DURAG D-LX 200 User manual

D−LX 200
D−LX 720
Compact Flame Monitor
GmbH · Kollaustraße 105 · 22453 Hamburg · www.durag.de

Translation of the original operating manual Compact Flame Monitor D−LX 200, D−LX 720
Document: man_dlx200_720_1_uk.doc
Version: 01.01.2009 -1
Last update: 15.01.2009
Print date: 03.03.2009
European
inspection base: EN 298 (2003) EN 230 (2005)
Fuel / Device: Gas Öl
Register number:
Inspected by TÜV Süddeutschland
Approved for intermittent operation, continuous operation and 72-hour operation. Registered by DVGW
DURAG GmbH Telephone: [phone] – 0
Kollaustraße 105 Fax : [phone]
22453 Hamburg E-Mail: [email protected]
Internet: www.durag.de
This documentation
(approx. 117 pages) has been compiled with the greatest care. However, all liability must be
excluded.
is not intended for the US American market. Documentation in accordance with ANSI Z535
standard can be requested. Reference addresses can be found on page 115.
or parts of it may not be duplicated, transmitted or translated into other languages, independent
of which way and through which means this happens, electronically or mechanically, without the
explicit permission of DURAG GmbH.
refers to the complete equipment in principle, even if individual program modules or devices
(device parts) have not been purchased.
refers to the current status of the equipment design at the time of updating this documentation
(see above).
can be changed without notice with regard to content.
© DURAG GmbH 2009 Editorial staff: Herbert Lange.
All rights reserved.
DURAG creates the German original version of this operation handbook and the
English translation of the original version. DURAG checks for the correctness of these
editions
For all other language specific versions DURAG GmbH takes no responsibility.
In doubts, the original version is valid.

Contents
D−LX 200, D−LX 720 3
Contents
0Foreword 7
1General 11
1.1 Brief overview of the contents 11
1.2 Typographical conventions 12
1.3 Meaning of the warnings and notes used 12
2Safety Instructions 17
2.1 General safety instructions 17
2.2 Hazard from electrical equipment 18
2.3 Hazard from hot, aggressive or explosive gases 18
2.4 Hazard to the device due to purge air failure 19
2.5 Proper use 20
2.6 Prevention of consequential damages in the event of system malfunction 20
2.7 Qualified personnel 20
3Product Description 25
3.1 Notes on delivery 25
3.2 Scope of supply / Design variants 25
3.3 Special accessories (optional) 26
3.4 Options 27
3.5 Notes on the product 27
3.6 Fields of application, intended use 27
3.7 Selection criteria for Compact Flame Monitor D−LX 200, D−LX 720 28
3.8 Conformity/Approvals 28
3.9 Identification of the product 30
3.10 Notes on warranty 30
4Design and Function 33
4.1 Functional description 33
4.2 Device description 36
5Installation, Commissioning 43
5.1 Safety 43
5.2 Transport 44
5.3 Installation 44
5.4 Commissioning 50
6Adjusting the Flame Monitor 53
6.1 Adjusting the thresholds 54
6.2 Setting the gain characteristic curve 57
6.3 Range selection 59
6.4 Setting the Modbus address 59
6.5 Setting process 59
6.6 Safety time 64
7D−LX 200 InformationCentre PC Version 69
7.1 System requirements 69

Contents
4D−LX 200, D−LX 720
7.2 Installation 69
7.3 Start / Execute 69
7.4 Pull-down menus 75
7.5 Error messages 77
7.6 Structure of the stored data records 77
8Modbus 83
8.1 Hardware and boundary conditions 83
8.2 Setting the Modbus slave address 83
8.3 Modbus 85
8.4 DURAG Modbus DataMap 88
9Maintenance 95
9.1 Customer service information 95
9.2 Safety 95
9.3 Maintenance intervals 96
9.4 Maintenance tasks 96
9.5 Fault 96
10 Technical Data 101
10.1 Technical data of the basic device 101
10.2 Factory settings (default) 102
10.3 Technical data for the integrated flame sensor 102
10.4 Presettings 102
11 Plans and Drawings for D−LX 200, D−LX 720 103
11.1 Wiring diagram D−LX 200, D−LX 720 103
11.2 Dimensional drawings 104
12 Declaration of conformity 107
13 Glossary 109
14 Index 111
15 DURAG GROUP company addresses 115

