BFI Automation CFC 1000L Original Operating Instructions Download Page 1

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Original Operating Instructions

Compact Flame Controller

Type:

CFC 1000L

Document-No.:

BA CFC1000L EN Rev1

Software settings

See

Document-No.:

HB CFC Com1 EN

BFI Automation Mindermann GmbH

Ruegenstr. 7

D-42579 Heiligenhaus / Germany

Tel49 (2056) 98946-0
Fac49 (2056) 98946-42

http://www.bfi-automation.de

Summary of Contents for CFC 1000L

Page 1: ...oller Type CFC 1000L Document No BA CFC1000L EN Rev1 Software settings See Document No HB CFC Com1 EN BFI Automation Mindermann GmbH Ruegenstr 7 D 42579 Heiligenhaus Germany Telephone 49 2056 98946 0 Facsimile 49 2056 98946 42 http www bfi automation de ...

Page 2: ......

Page 3: ... Safety Ordinance BetrSichV 2 6 2 5 4 Safety test prior to initial operation 2 6 3 Technical data 3 1 3 1 General characteristic features 3 1 3 2 Electrical system Optical and Mechanical Data 3 2 3 3 Weight 3 4 3 4 Dimensions 3 4 3 5 Block diagram CFC1000 3 5 4 Transport Installation and Connection 4 1 4 1 Scope of delivery 4 1 4 2 Accessories optional 4 1 4 3 Packaging 4 2 4 4 Forwarding instruct...

Page 4: ...gs 5 2 5 3 1 Safety switch OFF time of the safety channel 5 2 5 3 2 The optical shutter 5 3 6 Operation of the Compact Flame Controller 6 1 6 1 Test of the Compact Flame Controller 6 1 7 Care and Maintenance 7 1 8 Failures 8 1 9 Order data 9 1 10 Accessories 10 1 ...

Page 5: ...r 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 e...

Page 6: ...t 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...

Page 7: ...closure 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 elec tronic comp...

Page 8: ...d 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 pro...

Page 9: ...arly 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 tha...

Page 10: ...ssories 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...

Page 11: ...General aspects 1 7 1 8 Declaration of conformity ...

Page 12: ...cts 1 8 1 9 Address of the manufacturer BFI Automation Mindermann GmbH Ruegenstr 7 D 42579 Heiligenhaus Germany Tel 49 2056 98946 0 Fax 49 2056 98946 42 E mail info bfi automation de Internet www bfi automation de ...

Page 13: ...ces The CFC 1000 L may only be operated with fibre optic cables that were supplied by BFI Automation 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 n...

Page 14: ...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 ...

Page 15: ...eplace 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 company is responsible for ensuring th...

Page 16: ...as 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 compact flame control ler The compact flame controller is equipped with the follow ing safety devices Housing protection against accidental contact Ex proof housing optional Device earthing explosi...

Page 17: ...luding 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 When working on the plug the cable must be discon nected from the power supply Screw connections which have been loosened during ...

Page 18: ...nce 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 prior to initial operation Da...

Page 19: ...al and mixed fuel burners Type IR2 For monitoring gas and oil fired burn ers in the IR range Type IR3 For flames of all kinds also residues H2S and special gases Two channel flame monitoring system Sensitivity adjustable separately for both channels by software Analog output flame intensity 0 4 to 20 mA Flame analysis possibility by software LED status display for flame relay and flame intensity N...

Page 20: ...e max 1 A slow Design In accordance with protection class III SELV Range of operating temper ature 20 C to 70 Current output 0 4 to 20mA Ra 250Ω Current window variable by soft ware Flame relay 1 changeover contact floating wire break detection optional VDE 0110 Class A max 48V switching voltage max 1A switching current fused with 0 5A max 30W switching power Sitching thresholds programmable by so...

Page 21: ...of housing for 1 device for 2 or 3 devices without connector and mounting brackets 122 x 120 x 80mm 232 x 232 x 166 5mm 276 x 276 x 218mm Type of protection Standard housing Ex housing IP 65 ATEX Zone 2 IP 66 ATEX Zone 1 Declaration of conformity of housing manufacturer Approvals DIN DVGW CE CSA UL NG 2530BN0176 CE0085BN0347 217345 MH47747 SIL 3 according to EN 61508 2010 ...

Page 22: ...ight Standard housing 1 5 kg Ex proof housing for 1 device for 2 or 3 devices approx 7 0 approx 13 0 kg kg kg 3 4 Dimensions Standard 1 x Ex 2 or 3 x Ex Length 170 400 447 mm Width 122 226 276 mm Height with plug 95 165 218 mm ...

