Lamtec F152 User manual

www.lamtec.de
Sensors and Systems for Combustion Engineering
Manual
Flame Monitoring Device
F152

2
Table of Contents
Table of Contents
1 Important Information about the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Purpose/Applicability of the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safekeeping of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Target Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Classification of the Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Product-specific Dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Proper Use - Conditions of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Life Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5.1 Adjustable Holder, Cooling-air Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5.2 Connection Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.3 Flame Scanner Testing Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Design and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.1 Safety When Putting the Device Into Operation . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.2 Electrical Safety – Requirements to Be Met by Third-party Manufacturers. . . . 23
5.1.3 Special Points to Note When Using the Device in Explosion-proof Areas. . . . . 23
5.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.1 Electrical Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.2 Prerequisite for Mounting the Device Properly . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.3 Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.4 FFS07 and FFS08 Installation on Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.4.1 FFS07 mounting on the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.4.2 FFS08 mounting on the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Putting the Device into Operation for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.2 Adjustment and Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.3 Testing the Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3.4 Set Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3.5 Switch-off Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.6 Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.1 Mounting/Dismounting the Sluice Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3 Warranty and Delivery Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Table of Contents
7 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8 Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1 Fault Finding and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1.1 Faults During Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1.2 Faults after assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1.3 Faults During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.2 Information About the Repair Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10 Disposal Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1.1 Flame Monitor F152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1.2 Flame Scanner FFS07/FFS08. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.1.3 Connection Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.1.3.1 FG 21 Connecting housing (Aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.1.3.2 Connection Housing FG 24 Ex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.1.4 Flame Scanner Testing Device FFP30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.2 Connecting Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.2.1 F152 with FFS07/FFS08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.2.2 ETAMATIC with FFS07/08. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.3 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.4 Order Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4
1 Important Information about the Manual
1 Important Information about the Manual
1.1 Purpose/Applicability of the Document
This manual allows you to use the LAMTEC Flame Monitor F152 in combination with the
LAMTEC flame scanners FFS07 or FFS08 safely and efficiently.
This manual is valid for all F152/FFS07/FFS08 in any configuration.
F152 complies with the following standards and directives:
• DIN EN 298:2012
• DIN EN 60730-2-5:2015
• DIN EN 50156:2016, chapter 10.5
• DINEN746-2:2011 (Industrialthermoprocessingequipment –Part2:Safetyrequirements
for combustion and fuel handling systems)
• 2014/68/EU (Pressure Equipment Directive)
• 2009/142/EG (Gas Appliances Directive)
• EU/2016/426 Gas Appliance Regulation (GAR)
• 2014/35/EU (Low Voltage Directive)
• 2014/30/EU (EMC Directive)
• DIN EN 61508:2011, Ed.2 part 2 (SIL 3 requirements)
• DIN EN 60730-1:2012
• EN60079-0:2013, -15:2011, -31:2010 (Explosion protection) - FFS07 only
• UL 372 – UL Recognized-type
• 2011/65/EU (RoHS2 Directive)
1.2 Safekeeping of the Manual
Look after the manual and all the associated documents carefully.
The manual is part of the product and must be kept safe and be accessible to personnel at all
times.
Moreover, it is important that the manual:
• Is available when required.
• Is kept for the entire service life of the device.
• Is available to its next operator.

5
1 Important Information about the Manual
1.3 Target Group
These instructions must have been read carefully and completely before commencing with
any work. The basic prerequisite for working safely is compliance with all the specified safety
instructions.
NOTICE
All assembly, commissioning, troubleshooting and maintenance work may only be carried
out by authorised and trained personnel.
The device may be operated and maintained only by those who are capable of doing so
in terms of their level of knowledge and training.
Opening the devices is not permitted under any circumstances.
For safety reasons, access to parameterization must be restricted to authorised
personnel.

6
2 General Safety Instructions
2 General Safety Instructions
2.1 Classification of the Safety Instructions and Warnings
Thefollowingsymbols are usedinthis document to drawtheuser's attention toimportantsafe-
ty information. They are located at points where the information is required. It is essential that
the safety information is observed and followed, and that applies particularly to the warnings.
DANGER!
This draws the user's attention to imminent danger. If it is not avoided, it will result in death or
very serious injury. The plant including its surroundings could be damaged.
WARNING!
This draws the user's attention to the possibility of imminent danger. If it is not avoided, it may
result in death or very serious injury. The plant including its surroundings could be damaged.
CAUTION!
This draws the user's attention to the possibility of imminent danger. If it is not avoided, it may
result in minor injuries. The plant including its surroundings could be damaged.
NOTICE
This draws the user's attention to important additional information about the system or system
components and offers further tips.
The safety information described above is incorporated into the instructions.
Thus, the operator is requested to:
1 Comply with the accident prevention regulations whenever work is being carried out.
2 Do everything possible within his control to prevent personal injury and damage to prop-
erty.