Contents
D−LX 200, D−LX 720 5
Index of illustrations
Figure 4.1: System overview D−LX 200 .................................................................................................. 33
Figure 4.2: System overview D−LX 720 .................................................................................................. 33
Figure 4.3: Block diagram........................................................................................................................ 34
Figure 4.4: D−LX 200 .............................................................................................................................. 36
Figure 4.5: Exploded drawing D−LX 200................................................................................................. 38
Figure 4.6: Exploded drawing D−LX 720................................................................................................. 39
Figure 5.1: Safety screw.......................................................................................................................... 44
Figure 5.2: Dimensional drawing of swivel mount (optional for D−LX 200) D-ZS 033-I.......................... 45
Figure 5.3: Location of the fuses ............................................................................................................. 46
Figure 5.4: Wiring diagram D−LX 200, D−LX 720................................................................................... 47
Figure 5.5: Elimination of the potential isolation...................................................................................... 48
Figure 5.6: Volume flow depending on the purge air............................................................................... 49
Figure 5.7: Purge air connection ............................................................................................................. 49
Figure 6.1: Printed circuit board numbering ............................................................................................ 54
Figure 6.2: Front panel D−LX 200 ........................................................................................................... 55
Figure 6.3: Setting Intensity..................................................................................................................... 55
Figure 6.4: Flicker frequency setting [Hz] of the flame ............................................................................ 56
Figure 6.5: Gain characteristic curves..................................................................................................... 57
Figure 6.6: PCB no.2, () DIP switches S3 and S4 .............................................................................. 58
Figure 6.7: Flow chart for settings by means of current output/LED ....................................................... 61
Figure 6.8: Flow chart for settings by means of InformationCentre ........................................................ 63
Figure 7.1: InformationCentre front screen.............................................................................................. 70
Figure 7.2: "Connection" menu of the InformationCentre........................................................................ 71
Figure 7.3: Display view of the InformationCentre .................................................................................. 71
Figure 7.4: Display view Flame Information ............................................................................................ 72
Figure 7.5: Signal for a measuring cycle ................................................................................................. 73
Figure 7.6: System Settings .................................................................................................................... 74
Figure 7.7: "File" menu ............................................................................................................................ 75
Figure 7.8: "FileSetting" submenu ........................................................................................................... 75
Figure 7.9: "Adjust CurrentOutput" submenu .......................................................................................... 76
Figure 7.10: Extra window with error message ........................................................................................ 77
Figure 8.1: PCP no.4, jumper X2" .......................................................................................................... 84
Figure 8.2: PCB no.2, () DIP switch S5............................................................................................... 84
Figure 11.1: Wiring diagram D−LX 200, D−LX 720................................................................................ 103
Figure 11.2: Dimensional drawing D−LX 200......................................................................................... 104
Figure 11.3: Dimensional drawing D−LX 720......................................................................................... 105
Index of tables
Table 3.1: Default settings for D−LX 200, D−LX 720 .............................................................................. 27
Table 3.2: Suitability of device variants (spectral ranges)....................................................................... 28
Table 3.3: Device approvals .................................................................................................................... 29
Table 4.1: Meaning of the LEDs .............................................................................................................. 40
Table 5.1: Requirements for operation checklist ..................................................................................... 50
Table 6.1: Setting MODE switches S3 and S4........................................................................................ 58
Table 6.2: Setting MODE switches S3 and S4........................................................................................ 65
Table 7.1: System Settings...................................................................................................................... 74
Table 7.2: Data record structure.............................................................................................................. 79
Table 8.1: Setting the jumper X2 ............................................................................................................. 84
Table 8.2: Setting for MODE switch S5................................................................................................... 85
Table 8.3: Modbus RTU Message Frame ............................................................................................... 85
Table 8.4: Modbus Slave Address Range............................................................................................... 85
Table 8.5: Modbus FunktionCode ........................................................................................................... 86
Table 8.6: Modbus FunctionCode(0x03..0x04) Read 16BitRegisters Request....................................... 86

Contents
6D−LX 200, D−LX 720
Table 8.7: Modbus FunctionCode(0x03..0x04) Read 16BitRegisters Response ................................... 86
Table 8.8: Modbus FunctionCode(0x10) Write Multiple 16BitRegisters Request................................... 87
Table 8.9: Modbus FunctionCode(0x10) Write Multiple 16BitRegisters Response ................................ 87
Table 8.10: Modbus register and address information............................................................................. 88
Table 8.11: Modbus register and device-specific address information.................................................... 89
Table 9.1: Error messages..................................................................................................................... 97
Table 10.1: Technical data of the basic device...................................................................................... 101
Table 10.2: Factory settings (default)..................................................................................................... 102
Table 10.3: Technical data for the integrated flame sensor................................................................... 102
Table 10.4: Presettings........................................................................................................................... 102