Page 23: ... Pre amplifier 11 Flame relay 3 Band pass filter 12 Monitor relay 4 DC voltage part 13 AND logic 5 Frequency part 14 Relay contact with fuse F3 6 Modulation part J1 3 Monitor channel switch off time 7 Monitor channel µP Microprocessor 8 Analog output 0 4 to 20 mA 9 Fault output ...

Page 24: ...Technical data 3 6 ...

Page 25: ... Harting cable terminal box kit not with ex proof hous ing 4 2 Accessories optional Power supply unit 230 115 V AC 1 ball flange with 2 flange disk 1 3 way ball valve 1 heating insulator 1 pressure barrier 5 bar Optical alignment device Ex proof housing Fiber optic cable Double nipple Operating instruction HB CFC Com1 EN Refer to the order papers for the exact scope of delivery and compare with th...

Page 26: ... in sufficient time before the expiry of any periods of preclusion and or limitation relating to the compensation claims against third parties 4 3 Packaging The compact flame controller is shipped in different pack aging materials The most frequently used packaging materials are card board and plastics foils foamed material Packaging has to be disposed of in an environmentally friendly way and in ...

Page 27: ...Transport Installation and Connection 4 3 4 6 Space requirement See following illustration Standard housing ...

Page 28: ...Transport Installation and Connection 4 4 Ø13 12 232 262 304 195 5 232 Ex proof housing for 1 OE Converter For use in hazadous area Zone 1 ...

Page 29: ...pple 8 Swivel mount In order to ensure perfect flame monitoring the correct and low vibration position of the sighting tube relative to the flame is a significant pre requisite For selective burner monitoring the device has to be installed in such a way that the primary combustion zone in all load ranges is inside the visual angle of the compact flame controller The sighting axis must if possible ...

Page 30: ...ges appear mirror inverted in horizontal and vertical direction The length and the diameter of the sighting tube have a direct influence on the analysable flame radiation as the visual angle of the lens system is defined Without re striction of the visual range the maximum length L of a sighting tube for conventional tube diameters D is as fol lows D 1 1 5 2 L 0 5 m 0 8 m 1 1 m For this reason the...

Page 31: ...l Part No B 512 1 must be employed At pressurised firing in stallations an additional 3 port shut off device optional Part No B 520 should be installed for the sake of safety This prevents an escape of hot gases after the removal of the compact flame controller and provides additional cool ing and purging of the installation The entire mechanical peripheral system can be supplied by BFI Automation...

Page 32: ... approved specialist staff Compact flame controllers with variable sensitivity set tings are set to the highest value at the manufacturer s works Compact flame controllers with variable frequency filters have a high signal sensitivity on account of the pre set low frequency harmonisation Compact flame controllers with a variable shutter are set at the manufacturer s works to Shutter open which ens...

Page 33: ...pproved specialist staff All alignments and settings must be carried out when new spare parts have been fitted the compact flame con troller has been moved or the flame image has been changed e g due to additional fuels new burners changes in the burner air registers as well as during all initial installations For selective burner monitoring the device must be in stalled in such a way that the pri...

Page 34: ...sure that the available supply voltage complies with the voltage indicated on the type plate Prior to connection check the device and the connecting cables for visible damage For the contact assignment of the plug connector refer to the following terminal diagram The output signal 0 4 to 20 mA for the flame intensity is not separate from the supply voltage so that the signal re fers to the operati...

Page 35: ...ay lead x 2 br Flame relay Flame ON x 3 pk Flame relay Flame OFF x 4 gn Power supply 24V DC 24V DC 200mA 5 ye Power supply GND GND 6 gr Analog output 0 4 to 20 mA 7 bl Switchover to channel 2 24V DC ext x 8 rd Fault output 24 VDC 100 mA x Connection of compact flame controller with internal heating optional Internal External Con tact Conduc tor colour Function Burner control mA display Power suppl...

Page 36: ...rminal Description colour BFI Special cable KW6 1 Flame relay Root white 2 Flame relay Flame ON brown 3 Flame relay Flame OFF pink 4 Power supply 24 V DC green 5 Power supply 0V GND yellow 6 Current output 0 4 20 mA gray 7 not used blue 8 not used red ...

Page 37: ...ber may remain bare All contact chambers in the contact insert have to be fitted with crimp contacts For this purpose use a suitable crimp tool BFI part No 8980 4801 00 On the flame scanner side the external shielding is con nected to the housing mass by means of a clamp connec tion located between the plastic insert the threaded part in the cable gland On the other side the outer shielding is cut...

