Operating Instructions
Ignition and Pilot Burner
GFI 48 / 70 / 89 and Ex Variants
Sensors and Systems for Combustion Engineering
www.lamtec.de
Table of Contents
Table of Contents
1 Important Information about the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Purpose/Applicability of the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Target Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Safekeeping of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Classification of the Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Product-specific Dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Proper Use - Conditions of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Scope of Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Installation and Connection Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Important Information about the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.1 Life Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6.1 Technical data for the GFI 48 pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6.2 Technical data for the GFI 70 pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6.3 Technical data for the GFI 89 pilot burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6.4 Common technical data for GFI 48/70/89 pilot burner. . . . . . . . . . . . . . . . . . . . 17
3.6.5 Special version thermal rating with high power versions. . . . . . . . . . . . . . . . . . 21
3.6.6 Technical Data external Housing Ex-Zone I. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6.7 Technical data for NW48/70/89 sliding flange . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Design and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.1 Electrically Connecting the GFI Pilot Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.1 Adjusting the GFI 48 Flame Quality and Flame Stability. . . . . . . . . . . . . . . . . . 40
5.3.2 Adjusting the GFI 70 Flame Quality and Flame Stability. . . . . . . . . . . . . . . . . . 41
5.3.3 Adjusting the GFI 89 flame quality and flame stability. . . . . . . . . . . . . . . . . . . . 42
5.3.4 Connect Pressure-Measuring Equipment for Gas and Air. . . . . . . . . . . . . . . . . 43
5.3.5 Evaluate the Flame Stability using the Ionisation Current. . . . . . . . . . . . . . . . . 43
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1 Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Maintenance Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Perform Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.4 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5 Warranty and Delivery Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2
Table of Contents
7 Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.1 General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2 Fault Finding and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4 Information About the Repair Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8 Decommissioning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9 Disposal Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10 EU Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11 Order Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3
1 Important Information about the Manual
1 Important Information about the Manual
1.1 Purpose/Applicability of the Document
These instructions facilitate the safe and efficient handling of the pilot burner GFI and its
variants.
1.2 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.
For safety reasons, access to parameter settings must be restricted to authorised and
trained personnel.
Ensure that personnel have the proper qualifications when it comes to mounting,
commissioning and maintaining the Ex variants.
NOTICE
During the mounting, commissioning and maintenance of the Ex variant, it must be ensured
that only personnel familiar with explosion protection regulations who are qualified and authorised to perform this week work on and with this device.
1.3 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.
4
2 General Safety Instructions
2 General Safety Instructions
2.1 Classification of the Safety Instructions and Warnings
The following symbols are used in this document to draw the user's attention to important safety 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
property.
5
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.
6
2 General Safety Instructions
2.3 Product-specific Dangers
Installation and commissioning
WARNING!
All following warnings must be observed to avoid personal injury and damage to
property and the environment.
WARNING!
During the operation of electrical devices, certain parts inevitably have dangerous
voltage. If the following notices are not observed, severe bodily injury and property
damage could thus occur.
WARNING!
The integrated flame scanner is not provided with a direct switch-off of the fuel valves.
The subsequent signal processing must be carried out in the control system, which is
adapted to suit the combustion plant. The device may only be used with burner controllers which comply with local standards.
WARNING!
The integrated flame scanner 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 applies, in particular, in the event of a defective fuse.
7
2 General Safety Instructions
NOTICE
The integrated flame scanner of the pilot burner is a safety component for gaseous and liquid
fuels. When gas consumers according to EN 298 are used, they are subject to the Gas Appliances Directive 2009/142/EC.
• The applicable national safety regulations and standard notes are to be observed
in each case.
• The installation of the device must be carried out precisely according to the directions in
these operating instructions.
• Only connect the device when the technical data of the device matches the data of the
peripheral equipment.
• The device may only be operated in an environment for which it is specified in accordance
with the technical data.
• None of the safety labelling or markings may be removed from the device.
• No unauthorized modifications or attempts to repair the device
are permitted.
• Make sure that no spliced strands can come into contact with any of the adjacent connections. Use appropriate end splices.
• Make sure that the power cables are not interchanged between L and N.
• The plug connectors X13, X14, X15 and X16 do not have a secure disconnection from the
mains voltage.
• To replace or disconnect the plug connectors, all poles of the plant must be disconnected
from the mains.
• Measuring circuits must feature a secure disconnect according to EN 61140 "Protection
against electric shock " for active parts; for this reason, use only measurement and
evaluation devices which have a double or reinforced insulation.
• In order to provide for operating safety , make sure when installing the output contacts that
the circuitry of the radio interference suppression to be provided by the user is carried out
in such a way that there is no risk of shorting out the relay contact output (flame signal) by
defective component parts of the suppressor circuitry
• Work on electrical systems or equipment may be performed only by a certified electrician
or trained personnel managed and supervised by a certified electrician according to the
electrical engineering regulations.
