BST Solutions Flamonitec KLC 11 User manual

Operating Manual (US)
UV Flame Detector KLC 11

Content
1 General aspects 4
1.1 Introduction 4
1.2 Warning notes 4
1.3 Copyright protection 5
1.4 Disposal information 5
1.5 Warranty 5
1.6 Obligation of the operating company 6
1.7 Liability disclaimer 6
1.8 Declaration of conformity 8
1.9 Address of the manufacturer 8
2 Safety 9
2.1 Intended use 9
2.2 Requirements on persons 9
2.3 Safety instructions 10
2.4 Safety devices 10
2.4.1 Fundamental aspects 10
2.4.2 Safety devices on the UV flame detector 10
2.5 Safety instructions in case of maintenance
and troubleshooting 11
2.5.1 Fundamental aspects 11
2.5.2 Electrical / electronic devices 11
2.5.3 Inspection in accordance with the Ordinance on
Industrial Safety and Health 12
2.5.4 Safety test 12
3 Technical data 13
3.1 General characteristic features 13
3.2 Electrical system, optical system, mechanical system 13
3.3 Weight 14
3.4 Dimensions 14
3.5 Block diagram KLC 11 14
4 Transport, installation and connection 15
4.1 Scope of delivery 15
4.2 Packaging 15
4.3 Shipping instructions 16
4.4 Dimensions 16
4.5 Installation 16
4.5.1 Mounting flange KLC 17
4.5.2 Adapter ADP 17
4.6 Connection 18
4.6.1 Electrical connection 18
4.6.2 Connector diagram 18
4.7 Storage 18

5 Description 19
5.1 Functional description KLC 11 19
5.2 Optionally function blocks for KLC 11 19
5.2.1 Relay module for flame detectors RMF 1 19
6 Operation of the UV flame detector 20
6.1 Test of the UV flame detector 20
6.2 Operating indicator LED 20
6.3 Diagnostic with UVT-Com 20
7 Maintenance and servicing 21
7.1 Cleaning 21
7.2 Maintenance interval 21
7.3 Safety-related check 21
7.4 Behavior in case of error 21
8 Troubleshooting 22
9 Order data 22
10 Accessories 23

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1 | General aspects
1.1 Introduction
This operating manual is a helpful guide for ensuring the successful and safe operation of the
UV flame detector KLC 11. It contains important information on how to operate the system
safely, correctly and efficiently. Observing the operating manual 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 this operating manual are shown for illustration purposes
and do not contain details for design. The operating manual always has 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.
1.2 Warning notes
The following warning notes are used in these operating instructions:
DANGER
!
This warning level indicates an imminent hazardous situation. If the hazardous situation is
not prevented, this will result in death or severe injury. Follow the instructions that accom-
pany this warning to prevent the risk of death and severe personal injury.
WARNING
!
This warning level indicates a potentially hazardous situation. If the hazardous situation is
not prevented, this may result in death or severe injury. Follow the instructions that accom-
pany this warning to prevent the potential risk of death and severe personal injury.
CAUTION
!
This warning level indicates a potentially hazardous situation. If the hazardous situation is
not prevented, this may result in slight or moderate injuries. Follow the instructions that ac-
company 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.
NOTICE
A notice indicates additional information that will make the handling of the device easier.
GENERAL ASPECTS

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1.3 Copyright protection
These operating instructions have to be treated as confidential. They may only be used by
autorized staff. Access by third parties may only be granted upon written agreement of BST
Solutions.
All documents are protected in accordance with the German copyright law. The disclosure
and reproduction of documentation, in whole or in part, as well as the exploitation and com-
munication of its content shall not be permitted unless expressly stated otherwise. Offen-
ders are liable for prosecution 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 disposal.
1.5 Warranty
Read these operating manual carefully and in full before operating the UV flame detector
KLC 11!
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 inst-
ructions on the basis of national regulations on accident prevention and environmental pro-
tection, including information on supervision and notification requirements with respect to
special operating circumstances, i.e. regarding organization of work, working processes and
staff deployed.
The recognized technical rules for safe and professional working also have to be observed in
addition to the operating instructions and the regulations on accident prevention 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 approved by BST Solutions
• non-performance of specified maintenance work
It is recommended that the operator of the device concludes a service contract with
BST Solutions or by BST Solutions authorized companies. This guarantees that the de-
vice is regularly checked by our service staff and ensures that any required wearing and
spare parts are available without long delivery periods.
NOTICE
GENERAL ASPECTS