Foreword
D−LX 200, D−LX 720 7
0 Foreword
The purpose of this manual is to help you to become acquainted with your
DURAG product.
In this publication you will find information and technical data on planning,
installation / commissioning, operation and maintenance of the D−LX 200,
D−LX 720.
The two device types D−LX 200 and D−LX 720 are identical in design, apart
from the respective optics. Therefore both designations are always specified in
this manual, separated by a comma. The differences, exclusively in the front
part of the devices (the D−LX 720 is intended for use with an optional fibre-
optic system), are described in the relevant chapters, identified accordingly.
The functional diagram of the complete system and the device components
complete this information.
Our aim is to make a decisive contribution to your success with our products
and services. We hope that the information provided here will enable us to do
so.
Flame monitors are safety devices and are designed to ensure the safe
operation of a furnace plant.
The adjustment of flame monitors should therefore only be performed by
appropriately trained personnel. DURAG offers suitable training for this
purpose.
Should you have any further questions on products or applications from the
DURAG GROUP, please use our Support & Service!
You will find the relevant addresses and telephone numbers on page 115
(DURAG GROUP company addresses).
Further information is also available from www.durag.de
Please read this manual carefully before commissioning the Compact Flame
Monitor! The information provided is important for your safety and for
preventing damage to the D−LX 200, D−LX 720 and to the environment.

D−LX 200
D−LX 720
Compact Flame Monitor
0 01 1
1General
1.1 Brief overview of the contents
1.2 Typographical conventions
1.3 Meaning of the warnings and notes used

General
D−LX 200, D−LX 720 11
1 General
The product described in this manual left the factory in perfectly safe and
inspected condition. In order to maintain this condition and to achieve correct
and safe operation of this product, it may only be used as described by the
manufacturer. In addition, faultless and safe operation of the product requires
appropriate transport, correct storage and installation, as well as careful
operation and maintenance.
Flame monitors are safety devices and are designed to ensure the safe
operation of a furnace plant. For this reason flame monitors are type-approved
devices; any interventions or modifications to them will result in loss of the
approval. Repairs may therefore only be carried out by the manufacturer or his
representatives.
This manual contains information necessary for the normal use of the
Compact Flame Monitor D−LX 200, D−LX 720. It is intended for technically
qualified personnel who have been familiarised with the product, who are
specially trained or have pertinent knowledge in the field of measurement and
control engineering.
The knowledge and the technically flawless implementation of the safety
instructions and warnings contained in this manual are necessary for the safe
assembly and commissioning as well as for the safety during operation and
maintenance of the described product. Only appropriately qualified personnel
have the necessary expertise to interpret the safety instructions and warnings
provided in a general manner in this document correctly in concrete individual
cases and to apply the appropriate procedure.
This manual is an integral component of the scope of delivery, even if due to
logistical reasons the possibility of an issue on CD and the separate ordering
or respectively delivery have been provided for. For reasons of clear
arrangements it does not contain all details about all versions of the described
product, and can also not take every possible case for installation, operation,
maintenance and application of the systems into consideration.
If you require further information or if problems occur which are not dealt with
in sufficient detail in this document, please ask your competent DURAG GmbH
representative for the required information (see page 115).
1.1 Brief overview of the contents
This manual describes the following areas:
Chapter 1 + 2 Information on use of the manual, the pictograms used, safety instructions and
requirements on operating and maintenance personnel.
Chapter 3 – 4 Information on the product, technical data, function and system descriptions as
well as the available options.
Chapter 5 – 9 Information for the use of the product D−LX 200, with regard to D−LX 720
installation, assembly, commissioning, operation, maintenance, malfunction
diagnostics, repairs etc.
Appendix 10 – 15 Overview of technical data, standards and regulations to be complied with,
spare parts list, certifications, glossary, index and company addresses.