• Machine and plant parts on which inspection, maintenance, and repair work is performed
must be de-energised and secured against reactivation. First make sure the enabled parts
are de-energised, then earth and short-circuit them. Secure adjacent, live parts against
accidental contact by covering them.
• The electrical equipment of the system must be checked regularly. Defects must be
reported immediately and remedied.
• If work on live parts is necessary, a second person must be involved who can press the
emergency stop or main switch if required. Block off the working area with a red-and-white
safety chain and a warning sign. Use only voltage-insulated tools.
• In case of fire in electrical systems, do not extinguish with water under any circumstances.
Only the provided fire extinguishers may be used.
8
2 General Safety Instructions
2.4 Proper Use - Conditions of Use
Intended use
The ignition burner is utilised in industrial ovens, thermal processing systems and heating boilers for gas, oil and solid fuels.
It is used for the following purposes:
• Preheating the system
• Igniting the main burner
• Supporting the main burner flame
The ignition burner is intended only for the described use.
Any use going beyond the intended use shall be deemed improper.
The LAMTEC GmbH & Co KG shall not be liable for damage caused by the non-compliance.
2.5 Installation Notes
WARNING!
All following warnings must be observed to avoid personal injury and damage to
property and the environment..
Supply the feed cable with L, N and PE only. The neutral conductor may not have any
potential difference to PE.
Phase and neutral conductors may not be interchanged (this would lead to dangerous
malfunctioning, loss of protection against contact, etc.).
The supply cable of the integrated flame scanner must absolutely be fused with a 4 A
(slow) fuse. The minimum fusing amounts to 0.5A..
9
3 Product Description
3 Product Description
3.1 Scope of Supply
Check the scope of supply
The scope of supply comprises:
• Operating Instructions
• Pilot burner GFI, design A, B, C
Fig. 3-1 Lieferumfang LAMTEC Zündbrenner.tif
Check the scope of supply for completeness and faultless condition.
If parts are missing or there is damage:
• Do not mount the device
• Do not connect
• Do not place into operation
• Submit a claim to the supplier
10
3 Product Description
3.2 Rating Plate
Information on the rating plate
The rating plate is located on the pilot burner housing.
Fig. 3-2 Rating plate on the LAMTEC GFI pilot burner
On the rating plate, you will find information on the configuration of your pilot burner:
Rating plate example:
Fig. 3-3 Rating plate example LAMTEC GFI pilot burner
11
3 Product Description
3.3 Equipment
With respect to the electrical equipment, the pilot burner is available in 3 versions.
The versions differ as follows:
Fig. 3-4 Pilot burner versions A-B-C
Equipment Design A
Design B Design C
(standard)
1 Ignition electrode X X X
2 Ionisation electrode X X X
3 Ignition transformer X X
4 Flame scanner
1
(IFM)
1
IFM= ionisation flame scanning
2
either ignition transformer or IFM
X X
2
2
GFI 48 / 70 / 89 with optional bar graph
Fig. 3-5 Optional GFI housing with bar graph equipment
NOTICE
The bar graph is optional for versions A and B (if with IFM).
No bar graph available in Ex-area
Differences in the type of cable entry point
The connection cables are fed into the device enclosure either
via a screwed cable gland or via a plug-in connection. The difference is in the flexibility during installation and connection work.
There are no differences in terms of technology or functionality.
In these operating instructions, the device is always depicted
with screwed cable gland.
12
3 Product Description
3.4 Installation and Connection Materials
Installation and connection materials are not included in the scope of supply.
The following materials depicted below are required for the installation. See also chapter
Order Information
Fig. 3-6 Feed-through flange with seal
The steps described in chapter Montage are to be adhered to precisely for the installation.
3.5 Important Information about the Product
3.5.1 Life Cycle
The device has a limited lifespan. It is designed for 250,000 switching cycles at nominal load
and thus type-tested. With 50 switching operations per day , this results in a lifespan of approx.
10 years.
Increased load due to extreme operating conditions (e.g. temperature, vibration, contamination, etc.) can significantly reduce the service life.
The system operator is responsible for adapting the frequency of regular safety-related inspections to the operating conditions.
At the end of its service life, the device must be disposed of properly.