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GENERAL ASPECTS
1.6 Obligation of the operating company
The UV flame detector KLC 11 may cause hazards if it is operated inappropriately or in an
improper condition.
The operating company is under the obligation to operate the device properly. The operating
company must secure hazardous areas that exist between BST devices and the customer‘s
own equipment.
The operating company must appoint and instruct responsible staff:
• Only deploy trained or instructed staff.
• Clearly set out the responsibilities of the staff with regard to operation, set-up, maintenan-
ce and repair.
• Regularly check that staff are safety conscious, aware of hazards, and are observing the
operating instructions.
• Before starting work, staff who are assigned to work with/on the device must 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 must be stored in such a way that they
are accessible to operating and maintenance staff.
• Appoint who will have responsibility for device operation and ensure that this person has
the authority to overrule any unsafe instructions of third parties.
1.7 Liability disclaimer
All technical information, data and guidance on device operation that are contained within
this operating manual 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 respect to the further development of
the UV flame detector outlined in these operating instructions. No claims can be made based
on the specifications, illustrations and descriptions of this operating manual.
The UV tube is a consumable item, the service life of which is dependent on various
factors outside the control of BST Solutions. Therefore BST Solutions provides no war-
ranty on the life of UV tubes.
Generally valid legal and other binding regulations on accident prevention and environ-
mental protection must be observed and instructed, in addition to the operating inst-
ructions.
Warranty of this device does not cover damage in transit, lens glass breakage (UV tube)
or other damage caused by unqualified handling, incorrect adjustment or inadequate
maintenance.
NOTICE
NOTICE
NOTICE

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BST Solutions shall not be liable for damage or operating malfunctions that result from
operating errors, inappropriate repairs, or non-observance of the operating instructions. We
expressly state that only original spare parts and accessories approved by us shall be used.
This also applies to the components of other manufacturers that have been used.
The installation or use of non-approved spare and accessory parts and any unauthorized
retrofits and modifications are not permitted for safety reasons and exclude any liability by
BST Solutions for consequential damages.
BST Solutions 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 done in good faith. We cannot accept any liability for
translation errors; this also applies where the translation has been done or has been com-
missioned 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. Drawings and graphics are not to scale.
GENERAL ASPECTS

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GENERAL ASPECTS
1.8 Address of the manufacturer
BST Solutions GmbH
Ruegenstr. 7 . 42579 Heiligenhaus . Germany



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SAFETY
2 | Safety
2.1 Intended use
The UV flame detector KLC 11 has been developed to meet the requirements of UL 372-2, CSA
C22.2 and EN 298. The internal increase of the UV tube voltage immediately after apply supply
voltage ensures the safety requirements for the examination of the UV tube to through-ig-
nition. A simple change from ionisation flame control to the KLC 11 is permissible therefore
also with control boxes without own UV tube input.
For safety reasons and technical regulations, a restart controlled by the system of at least
once per 24 h operating hours must be guaranteed.
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.
2.2 Requirements on persons
Do not allow any persons who are being apprenticed, educated, instructed or on a general
training program 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 re-
activity shall not be permitted to carry out work on the device.
Connection, set-up, maintenance and repair work may only be done by qualified specialist
staff. This device may cause hazards if it is operated inappropriately by untrained staff or if
it is not used for its intended purpose. Generally valid legal and other binding regulations on
accident prevention and environmental protection in addition to basic health and safety re-
quirements have to be observed. The operating company has to instruct its staff accordingly.
Danger when improperly used!
The device may cause hazards if it is not used as intended 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 manual have to be observed.
DANGER
!
Work on/with the device may only be performed by persons authorized to do so based
on their training and qualification. Furthermore, such persons have to have been com-
missioned by the operating company.
NOTICE
The UV flame detector KLC 11 has to be switched off for more than 5 seconds before
burner operation can be started again.