Page 38: ...with screwed cap I On the second stage the PUR sheath must be tightend with screwed cap II The inner screening shall be cut of on the scanner side and connected to ground at the flame controler No Item No Item 1 Screwed coupler 8 Screwed cap 2 2 Rubber casket 1 9 PUR cable sheath 3 Clamp collar 1 10 Ex de IIC housing 4 Outer braided shield 11 wire end ferrule 5 Clamp collar 2 12 heat shrinkable tu...

Page 39: ... dry place Maximum relative humidity 60 Ensure that the packages are not stored outdoors In addition It has to be assured that the floor in the storage area will remain dry throughout the storage pe riod Protect from direct sunlight Storage temperature 15 degrees to 25 degrees C 59 degrees to 77 degrees F Store in a dust free location Avoid mechanical vibrations and damage ...

Page 40: ...Transport Installation and Connection 4 16 ...

Page 41: ...m neighbouring burners to be distinguished from the monitored flame Further function groups include i a the signal processing for the dynamic monitor channel that continuously moni tors the fault free state of the device A part of component defect results in the immediate switch OFF of the flame relay that represents a floating changeover contact for processing in the burner control ler The switch...

Page 42: ...channel The safety switch OFF time of the safety channel hard ware is set by means of a jumper The settings are as fol lows Jumper 1 bridged 1 second Jumper 2 bridged 3 seconds Jumper 3 bridged 5 seconds If a switch OFF time of 2 seconds is required the jumper must be inserted in position 2 3 seconds and the switch OFF time of the evaluation channel set by software to 2 seconds see Handbook HB CFC...

Page 43: ...e element is ob tained when the smallest hole is positioned in front of the sensor element The shutter can be latched in 4 different positions The shutter is linked mechanically to the detector holder To adjust the shutter loosen the screws through the holes in the screen of the pre amplifier The upper screw 1 se cures the shutter the lower screw 2 centres the shutter 1 2 3 ...

Page 44: ...5 4 ...

Page 45: ...e controller depends on the burner configuration as well as on the air flow and the spectral characteristic wave length 6 1 Test of the Compact Flame Controller In order to ensure correct operation the compact flame controller must be tested several times for all applications by starting and stopping the burner several times the flame relay must reliably shut down in all cases when there is no fla...

Page 46: ...Operation of the Compact Flame Controller 6 2 ...

Page 47: ...7 1 7 Care and Maintenance The compact flame controller is maintenance free For cleaning use a moist cloth to wipe the housing from the outside only and clean the lens in regular intervals Take care not to scratch the lens ...

Page 48: ...Care and Maintenance 7 2 ...

Page 49: ...elf test fault Check fault memory Possibly remove plug for 5 sec onds then start the burner again Replace compact flame control ler Flame signal soft ware above the starting thresholds Yellow LED ON Green LED ON Relay contact or wiring problem Check fuse F3 in relay output circuit Check electrical connection Burner fails Flame signal soft ware drops Below the shut off thresh old the flame relay sw...

Page 50: ...Failures 8 2 ...

Page 51: ...3 00 Compact flame controller in Ex proof housing GUB02 zone 1 Typ Material No OE Converter CFC 1000 UV LEX 7013 1034 00 OE Converter CFC 1000 UV1 LEX 7013 1004 00 OE Converter CFC 1000 IR LEX 7013 1044 00 OE Converter CFC 1000 IR2 LEX 7013 1064 00 OE Converter CFC 1000 IR3 LEX 7013 1084 00 2 compact flame controller in Ex proof housing GUB03 zone 1 Typ Material No OE Converter CFC 1000 UV LEX2 70...

Page 52: ...oof housing GUB03 zone 1 Typ Material No OE Converter CFC 1000 UV LEX3 7013 1034 12 OE Converter CFC 1000 UV1 LEX3 7013 1004 12 OE Converter CFC 1000 IR LEX3 7013 1044 12 OE Converter CFC 1000 IR2 LEX3 7013 1064 12 OE Converter CFC 1000 IR3 LEX3 7013 1084 12 ...

Page 53: ...re 3m 6040 4810 13 Additional accessories Typ Material No Power supply 5002 6020 5012 00 Special cable KW6 yard good 6060 0680 00 Swivel mount 1 with a 2 flange plate 6590 9020 01 3 Way ballvalve 1 1594 8831 00 Heating insulator 1 1598 0141 00 Double nipple 2 x 1 outer thread 1591 0241 00 Optical alignment device BFI 235 LWL 6030 0235 03 More accessories you will find in our product catalog ...

Page 54: ...Fault elimination 10 2 ...

Page 55: ...Accessories 10 3 ...

Page 56: ...Fault elimination 10 4 BFI Automation 2018 ...

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