13
3 Product Description
3.6 Technical Data
3.6.1 Technical data for the GFI 48 pilot burner
Fig. 3-7 Side view of GFI48 pilot burner design A/B
Fig. 3-8 Dimensions of GFI48 pilot burner design A/B
Fig. 3-9 Side view of GFI48 pilot burner Ex-Zone II
Fig. 3-10 Dimensions of GFI48 pilot burner ExZone II
14
3 Product Description
Fig. 3-11 Side view of GFI48 pilot burner design C
Fig. 3-12 Dimensions of GFI48 pilot burner design C
1 Dimension outer tube length (customer-specific)
2 Outer tube diameter 48.3 mm x 2 mm (1.90 x 0.078 in)
3 Housing length versions A and B
4 Housing dimensions
5 Air supply connection 1 inch (BSPP inner threads)
6 Gas supply connection 1/2 inch (BSPP inner threads)
7 Distance between housing and connec-
tion flange
15
3 Product Description
3.6.2 Technical data for the GFI 70 pilot burner
Fig. 3-13 Side view of GFI70 pilot burner design A/B
Fig. 3-14 Dimensions of GFI70 pilot burner design A/B
Fig. 3-15 Side view of GFI70 pilot burner ExZone II
Fig. 3-16 Dimensions of GFI70 pilot burner
Zone II
16
3 Product Description
Fig. 3-17 Side view of GFI70 pilot burner design C
Fig. 3-18 Dimensions of GFI70 pilot burner design C
1 Dimension outer tube length (customer-specific)
2 Outer tube diameter 70 mm x 2 mm ( 2.75 x 0.078 in)
3 Housing length versions A and B
4 Housing dimensions
5 Air supply connection 1 1/2 inch (BSPP inner threads)
6 Gas supply connection 3/4 inch (BSPP inner threads)
7 Distance between housing and connec-
tion flange
17
3 Product Description
3.6.3 Technical data for the GFI 89 pilot burner
Fig. 3-19 Side view of GFI89 pilot burner design A/B
Fig. 3-20 Dimensions of GFI70 pilot burner design A/B
Fig. 3-21 Side view of GFI89 pilot burner ExZone II
Fig. 3-22 Dimensions of GFI70 pilot burner ExZone II
18
3 Product Description
Fig. 3-23 Side view of GFI89 pilot burner design C
Fig. 3-24 Dimensions of GFI89 pilot burner design C
1 Dimension outer tube length (customer-specific)
2 Outer tube diameter GFI89: 88.9 mm x 2 mm ( 3.5 x 0.078 in)
3 Housing length versions A and B
4 Housing dimensions
5 Air supply connection 2 inch (BSPP inner threads)
6 Gas supply connection 1 1/2 inch (BSPP inner threads)
7 Distance between housing and connec-
tion flange
19
3 Product Description
3.6.4 Common technical data for GFI 48/70/89 pilot burner
NOTICE
The electrical data are identical for all devices, only the air and gas volume flows differ.
Design A: Power supply voltage connection
Electrical data 120/127/220/230 VAC; -15/+10% (within the scope of the EU
Gas Appliances Directive), cf. rating plate
240 VAC; -20/+5% (outside the scope of the EU Gas Appli-
ances Directive), cf. rating plate
Mains frequency 50/60 Hz
Power consumption 10 V A flame scanner when UN = 230 V, 230 VA ignition trans-
former,
10 V A flame scanner when UN = 120 V, 192 VA ignition trans-
former,
Ignition transformer duty cycle ED= 50% on 2 min. (1’ on; 1’ off) 45 °C when UN=230V
ED= 15% on 1 min. (9”on; 51” off) -20°C<Ta<60°C when
UN=120V
Design A: connection to relays
Electrical data
NO contact NO contact (flame on)
Switching voltage
Switching current
1
1, 2
230 V or 48 VDC
max. 0.5 A cos 0.4 min 10 mA
Contact fusing (internal, soldered): 0.5 AT
Versions A and B: Integrated flame scanner
Ionisation input
Ionisation current from 1 ADC flame ON
Operating mode Continuous operation capable
Flame signal output contact
Contact type Safety-oriented, floating contact
Contact type NO, for "flame on", the contact is closed
Level of protection SKII, base isolation for the status signal
Permissible switching voltage
Permissible switching current
1
1, 2
230 VAC 48 VDC
Max. 0.5 A cos 0.4 Min. 10 mA
Contact fusing 0.5 AT (internal, soldered)
Safety time (FFDT)
Response time in the event of the flame going
tV off 1 s
out
Switch-on time tV on 1 s
Measuring shunt runs mains potential
Transmission ratio of measurement voltage to
10 mV (DC) = 1 A (DC)
ionisation current
20
3 Product Description
Versions A and B: Integrated flame scanner
Intrinsic error 2%
Electrical safety Contact protection by means of protective impedances
Min. impedance of the connected
measuring device
1
The product is not permitted to be transported, stored or operated outside the specified range.
Doing so will invalidate any guarantees with regard to safety relevant functions.
2
Provide external spark quenching for inductive loads, do not connect any capacitive loads.
NOTICE
Use device manufacturer recommended silicone shielded cable. The device manufacturer will
only guarantee proper functioning if this cable is used. This cable is available in any length up
to the maximum cable length.