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2.3 Safety instructions
Before working at the UV flame detector switch off the power supply. Before first commis-
sioning or replacement of the device check external wiring!
The following instructions on accident prevention have to be observed when operating the
flame detector:
2.4 Safety devices
2.4.1 Fundamental aspects
Check 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 UV flame detector is responsible for the proper operation of the device.
2.4.2 Safety devices on the UV flame detector
The UV flame detector KLC 11 has been fitted with the following safety devices:
• Housing (protection against accidental contact)
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! Imme-
diately notify the appropriate authority/person of any changes that occur (including
changes in operating performance). If necessary, stop and secure the device imme-
diately.
• Allow only autorized specialist staff to carry out set-up and/or maintenance work.
• 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 manual 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 manual always has to be kept close to the device and be readily at hand.
• Any non-compliance with the safety instructions outlined in this operating manual
may lead to damage to property, personal injury or even death.
The device has been fitted with warning and danger signs for the protection of operating
staff. These signs must be observed. Damaged or illegible signs must be replaced im-
mediately.
NOTICE
NOTICE
SAFETY

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2.5 Safety instructions in case of maintenance and troubleshooting
2.5.1 Fundamental aspects
• Deadlines set or indicated in the operating manual for repetitive checks / inspections shall
be observed!
• Appropriate workshop equipment is essential for performing maintenance work.
• In conformance with electrical regulations, work on electrical equipment of the system may
only be done by an electrical specialist or by trained staff under the direction and super-
vision of an electrical specialist.
• The adjustment, maintenance and inspection activities, and deadlines stipulated by BST So-
lutions, including information on the replacement of parts / assemblies, must be observed!
These tasks may only be done by authorized specialist staff.
• Operating staff have to be informed before maintenance or other special work is done.
A supervisor must be appointed.
• Screw connections which have been loosened during maintenance and servicing work, must
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 com-
pleted.
• Ensure safe and environmentally friendly disposal of replacement parts!
• Spare parts supplied by BST Solutions or approved of by BST Solutions only may be used.
2.5.2 Electrical / electronic devices
SAFETY
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 detector from the
power supply network!
DANGER
!
In keeping with the electrical regulations, work on electrical, electronic parts,
components may only be done by electrical specialists.
NOTICE
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 corrected.
• Equipment parts undergoing inspection, maintenance or repair work have to be made de-
energized, if required. First check that the disconnected parts are no longer live, then short
to earth (ground). Also isolate neighboring 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 original fuses with the specified current!

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2.5.3 Inspection in accordance with the Ordinance on Industrial Safety and Health
In the event of the combination or installation of units from different manufacturers or sup-
pliers, a precise test must be done by the operator before commissioning in accordance with
the applicable industrial safety regulations and the applicable electrical engineering rules.
In case of queries, please get in touch with BST Solutions.
2.5.4 Safety test
SAFETY
To ensure proper operation, the UV flame detector must be tested several times in all
applications by starting and stopping the burner several times. The ionization cur-
rent simulation must switch off reliably in all cases when there is no flame. This test
should be done in different operating situations (see technical data sheet). This is an
indispensable prerequisite for safe and proper operation of the unit!
WARNING
!

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3 | Technical data
3.1 General characteristic features
• UV-Tube
• Fully electronic construction
• Intermittend operation
• MH47747
3.2 Electrical system, optical system, mechanical system
TECHNICAL DATA
Optical features 185 to 260 nm
tolerated flame signal fades approx. 200 ms
Orientation to flame radial, left (optional axial -> thereby reduced
sensitivity approx. 40 %)
Lifetime of the UV-tube > 10,000 h
Operating voltage 120 V AC
50 to 60 Hz
consumption max. 5.5 mA
Operating temperature 0 °F to 140 °F
(temperatures above > 125 °F reduces lifetime)
Humidity max. 95 % r.H., non-condensing
Operating position any position
Protection class IP 41
Protection level II
Switch-On delay after flame on typically 0.5 s
Switch-Off delay after flame off < 0.6 s
Deenergizing time before restart > 5 s
Output Potential-free, Semi conductor relay
max. switched current 15 mA
max. switched power 0.3 W
max. switched voltage 280 V AC / 400 V DC
Applies for the maximum length of cable:
By an appropriate size depending on the length of cable is to ensure the compliance with
the data in the controller specified switching voltages /currents.
NOTICE