General
1.2 Typographical conventions
In order to make the text of this manual clear, text elements such as safety
instructions, warnings, tips, keyboard symbols, menu addresses etc. are
displayed differently.
The following conventions apply in this manual:
Safety instructions and warnings appear as follows in this manual:
WARNING Danger from electrical equipment
Before removing the housing or accidental-contact protection, the equipment
must be disconnected from the power supply.
A note or tip is shown like this:
Rotary switches S1 to S8 do not have a stop. The switch can be turned from
switch position F to switch position 0.
Explicitly identified paragraphs only refer to the specified device variant. All
other information applies for both device variants.
This DIP switch is OFF
This DIP switch is ON
A () indicates that the following term is explained in the glossary.
Unless otherwise specified: all dimensions in mm
This manual is also available as a pdf file on CD/DVD!
1.3 Meaning of the warnings and notes used
Please always comply with the following warnings and safety instructions in
this manual. They serve to avert dangers to life and limb of users and
maintenance personnel and to prevent damage to property.
They are highlighted in this manual by the signs defined here. They are also
marked by symbols at the points where they appear. The signs used have the
following meanings for the purposes of this manual and the information on the
product itself:
DANGER Failure to comply with instructions highlighted in this way can result in severe
and even fatal injuries.
Also means that substantial damage to property can occur, if the relevant
precautions are not taken.
> Comply with all hazard warnings, in order to prevent injuries.
12 D−LX 200, D−LX 720

General
D−LX 200, D−LX 720 13
WARNING Failure to comply with instructions highlighted in this way can result in serious
injuries or damage to property.
> Comply with all warnings, in order to prevent injuries and to ensure safe
operation of the system.
CAUTION Failure to comply with instructions highlighted in this way can result in minor
injuries or damage.
> Comply with all caution warnings, in order to prevent injuries and to ensure
safe operation of the system.
In order to specify the potential risk the general warning sign can also be
replaced by a special warning sign.
General warning sign Hot surface
Electric current explosive atmosphere
Electrostatically
endangered
components (ESD)
In addition to the warnings and safety instructions, the following general notes
and related pictograms are also used to draw your attention to particularly
important information:
Here you will find interesting information or tips on the product and its use.

D−LX 200
D−LX 720
Compact Flame Monitor
0 02 2
2Safety Instructions
2.1 General safety instructions
2.2 Hazard from electrical equipment
2.3 Hazard from hot, aggressive or explosive gases
2.4 Hazard to the device due to purge air failure
2.5 Proper use
2.6 Prevention of consequential damages in the event of system malfunction
2.7 Qualified personnel

Safety Instructions
D−LX 200, D−LX 720 17
2 Safety Instructions
Please always comply with the following warnings and safety instructions in
this manual. They serve to avert dangers to life and limb of users and
maintenance personnel and to prevent damage to property.
2.1 General safety instructions
The DURAG Compact Flame Monitor D−LX 200, D−LX 720 is in accordance
with the current state of technology and the recognized technical safety
regulations, nevertheless hazards can arise.
Therefore only operate the product in perfect condition and in compliance with
the operating manual. Changes in the normal operation are indications of
functional impairments which must be taken seriously. In this connection, pay
attention to:
The development of smoke or unusual odours,
Excessive temperature of system parts,
Unexplained changes in power consumption,
Triggering of monitoring devices.
Improper use or handling can result in damage to health or property.
Therefore, please read this chapter thoroughly and comply with the
instructions during all activities on the D−LX 200, D−LX 720 as well as the
safety instructions and warnings in the individual chapters of this operating
manual.
In principle, the following warnings and safety instructions apply for the
D−LX 200, D−LX 720:
The flame monitor is a type-approved device. Any interventions or
modifications will result in loss of the approval. Repairs may only be performed
by the manufacturer or his representatives, as only they can verify full
functionality following repair, by means of extensive long-term tests and
suitable test devices.
The statutory provisions applicable for the system and the technical
regulations implementing these provisions must be complied with during
preparation and performance of work.
Persons working with the system must take account of the local, system-
specific conditions and operation-related dangers and provisions.
Operating manuals and documentation belonging to the device D−LX 200,
D−LX 720 must be present in-situ. The information highlighted therein for
the prevention of dangers and damage must be complied with.
Suitable protective devices and personal safety gear must be available in
adequate quantities and be used by the personnel according to the
respective danger potential.
The device may only be operated in perfect condition and in compliance
with the safety instructions!
The devices as a whole, as well as the individual components, may only
be operated in the original design.
Any interventions or modifications to the design of approved devices will
result in loss of the approval.