Design B: Connection of external flame scanner to the ionisation electrode
Recommended cable specifications
Cable type RG62 coaxial cable
Cable lengths
1 M
< 10 m/32,8 ft
Inner conductor Solid copper-plated steel wire, uninsulated Ø: 0.64 ± 0.025
mm (0.025 ± 0,00098 in)
Wire insulation PE hollow space insulation (helix made from PE strands with
PE hose on top) Ø: 3.7 mm (0.14 in)
Shield Braided from bare Cu wires, 96 % coverage
(nominal value)
Outer shell PVC, black outside diameter: 6.15 ± 0.18 mm (0.24 ± 0.0070
in)
Conductor resistance max. 144 Ohm/km
Operating capacity max. 43 pF/m (1 kHz)
Rated voltage 0.8 kV (50 Hz)
Test voltage 2 kV
Temperature range -40 °C to 80 °C (-40 °F to 176 °F)(fixed installation)
Design B and C: Power supply voltage connection to the external ignition transformer
Recommended cable specifications
Cable lengths Max. 200 m (656.168 ft)
Cable cross-section 3 x 1.0 mm2 (3 x 17 AWG)
Isolation PVC
Temperature range -40 °C ... +90 °C (-40 °F ... 194 °F)
Design C: Connection of external ignition transformer to the ignition electrode
Electrical data
Ignition voltage to earth max. 8 kV (at UN=230 V)
max. 7 kV (at UN=120 V)
Recommended cable specifications
21
3 Product Description
Design C: Connection of external ignition transformer to the ignition electrode
Cable lengths max. 20 m (65.62 ft)
Cable cross-section 1 x 1.0 mm
Isolation Silicone, red-brown
Temperature range -60 ... +180 °C (-76 ... 356 °F)
Design C: Connection of external flame scanner to the ionisation electrode
(same procedure as for B)
Design C: Ground cable
Recommended cable specifications
Cable lengths Max. 200 m (656.168 ft)
Cable cross-section 1 x 1.5 mm
regulation
DANGER!
High voltage on the bare ignition electrode!
Pilot burner is only permitted to be operated with correct earthing.
With version C in particular there is a danger of death when removing or omitting the earthing, the housing earthing must be connected directly to the ignition transformer earthing!
In the event of damage to the earthing insulation, the device should be shut down; further
operation without repair is not permitted.
2
(1 x 17 AWG)
2
(1 x 15 AWG) and/or according to regional
Connection: GFI48 gas
Gas type Natural gas or propane
Flow rate (gas quantity) Natural gas: 8.0...15.0 m3/h (10.46 ... 19.61 yd3/h)
Propane: 3.2...6.0 m3/h (4.18 ... 7.84 yd3/h)
Operating pressure Min. 50 mbar (0.725 psi)
Max. 200 mbar (2.90 psi)
Connection: GFI70 gas
Gas type Natural gas or propane
Flow rate (gas quantity) Natural gas: 15.0 ... 30.0 m3/h (19.61 ... 39.23 yd3/h)
Propane: 6 ... 12.0 m3/h (7.84 yd3/h ... 15.69 yd3/h)
Operating pressure Min. 50 mbar (0.725 psi)
Max. 200 mbar (2.90 psi)
Connection: GFI89 gas
Gas type Natural gas or propane
Flow rate (gas quantity) Natural gas: 35.0...70.0 m3/h (45.77 ... 91.55 yd3/h)
Propane: 14...28.0 m3/h (18.31 ... 36.62 yd3/h)
Operating pressure Min. 50 mbar (0.725 psi)
Max. 200 mbar (2.90 psi)
NOTICE
Higher pressure ratings can be realised by connecting a restrictor upstream.
22
3 Product Description
Connection: Air
Air type Combustion air
Operating pressure GFI48/70: min. 15 mbar (0.217 psi) + 6 mbar (0.087psi) per
metre of tube length
GFI89: min. 15 mbar 0.217 psi) + 5 mbar (0.087psi) per metre
of tube length
Air temperature max. 80 °C (176 °F)
Rel. air humidity max. 70 %
Air quality Free of dust, oil, grease and aerosols
The quality for the compressed air supply should conform to
ISO 8573-1:2010 class ( 7 : 4 : 4 ). Non-observance can
result in short-circuits due to material deposits in the housing.
Air ratio 0.3...0.5 (the remaining air quantity must be provided by the
combustion chamber)
Flow rate (air quantity) GFI48: max. 50 m3/h (65.39 yd3/h)
GFI70: max. 150 m3/h (196.19 yd3/h)
GFI89: max. 250 m3/h (326.98 yd3/h)
NOTICE
At temperatures in the combustion chamber of over 500 °C (932 °F), if the pilot burner is off,
a cooling air supply of 50% of the max. combustion air should be provided.