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3.3 Weight
Weight approx. 1.02 oz
3.4 Dimensions
Length ( incl. plug ) 4.53 in
Width 1.18 in
Height 0.87 in
Drawing see item 4.4
3.5 Block diagram KLC 11
TECHNICAL DATA
1 UV-Sensor
2 Preamplifier
3 Filter
4 Signalswitch
5 Power supply
1
2
3
4
5
Signal
L1
N

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TRANSPORT, INSTALLATION AND CONNECTION
4 | Transport, installation
and connection
4.1 Scope of delivery
• UV flame detector KLC 11
• Operating manual (optional, customer-dependent)
• Connection cable (optional)
• Mounting flange (optional)
• Adapter ADP (optional)
• Angle adapter KLC (optional)
• Diagnostic tool KLC-com (optional)
Refer to the order papers for the exact scope of delivery and compare with the delivery note.
Checking for completeness
Check the entire delivery for completeness against the accompanying delivery note. Please
refer to our terms of sale and delivery otherwise.
Report any damage
After arrival of the device and accessories, notify the shipping or carrier, and BST Solutions
immediately in case of any damage caused by transport or inadequate packaging.
Take steps to minimize and prevent further damage.
Take measures to minimize and prevent further damage. Report the case of damage to the
distributor immediately.
All installation and connection work must only be done by qualified and approved
specialist staff! Observe the legal stipulations and adjustment instructions of the plant
operator!
NOTICE
4.2 Packaging
The UV flame detector KLC 11 is shipped in different packaging materials. The most frequently used
packaging materials are cardbard and plastics (foils, foamed material).
Packaging has to be disposed of in an environmentally friendly way and in accordance
with the relevant provisions on disposal.
NOTICE

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TRANSPORT, INSTALLATION AND CONNECTION
4.4 Dimensions
see the following illustration:
4.3 Shipping instructions
Do not subject the appliance to heavy impacts during transport. Do not subject the
appliance to any humidity!
NOTICE
4.5 Installation
The KLC 11 should be mounted close to the flame with straight alignment. The flame detector

opening. Mount the UV flame detector with the holder. The angle of view, especially with sight
tubes, must be of appropriate dimensions to avoid any reduction of flame radiation. Protect
the sensor against other light sources.
To prevent faults, the direct view of an ignition spark must be avoided. Faults in the pre-pur-
ge phase can be caused by this. The maximum cable length of the connection cable must be
observed. The connection cable must be kept separate from high-energy ignition and mains
cables and must not be laid parallel to them over long distances.
All installation and connection must only be done by qualified and approved specialist
staff! The legal regulations as well as adjustment instructions of the plant operator
have to be observed!
NOTICE
4.53
1.18
0.53
All dimensions in inch
0.87
2.171.97
1.22
Radial view opening

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TRANSPORT, INSTALLATION AND CONNECTION
For the mounting BST solutions offers different accessories:
4.5.1 Mounting flange KLC
The mounting flange holds the detector in a suitable position to view the flame. Two over-
all heights of 0.28 in and 0.52 in are available. An O-ring seal is available which will give the
mounting flange an air tight seal to the burner housing if required.
4.5.2 Adapter ADP
Adapter ADP enables installation of the UV flame detector series KLC 11 with optional axial
direction directly at a combustion chamber. A quartz glass serves as a pressure barrier and pre-
vents the escape of heating gases from the combustion chamber. For the application of the flame
detector KLC at high surface temperatures, the version made of heat-insulating material should
be used.
For safety reasons, there must be at least one control shutdown per 24 hours. During
start-up, the KLC 11 independently carries out an internal voltage increase to test the
UV tube. After the end of the heat requirement, the KLC 11 must be de-energized for > 5
s by means of suitable connection wiring. The voltage should only be switched on at the
time of the heat requirement and absolutely before the external light check. If the KLC
11 is permanently live, an burner control must be used to check to determine whether
a flame signal is present after a control shutdown.
DANGER
!