7
2 General Safety Instructions
2.2 Product Safety
WARNING!
This product is state-of-the-art technology and complies with the generally accepted
safety-related rules and regulations.
Every device is tested before delivery to ensure that it is working properly and safely.
Only use this product when it is perfect condition and in accordance with the manual, the
prevailing regulations and guidelines and the applicable safety and accident prevention
regulations.
WARNING!
The risk of danger in the event of external fire, traffic and wind, flood waves and earthquakes
depend on the installation situation and the installation site to be assessed separately where
appropriate.

8
2 General Safety Instructions
2.3 Product-specific Dangers
DANGER!
The F152 is not designed to switch off the fuel valves.
The subsequent signal processing must be carried out in the control system, which is
adapted to suit the combustion plant..
WARNING!
The F152 is a safety device. Only specialist staff of the manufacturer or people approved by
the manufacturer may intervene. No interventions by anyone else are permissible. This ap-
plies, in particular, in the event of a defective fuse..
WARNING!
Radio interference suppression of the output contacts
In the interests of safety, ensure when installing the output contacts that:
The user suppresses radio interference in such a way that the contacts of the safety relay
contact output cannot be shorted by defective components of the suppressor circuitry.

9
3 Product Description
3 Product Description
3.1 Proper Use - Conditions of Use
Refer to the table in chapter 3.4 Selection Criteria, for which application the flame scanners
FFS07/FFS08-Types are preferred to use.
Please respect the following information while operating the LAMTEC flame scanners:
• Safety instructions in this manual
• Chapter 11.1 Technical Data in this manual
Any other use of this devices is considered to be improper. LAMTEC GmbH & Co. KG is not
liable for damages resulting in improper use.
3.2 Life Cycle
The device is designed to have a service life of 10 years or 250,000 cycles. The functional
safety calculations are based on these values.
The actual service life of the F152 depends on the ambient temperature among other factors.
In particular, operation at high temperatures reduces the actual service life.
F152 The Flame Monitor F152 is particularly designed for safety rele-
vant monitoring of burner flames in mono-burner plants.
The Flame Monitor F152 is provided for mounting in a control cab-
inet.
FFS07 The flame scanner FFS07 can be used as a explosion-protected
equipment in explosive atmospheres up to Ex-zone 2. In variant
FFS07-Ex it can be used in Ex-zone 1 as well. The flame scanner
FFS07 is designed to be used outdoor.
FFS08 The flame scanner FFS08 is designed to be used outdoor.

10
3 Product Description
3.3 Rating Plate
You will find details of the configuration on the rating plate:
Type plate example:
NOTICE
The flame monitoring device is only available in the 120V version with UL approval..
Fig. 3-1 Type plate FFS07 and 08

11
3 Product Description
3.4 Selection Criteria
The Flame Monitor is particularly designed for mono-burner plants. It can be used with the fol-
lowing fuels:
• Oil
• Gas
• Biomass
• Solids (wood dust, etc.)
• chemical and other waste products
• or a combination of these
Selection Criteria Spectrum and Frequency
The spectral sensitivity of the flame scanners determines their suitability for specific fuels.
NOTICE
LAMTEC guarantees that the flame sensor is in perfect working order but cannot offer any
guarantees if it is used improperly.
Note the specific requirements of your plant when selecting the flame sensors. We will be
pleased to answer any questions you may have in relation to LAMTEC products.
Selection criteria fuel:
The following table provides an overview:
Type Sensor Sensi-
tivity Spectrum [nm] Sight angle
approx
Preferred Area of Application/Fuels
FFS07,
FFS07 Ex,
FFS08
UV-1 +
o 260 ... 400 nm 8° • Oil
• Gas
UV-4 ++ 215 ... 360 nm 8° • Oil
• Gas
• Special gases such as refinery gas,
blast furnace gases and hydrogen
--
FFS07,
FFS 07 Ex ,
FFS08
IR-1 ++ 1000 ... 2500 nm 60°
• Oil
• Gas
• Furnaces with a high level of flue-gas
recirculation
• Yellowish waste gases without UV
radiation