Operating modes
Permitted operating modes Intermittent operation/continuous operation
Ambient conditions during operation
Permissible ambient temperatures -20 ... +60 °C (-4 ... 140 °F)(without bar graph) 0 ... +60 °C
(32 ... 140 °F) (with bar graph)
Rel. air humidity Max. 85 % (non-condensing)
Ambient conditions for storage
Ambient temperature -20 ... +60 °C (-4 ... 140 °F)
Rel. air humidity Max. 85 % (non-condensing)
Thermal rating
Thermal rating GFI48: 70 ... 150 kW
GFI70: 150 ... 300 kW
GFI89: 400 ... 700 kW
SIL classification
Level SIL 3
Electrical safety
Protection class IP 65 / NEMA 4 / NEMA 4X
IEC
for integrated power unit Ex zone II: Ex ec IIB+H2 T4 Gc
23
3 Product Description
3.6.5 Special version thermal rating with high power versions
NOTICE
The following technical data relates exclusively to the scope of the NFPA.
Connection: GFI48 gas
Flow rate (gas quantity) Natural gas: 25 ... 40 m3/h (32.69 ... 52.31 yd3/h)
Propane: 9.5 ... 15 m3/h (12.42 ... 19.61 yd3/h)
Operating pressure Natural gas: 500 ... 1000 mbar (7.25 ... 14.50 psi)
Propane: 400 ... 800 mbar (5.80 ... 11.60 psi)
Connection: GFI70 gas
Flow rate (gas quantity) Natural gas: 50 ... 80 m3/h (65.39 ... 104.63 yd3/h)
Propane: 19 ... 31 m3/h (24.85 ... 40.54 yd3/h)
Operating pressure Natural gas: 500 ... 1000 mbar (7.25 ... 14.50 psi)
Propane: 500 ... 1000 mbar (7.25 ... 14.50 psi)
Connection: GFI89 gas
Flow rate (gas quantity) Natural gas I: 230 ... 300 m3/h (300.82 ... 392.38 yd3/h)
Natural gas II: 460 ... 600 m3/h (601.65 ... 784.76 yd3/h)
Propane: 90 ... 115 m3/h (117.71 ... 150.41 yd3/h)
Operating pressure Natural gas I: 700 ... 1000 mbar (10.15 ... 14.50 psi)
Natural gas II: 700 ... 1000 mbar (10.15 ... 14.50 psi)
Propane: 700 ... 1000 mbar (10.15 ... 14.50 psi)
Thermal rating with high power versions
GFI 48 Natural gas: 250 ... 400 kW
Propane: 250 ... 400 kW
GFI70 Natural gas: 500 ... 800 kW
Propane: 500 ... 800 kW
GFI89 Natural gas I: 2300 ... 3000 kW
Natural gas II: 4600 ... 6000 kW
Propane: 2300 ... 3000 kW
NOTICE
This is not a control range as for a burner as the appropriate air volume must be set accordingly when changing the gas pre-pressure.
Connection: Air
Air type Combustion air
Operating pressure GFI48/70: min. 15 mbar + 6 mbar (0.217 psi + 0.087psi ) per
metre of tube length
GFI89: min. 15 mbar + 5 mbar (0.217 psi + 0.072 psi) per
metre of tube length
Air temperature max. 80 °C (176 °F)
Rel. air humidity max. 70 %
24
3 Product Description
Connection: Air
Air quality Free of dust, oil, grease and aerosols
The quality for the compressed air supply should conform to
ISO 8573-1:2010 class ( 7 : 4 : 4 ). Non-observance can
result in short-circuits due to material deposits in the housing.
Air ratio 0.3...0.5 (the remaining air quantity must be provided by the
combustion chamber)
Flow rate (air quantity) GFI48: max. 50 m3/h (65.39 yd3/h)
GFI70: max. 150 m3/h (196.19 yd3/h)
GFI89: max. 250 m3/h (326.98 yd3/h)
NOTICE
At temperatures in the combustion chamber of over 500°C (932 °F), if the pilot burner is off, a
cooling air supply of 50% of the max. combustion air should be provided.
25
3 Product Description
3.6.6 Technical Data external Housing Ex-Zone I
Fig. 3-25 External power unit Ex-Zone I
Fig. 3-26 Dimensions of the External power unit - Ex-Zone I
Technische Daten
Explosion protection: II 2 G Ex db IIB + H2 T6/T5 GbII 2 D Ex tb IIIC T80 °C...T95 °C Db
Material: copper-free aluminium, stainless steel 1.4404/316
Certificates/Test certificates: ITS 15 ATEX 18302X, IECEx ITS 15.0041X
Electrical safety: IP 66 according to EN 60529
Impact resistance: 7 Joule according to EN 60079-0
Temperatureinsatzbereich: -20 °C ... +60 °C (-4 ... 140 °F)
26
3 Product Description
3.6.7 Technical data for NW48/70/89 sliding flange
Technical data for NW48/70/89 sliding flange
Fig. 3-27 Dimensions of the sliding flange of the GFI pilot burner
The flange is equipped with 4 grub screws to fix the outer tube in a defined
position. The pipe leadthrough contains an EPDM O-ring seal.
