burner systems.
The flame amplifier renders available to the burner control
the safety-oriented binary signals for "Flame ON/OFF".
On account of the continuous fully electronic self-test of
its function, the flame amplifier is approved for continuous
operation.
Danger when improperly used !
The device may cause hazards if it is not used as in-
tended and/or for any other purposes.
The device has to be used only for the purposes for which
it is intended.
The procedures described in the operating instructions
have to be observed.
The manufacturer/supplier shall not be liable for damage
resulting from use for non-intended purposes. The
user/operating company alone shall bear the risk.

Safety
2-2
2.2 Requirements on persons
Work on/with the device may only be performed by per-
sons authorized to do so based on their training and quali-
fication. Furthermore, such persons have to have been
commissioned by the operating company.
Do not allow any persons who are being apprenticed, ed-
ucated, instructed or on a general training programme to
work on the device without the constant supervision of an
experienced person.
Persons who are under the influence of drugs, alcohol or
medication that affects reactivity shall not be permitted to
carry out work on the device.
Connection, set-up, maintenance and repair work may
only be carried out by qualified specialist staff.
This device may cause hazards if it is operated inappro-
priately by untrained staff or if it is not used for its in-
tended purpose.
Generally valid legal and other binding regulations on ac-
cident prevention and environmental protection in addition
to basic health and safety requirements have to be ob-
served. The operating company has to instruct its staff ac-
cordingly.

Safety
2-3
2.3 Safety instructions
The following instructions on accident prevention have to
be observed when operating the flame amplifier.
Only operate the device if it is in a proper state !
Do not remove or disable safety devices.
Check for externally noticeable damage and defects
prior to using the device ! Immediately notify the appro-
priate authority/person of any changes that occur (in-
cluding changes in operating performance). If neces-
sary, stop and secure the device immediately.
Allow only authorised specialist staff to carry out set-up
and/or maintenance work.
Operating staff have to be informed before mainte-
nance or other special work is carried out.
Replace worn or defective parts.
Use suitable maintenance tools only.
After repair work, refit all safety devices and carry out
electrical and mechanical checks.
Check the operating instructions for details of displays
as well as switch-on and switch-off procedures.
Prior to switching on the device, make sure that no-one
can be endangered by the device !
The operating instructions always have to be kept
close to the device and be readily at hand.
Any non-compliance with the safety instructions out-
lined in these operating instructions may lead to dam-
age to property, personal injury or even death.

Safety
2-4
2.4 Safety devices
2.4.1 Fundamental aspects
Check the safety equipment and locking devices on the
device for safe operational condition.
Only operate the device if all safety devices are present
and enabled. The operating company or operator of the
flame amplifier is responsible for the proper operation of
the device.
The device has been fitted with warning and danger signs
for the protection of operating staff. These signs have to
be observed. Damaged or illegible signs have to be re-
placed immediately.
2.4.2 Safety devices on the flame amplifier
The flame amplifier has been fitted with the following
safety devices:
Housing (protection against accidental contact)
Flame-proof housing (optional)
Earth connection of device housing (optional)
Explosion protection barriers (optional)

Safety
2-5
2.5 Safety instructions in case of mainte-
nance and troubleshooting
2.5.1 Fundamental aspects
Deadlines set or indicated in the operating instructions
for repetitive checks / inspections shall have to be ob-
served !
Appropriate workshop equipment is essential for per-
forming maintenance work.
In conformity with the electrical regulations, work on
the electrical equipment of the system may only be car-
ried out by an electrical specialist or by trained staff un-
der the direction and supervision of an electrical spe-
cialist.
The adjustment, maintenance and inspection activities
and deadlines stipulated by BFI Automation, including
information on the replacement of parts / assemblies,
have to be observed! These tasks may only be carried
out by authorised specialist staff.
Operating staff have to be informed before mainte-
nance or other special work is carried out. A supervisor
has to be appointed.
Screw connections which have been loosened during
maintenance and servicing work, have to be tightened.
If maintenance and repairs require safety devices to be
dismantled, these devices have to be remounted and
checked as soon as the maintenance and repair work
has been completed.
Operating and auxiliary materials as well as exchanged
parts have to be disposed of in a safe and eco-friendly
way.
Spare parts supplied by BFI Automation or approved of
by BFI Automation only may be used.

Safety
2-6
2.5.2 Electrical / electronic devices
Danger to life caused by electrical current!
Contact with live wires or components presents a danger
to life !
Prior to any work on the electrical equipment, disconnect
the flame monitoring system from the power supply net-
work !
In keeping with the electrical regulations, work on electri-
cal / electronic parts / components may only be carried
out by electrical specialists.
Important rules of conduct
Check the device in regular intervals. Any defects or
faults ascertained have to be corrected immediately.
Switch off the device until the defects have been cor-
rected.
Equipment parts undergoing inspection, maintenance
or repair work have to be made de-energised, if re-
quired. First check that the disconnected parts are no
longer live, then short to earth. Also isolate neighbour-
ing live parts
If work is required on live parts, a second person has
to be assigned who can disconnect the power supply in
case of an emergency. Only use insulated tools !
Fuses must not be repaired or bridged. Only use origi-
nal fuses with the specified current !

Safety
2-7
2.5.3 Testing in keeping with the German Work-
place Safety Ordinance (BetrSichV)
In case of the coupling or installation of devices from vari-
ous manufacturers or suppliers, the operating company
has to carry out a precise test, prior to start-up, in keeping
with the German Workplace Safety Ordinance (BetrSichV)
in force and the applicable electrical regulations.
In case of queries, please get in touch with BFI Automa-
tion.
2.5.4 Safety test
In order to ensure correct operation, the flame scanners
as well as flame amplifiers of all applications have to be
tested several times by starting and stopping the burner
several times. In all cases the flame relay has to be
switched off reliably in case of an absent flame. Carry out
this test whilst several neighbouring burners are started
and stopped and different boiler outputs are used. This is
an indispensable pre-requisite for a safe and correct oper-
ation of the device !

Safety
2-8