12
3 Product Description
Additional letters are describing additional properties:
The suitability of the device types may differ from that indicated in the table depending on par-
ticular circumstances.
Example type identification:
FFS07 IR-1 T
FFS08 IR-1 T S2
FFS07 IR-1 T Ex
Fig. 3-2 Spectrum of the flame
Addl.
Identifyer especially used with Property Area
T IR in the field of low
frequencies little turbulent flames, such as in strong recirculation
S2 IR low sensitivity high residual radiation out of the com-
bustion chamber, high intensity such as
at some pulverised fuel burners

13
3 Product Description
3.5 Accessories
3.5.1 Adjustable Holder, Cooling-air Housings
Optimised LAMTEC ball-and-socket joint for FFS07 /V/ EX
Fig. 3-3 Brackets for FFS07
An overview of the brackets and cooling air housing for LAMTEC flame scanners are to be
found in the document "Flame Monitoring Systems and Accessories" (DLT7673).

14
3 Product Description
Special features for installation of FFS07 with the bracket FH30...
In order to avoid dirt in the optical lense during operation, the following graphics of installation
steps are to be noted.
NOTICE
It is to be ensured particularly that the flame sensor FFS07 standard, sealed in the provided
plastic seal of the bracket is press-fitted before the clamping device is tightened.
Fig. 3-4 FFS07 standard installation on FH30-00

15
3 Product Description
Optimised LAMTEC ball-and-socket joint for FFS08
Fig. 3-5 Brackets for FFS08

16
3 Product Description
Installation/de-installation of FFS08 with the FS60-00 bracket
Installation of FFS08 with FS60-00 bracket
1. Turn bracket on burner approx. 20° to the left up to the stop and fasten both screws (1).
2. Insert the flame sensor in the bracket and position it to the flame optimally. Fasten the
flame sensor with clamping screw.
Fig. 3-6 Bracket installation FS60-00
De-installation e.g. for maintenance/cleaning:
1. Loosen screws (1), and remove bracket from burner by turning bracket with fixed flame
sensor approx. 20° to the right.
2. For installation according to maintenance, mount in reverse order, turn brackets to the left
up to a stop and fasten both screws(1).
The initial position of the flame sensor installation position is restored.

17
3 Product Description
Insulation piece for thermical decoupling of FFS07 659S3900
For more information, refer to document "Brackets for Flame Scanner Systems" (DLT7660)
Fig. 3-7 Insulation piece for flame brackets
Fig. 3-8 Temperature according to thermical decoupling
NOTICE
The specifications do not take into account the influence of ambient temperature or radiant
heat on the Flame Scanner.
Cooling air housing FS30 for FFS07 659R0109
Cooling air housing FS65 for FFS08 659R3109
An overview of all brackets and cooling air housing for LAMTEC flame scanner can be found
in the document "Flame Monitoring Systems and Accessories" (DLT7673).

18
3 Product Description
3.5.2 Connection Housing
You may use the connection housing offered by LAMTEC or customary connection housing.
Beside all usual requirements respect the additional requirements in chapter 5.1 Safety for
mounting and installation.
3.5.3 Flame Scanner Testing Device
Fig. 3-9 FFP30 flame-scanner testing device
You can use the FFP30 to test that your flame scanner is working properly.
The testing device simulates a variable flame frequency
The testing device is screwed onto the flame scanner and adjusted for the IR or UV range by
means of a toggle switch. The device has to be adjusted sufficiently for detection of the simu-
lation.
DANGER!
Explosion hazard!
Flame sensors must not be tested in a potentially explosive atmosphere
You will find the technical specifications for this device in section 11.1.4 Flame Scanner Test-
ing Device FFP30.

19
4 Design and Functions
4 Design and Functions
4.1 Design
The flame monitor consists of the flame monitoring system F152 and the flame scanner
FFS07 or FFS08.
Connection:
The connection is made via plug-in screw terminals at the F152.
Terminals used for:
• Feed in axillary power (mains)
• Flame signal/indicator signal
• Measuring power for intensity
• Flame sensor cable
Alignment of the control and operating elements see chapter 4.3 Control Elements
F152 Plastic housing
Top hat rail mounting
FFS07 Cylindrical metal housing with axial light entry
For mounting with LAMTEC holding devices
FFS08 Cylindrical metal housing with radial light entry
For mounting with LAMTEC holding devices