Material
Flange 1.4571 stainless steel, galvanized steel
O-ring seal EPDM
Temperature range -40 ... +120 °C (-40 °F ... 248 °F)
Pressure 1.0 bar (14.50 psi)
Weight NW48: 1.24 kg (2.73 lb)
NW70: 1.5 kg (3.30 lb)
NW89: 2.4 kg (5.29 lb)
Dimensions
b Flange plate thickness NW48: 10 mm (0,39 in)
NW70: 10 mm (0,39 in)
NW89: 15 mm (0,47 in)
D Flange diameter NW48: 140 mm (5,51 in)
NW70: 160 mm (6,29 in)
NW89: 190 mm (7,48 in)
d1 Outside collar diameter NW48: 70 mm (2,75 in)
NW70: 90 mm (3,54 in)
NW89: 115 mm (4,33 in)
d2 Hole diameter NW48: 14 mm (0,55 in)
NW70: 14 mm (0,55 in)
NW89: 18 mm (0,70 in)
h Total height NW48: 25 mm (0,98 in)
NW70: 25 mm (0,98 in)
NW89: 30 mm (1,18 in)
k Hole circle diameter NW48: 110 mm (4,33 in)
NW70: 130 mm (5,11 in)
NW89: 150 mm (5,90 in)
DN Nominal diameter 48/70/89
27
4 Design and Functions
4 Design and Functions
4.1 Design
Construction of pilot burner versions A and B
Fig. 4-1 Main components of LAMTEC GFI pilot
burner
Connections: Gas and air supply
1 Outer tube
2 Air housing
3 Gas block
4 Connection enclosure
Fig. 4-2 Gas and air supply connections
Connections: Measurement sockets
Fig. 4-3 Connections of the measurement sockets for gas and air
Connections: test sockets
1 Air supply connection
2 Gas supply connection
1 Measurement socket - air
2 Measurement socket - gas
Fig. 4-4 Test socket connections
28
1 and 2 test sockets for the temporary
connection of a measurement device
for
flame setting
4 Design and Functions
4.2 Functional Description
Operating mode of the pilot burner
Fig. 4-5 Pilot burner versions A-B-C
1 Ignition electrode 3 Ionisation electrode 5 System control
2 Ignition transformer 4 Flame scanner
DANGER!
High voltage on the bare ignition electrode!
Pilot burner is only permitted to be operated with correct earthing.
With version C in particular there is a danger of death when removing or omitting the earthing; the housing earthing must be connected directly to the ignition transformer earthing!
In the event of damage to the earthing insulation, the device should be shut down; further
operation without repair is not permitted.
The ignition electrode is connected to the ignition transformer. The ignition transformer is supplied from the system control.
The ionisation diode in the flame area of the pilot burner is connected to the flame scanner.
The flame scanner measures the ionisation current and evaluates it.
The amount of the ionisation current can also be determined via a shunt measuring principle
using a multimeter. The measured voltage is to be converted as follows into the ionisation current: 10 mVDC = 1 ADC
When the flame is detected, the flame scanner activates the relay and the pilot light indicates
"flame on".
The system control detects the relay activity and implements this into system-specific actions.
WARNING!
Both analogue outputs have supply voltage reference!
Contact protection must be observed.
Measuring circuits must be safely separated from dangerous active components to
EN 61140 "Protection against electric shock".
Only use measurement and data interpreting devices that have double or reinforced insu-
lation.
29
5 Commissioning
5 Commissioning
5.1 Transport
NOTICE
Depending on the version, the device can be heavy and bulky.
The following regulations should be observed during transport:
Always transport the device in the original protective packaging.
Depending on the weight and situation, use lifting gear and/or obtain assistance from an-
other person
5.2 Assembly
Observe the safety regulations!
NOTICE
Fragile!
Isolators installed in the pilot burner are ceramic and may break.
Do not allow pilot burners to drop or suffer impact.
CAUTION!
Loose, unfastened pilot burner!
Risk of injury due to falling pilot burners.
Secure the pilot burner against falling for the duration of the assembly process by hand or
using a suitable device.
WARNING!
All activities described in this chapter must only be performed by qualified, authorised personnel observing all safety requirements.
Select mounting location
The mounting location must meet the following requirements:
• Space requirement for mounting and removal: See section "Space requirement for mounting and removal".