0.27
0.1 6
0.1 8
1.89
1.38

All dimensions in inch
All dimensions in inch
2.562.95




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TRANSPORT, INSTALLATION AND CONNECTION
4.6 Connection
4.6.1 Electrical connection
Refer to the Technical Data chapter and the following wiring diagram for connection data.
Check that the mains voltage corresponds to the voltage indicated on the type plate.
Before connecting, check the device and the connecting cables for visible damage.
4.6.2 Connector diagram
4.7 Storage
Do not unpack packed UV flame detector and accessories.
The following conditions apply to storage:
• Store in a dry place. Maximum relative humidity: 95 % r. h., non-condensing.
• maximum storage time 3 years
• Ensure that the packages are not stored outdoors.
• In addition, ensure that the floor of the storage room is dry during storage.
• Protect from direct sunlight. Storage temperature: 40 °F to 120 °F
• Store dust-free.
• Avoid mechanical shocks and damage.
Danger to life caused by electrical current!
When connecting, observe the safety instructions and the locally applicable safety regulations!
DANGER
!
LED
Type of control box Connection for
Red N
Black Ion
Brown L1
Please ask for connection details for all other
types/manufacturers burner control boxes.

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DESCRIPTION
5 | Description
5.1 Functional description KLC 11
The KLC 11 is a compact UV flame detector specially designed for single burner furnaces
which produce almost no radiation in the visible light spectrum or operate with very low fla-
me modulation. The UV tube used ensures that background radiation, e.g. from glowing brick
linings or mixing equipment parts, is not detected.
The flame signal intensity can be easily recognized without any effort by means of an LED
as optical indicator. By using the UVTcom readout unit, the flame signal can be read out and
logged by the BSTcom software on a PC.
The KLC 11 can be connected directly to the ionization or LDR input of the burner control. It
is compatible in its dimensions, connection dimensions and pin assignment with other units
from the KLC series. All accessories are therefore identical and reduce the variety of parts in
production and service.
The internal boost of the UV tube voltage immediately after applying the supply voltage en-
sures the safety requirements according to UL 372 for the check of the UV tube for ignition.
A simple conversion from ionization monitoring to the KLC 11 is therefore also possible with
burner controls without an own UV-cell input.
Since the KLC 11 performs a self-test only at the moment of switch-on, it is approved for
intermittent operation. The flame detector must be disconnected from the mains for at least
5 s and restarted at least once every 24 hours.
5.2 Optionally function blocks for KLC 11
5.2.1 Relay module for flame detectors RMF 1
The UV flame detector KLC 11 is a low power signal out-put equipped to simulate ionizati-
ontion or LDR signal. If a relay switch contact is required, the use of Relay module for flame
detector RMF 1 / 120 is recommended. The RMF 1 / 120 has an electrically potential free switch
contact with a maximum switching voltage of 250 V AC, a maximum switching current of 1 A
and a maximum rating of 250 VA. More information can be found in the operating manual of
the RMF 1 / 120 in its current version.

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OPERATION OF THE UV FLAME DETECTOR
6 | Operation of the UV flame detector
6.1 Test of the UV flame detector
To ensure proper operation, the UV flame detector has to be tested several times by starting
and stopping the burner. As long as there is no flame in all cases the UV flame detector has
to be switched off solid. The test should be repeated for different operation situations (see
datasheet). This is an essential condition for safe and proper operation.
6.2 Operating indicator LED
UV flame detector KLC 11 uses a built-in LED to indicate the following operating conditions:
6.3 Diagnostic with UVT-Com
The UVT-Com readout unit consists of an optical adapter with cable, USB interface and soft-
ware BST-Com. It displays current pulses of the KLC 11 UV tube.
For this purpose, the USB-optoadapter UVT-Com must be inserted into the recess of the
LED. Via the connection cable and the interface, the data can be read into a laptop or PC
using the corresponding BST-Com software. Further information can be found in the BST-
Com operating instructions.
LED Meaning
off KLC is not active or without potential.
flashing KLC has detected a flame; the quality of the flame
signal is indicated by the intensity of the flashing of
the LED – fast flashing indicates a healthy flame si-
gnal and vice versa - slow flashing indicates a weak
flame signal.
on KLC has detected the strongest level of flame signal.