Safety Instructions
2.2 Hazard from electrical equipment
This device is operated with electricity. Therefore, only appropriately qualified
personnel may carry out work on this device. These personnel must be
thoroughly familiar with all danger sources and repair measures in accordance
with these operating instructions.
WARNING Danger from electrical equipment
Before removing the housing or accidental-contact protection, the equipment
must be disconnected from the power supply.
The devices may only be connected to the supply voltage shown on the
type plate.
The devices may only be operated on a power supply with an earthing
contact. The protective action must not be cancelled by an extension
without an earthing contact. Any interruption in the protective earth
conductor inside or outside the device is dangerous and is not permitted.
Cables should be laid so that risk of accident due to tripping or getting
caught on the lines is excluded.
We recommend a power supply that guarantees a safe separation between
primary and secondary power circuits (e.g. DURAG D-NG 24/05).
CAUTION Damage to electronic components through
electrostatic discharge (ESD)
Electronic components are becoming ever smaller and more complex. With
this their susceptibility towards electrostatic discharges also increases. To
protect these components, measures must be taken against electrostatic
discharges (ESD protection) when performing any work on the open device.
For prevention of static charging of the human body, service employees can
for example be equipped with a personal grounding system.
2.3 Hazard from hot, aggressive or explosive gases
WARNING Use of the Compact Flame Monitor D−LX 200, D−LX 720 in potentially
explosive areas is only permitted with the appropriately identified device
variant, which is designed for this environment! The zone identification
printed on the device must be noted.
The Compact Flame Monitor is mounted directly on the boiler. In the case
of systems with a low danger potential (ambient pressure, low
temperatures, no health hazard), mounting/removal can occur during
system operation. The applicable provisions and safety regulations for the
system must be complied with and any necessary and appropriate
protective measures taken.
18 D−LX 200, D−LX 720

Safety Instructions
D−LX 200, D−LX 720 19
WARNING Never touch parts that could be hot without temperature-resistant safety
gloves
2.4 Hazard to the device due to purge air failure
CAUTION The purge air serves to protect the system mounted on the boiler. It shields the
components from hot and/or aggressive gases and dusts. The purge air supply
must therefore be reliably ensured even when the system is stationary. If the
purge air fails, the lens can quickly become soiled and the device can overheat
due to heat accumulation and be destroyed.
The operator must therefore ensure that:
the purge air supply operates reliably and without interruption,
a failure is detected immediately,
the Compact Flame Monitor is protected by a valve or disconnection in the
event of a purge air failure.

Safety Instructions
2.5 Proper use
The DURAG D−LX 200, D−LX 720 described in this manual is an Compact
Flame Monitor for monitoring gas, oil, coal and wood flames.
The D−LX 200, D−LX 720 is used as a flame monitor, for example in large
power stations through to smaller district heating plants, chemical process or
thermal exhaust gas incineration plants, refineries etc.. This flame monitor is
suitable for continuous operation and 72-hour operation in accordance with
TRD 604. The device can monitor the flames of all fuels and incineration
technologies, particularly for gas, oil, coal and wood, low-NOx, recirculating
operation, Claus plants etc.
The parameters specified in the Technical Data from page 101, especially the
ambient conditions, must be complied with and observed.
Faultless and safe operation of this device also requires appropriate transport,
correct storage, installation and assembly as well as careful operation and
maintenance by qualified personnel.
The D−LX 200, D−LX 720 has been developed, manufactured, inspected and
documented in compliance with the pertinent safety standards. If the handling
and safety instructions described for project planning, assembly, proper
operation and maintenance are complied with, no dangers normally arise from
the device in respect of damage to property or the health of people.
2.6 Prevention of consequential damages in the event of system
malfunction
In order to prevent and limit faults that can directly or indirectly result in
physical injuries or damage to property, the operator must ensure that:
Competent maintenance personnel can be promptly notified and are
available at all times.
Maintenance personnel are trained in the targeted localisation and
rectification of faults in the D−LX 200, D−LX 720 and associated systems.
The defective system parts are shut down immediately if necessary.
A shut-down does not lead to incalculable consequential malfunctions and
damages.
2.7 Qualified personnel
The operator's personnel who are responsible for safety must ensure that work
on DURAG equipment or systems is only carried out by qualified skilled
personnel, whose competence has been checked by responsible experts.
In the event of unqualified operations on the device or failure to comply with
the warnings provided in this manual or affixed to the device, physical injuries
and/or damage to property can occur.
Qualified personnel for the purposes of the safety-related instructions in this
manual or on the product itself are persons who can identify potential dangers
in good time and prevent them. Skilled personnel/experts are persons in
accordance with DIN VDE 0105 or IEC 364 or directly comparable standards.
The following knowledge is essential:
20 D−LX 200, D−LX 720