• Remaining clearance after mounting: See section "Remaining clearance after mounting".
• Ambient conditions: For more details, see chapter 3.6 Technical Data
• The mounting surface must be torsion-resistant, stable and even.
• Distance to external components and to the system control: For more details, see chapter
3.6.1 Technical data for the GFI 48 pilot burner
30
5 Commissioning
Mounting position
Due to the pilot burner falling due to vibrations for overhead assembly with sliding
flange!
Overhead assembly is only permitted with welded flange!
DANGER!
Fig. 5-1 Possible installation situations
1 Mounting angle in relation to the hori-
zontal 0…90°. A corresponding adapter
for angled assembly must be present
on-site.
2 Upright or vertical mounting position 4 Level or horizontal mounting position
Plan supply lines
Control devices are to be provided for the gas and air supply.
3 Not permissible with sliding flange.
Overhead assembly is permissible
solely with a welded flange!
31
5 Commissioning
The following materials are required for the installation.
Fig. 5-2 Feed-through flange with seal and screws
Designation Specification
1 Feed-through flange Appropriate to the pilot burner, with radially
1 Seal
4 x M12 screws (GFI48/GFI70)
4 x M16 screws (GFI89)
4 washers
4 screw nuts
arranged grub screws for securing the outer tube.
The following material is required for the electrical connection.
Designation Specification
Terminal lug Ring terminal
Ground cable
Ignition cable
Ionisation cable
Specific cable specifications, see chapter 3.6 Technical Data
32
5 Commissioning
Space requirement for mounting and removal
Fig. 5-3 LAMTEC GFI pilot burner space requirement for mounting and removal
For the insertion of the device, at least the full device length in axial extension of the outer tube
is to be kept clear. For maintenance and servicing, there must be the possibility of being able
to completely remove the device again.
Subsequently attached system components in the surrounding environment must be easily removable.
Remaining clearance after mounting
Care must be taken to ensure that the following clearance on the rear side of the device remains clear at all times even after mounting:
Fig. 5-4 Remaining clearance after mounting the pilot burner
1 Space for
cable connection
2 Working space for
connecting of the
measurement device plugs
3 View area for the
detection of the
pilot lamp
33
5 Commissioning
Before the installation: Check the ionisation electrode
High voltage on the bare ionisation electrode.
Risk of death from contact.
Only allow qualified electricians to perform the electrode test.
Wear face protection and insulating protective gloves.
Switch off and secure additional aggregates, burners and gas valves.
Inertise the gas line completely.
Line breaks and earth short circuits can be determined with the electrode test. Testing principle: An existing flame is simulated by connecting an inspection diode.
An inspection diode is required for the electrode test: Item number: 646R0100
DANGER!
Fig. 5-5 Inspection diode for ionisation electrode test
Depending on the pilot burner design, the following components are to be temporarily
connected:
Version External flame scanner Power supply
A X
B X X
C X X
34
5 Commissioning
Perform the electrode test as follows:
NOTICE
Disconnect the pilot burner during the test from subordinate burner control.
Simulating the flame switches the flame relay.
1. Deactivate the flame scanner.
2. Clamp the red clamp of the inspection diode to
attach the ionisation electrode.
3. Activate the flame scanner.
4. Using the yellow/green clamp, connect to
earth, e.g. connect to the outer tube.
5. Check with contact to earth whether the
flame scanner activates.
If the flame scanner activates, the electrode is
functional, and the pilot burner can be installed.
If the flame scanner does not activate, the electrode is not functional, and the pilot burner may
not be installed.
Fig. 5-6 Test of the ionisation electrode
Check possible causes of error:
1. No power supply voltage applied to the flame scanner.
2. Polarity of the inspection diode is reversed.
3. The ceramic insulators are moist, contaminated or broken.
4. Accidental earth of the ionisation electrode present.
5. Line break between ionisation electrode and flame scanner present.
If one of these faults is present, it must be rectified.
Then perform the test again.
If the flame scanner activates after repeating the test, the pilot burner
can be installed. Otherwise the pilot burner must be inspected by the manufacturer.
35
5 Commissioning
Mount the pilot burner
Fig. 5-7 Mount the pilot burner
Loosen the grub screws on the feed-through
flange and insert the pilot burner up to the
desired position in the feed-through flange.
Tighten the
grub screws in a cross-wise pattern to secure the
pilot burner.
Fig. 5-8 Tighten the grub screws
NOTICE
If the combustion chamber overpressure is greater than 200 mbar (2.90 psi) , the attachment
of the pilot burner to the feed-through flange must be secured by additional means against detaching due to vibration or other forces.
An additional possibility would be to dispense with the sliding flange altogether and for an appropriate mounting flange to be factory-fitted.
NOTICE
For this, the precise installation length must be specified in advance as it will not possible to
adapt later on site.
36
5 Commissioning
Connect gas and air supply
NOTICE
The quality for the compressed air supply should conform to ISO 8573-1:2010 class ( 7 : 4 : 4
). Non-observance can result in short-circuits due to material deposits in the housing.
NOTICE
At temperatures in the combustion chamber of over 500°C (932 °F), if the pilot burner is off, a
cooling air supply of 50% of the max. combustion air should be provided.
Fig. 5-9 Connect gas and air supply
1. Conduct the gas and air supply lines
through
to the pilot burner through the control
devices.
2. Remove the transport safety devices
from the connections.
3. Connect air supply to "A" (Air).
4. Connect gas supply to "G" (Gas).
5. Observe the torques from the table
when tightening the screw connections!
Thread Torque Thread Torque
1/8" 5 Nm 1" 15 Nm
1/4" 7 Nm 1 1/2" 20 Nm
1/2" 10 Nm 2" 25 Nm
3/4" 15 Nm
37
5 Commissioning
5.2.1 Electrically Connecting the GFI Pilot Burner
Design A: Electrically connect the pilot burner
Fig. 5-10 Connect pilot burner version A
Connect the pilot burner
cables as follows
No. Wire colour Function
1 bl Phase
2 bl Neutral conductor
3 bl Ignition transformer NTR-N
4 bl Ignition transformer LTR-L
5 bl COM
6 bl NO
PE gn/ye Protective conductor
Design B: Electrically connect the pilot burner
No. Wire colour Function
1 bl Phase
2 bl Neutral conductor
3 bl Ignition transformer NTR-N
4 bl Ignition transformer LTR-L
5 bl COM
6 bl NO/ionisation electrode
PE gn/ye Productive conductor
Fig. 5-11 Electrically connect the pilot burner
design B
NOTICE
Version B has the same connection as version A.
For version B however, the following applies:
If only the ignition transformer is used, only connect wires 3,4 and PE.
With an external flame scanner, the ionisation cable should be connected to wire 6
The remainder is without function. If only the IFM is used, only connect wires 1,2,5,6 and PE.
38
5 Commissioning
Design C: Connect earth cable
Fig. 5-12 Connect version C earth cable
Design C: Ignition and ionisation cables
1 Connection thread
2 Ring terminal lug
3 Spring washer
4 Earthing bolt
Fig. 5-13 Electrical connection of GFI89 version C
1 Ignition cable 2 Ionisation cable 3 Ground connection
DANGER!
High voltage on the bare ignition electrode!
Pilot burner is only permitted to be operated with correct earthing.
With version C in particular there is a danger of death when removing or omitting the earthing, the housing earthing must be connected directly to the ignition transformer earthing!
In the event of damage to the earthing insulation, the device should be shut down; further
operation without repair is not permitted.
39
5 Commissioning
Connection Design C to external housing
Fig. 5-14 Connection Design C to external housing Ex-Zone I
Design C: Electrically connect the pilot burner
Connect the pilot burner
cables as follows
No. Wire colour Function
1 bl Phase
2 bl Neutral conductor
3 bl Ignition transformer NTR-N
4 bl Ignition transformer LTR-L
5 bl COM
6 bl NO
PE gn/ye Protective conductor
Fig. 5-15 Connect pilot burner version C
DANGER!
High voltage on the bare ignition electrode!
Pilot burner is only permitted to be operated with correct earthing.
With version C in particular there is a danger of death when removing or omitting the earthing, the housing earthing must be connected directly to the ignition transformer earthing!
In the event of damage to the earthing insulation, the device should be shut down; further
operation without repair is not permitted.
40
5 Commissioning
5.3 Commissioning
Observe the safety regulations!
NOTICE
Wear personal safety equipment.
Face protection
Insulating safety gloves
Safety shoes
All activities described in this chapter must be performed by qualified, authorised personnel
only under observance of requirements from the following regulating bodies:
Official Journal of the European Union L 96/309, Directive 2014/34/EU of 26 February
2014 relating to equipment and protective systems intended for use in potentially
explosive atmospheres (recast)
EN 60079-0:2014-06 (VDE 0170-1:2014-06) Explosive atmospheres – Part 0:
Equipment – General requirements
WARNING!
WARNING!
Security relevant functionality.
Risk of death and risk of material damage if commissioned incorrectly.
Commissioning may only be performed by authorised specialist personnel.
DANGER!
For ignition attempts, there is a risk of flashing caused by residual gas in the gas tube
or gases in the environment.
For pilot attempts, secure the hazard area in front of the pilot burner mouth.
Clear the pilot burner with purge air from residual gas as necessary.
The ignition should ideally only be tested in installed status.
Integrate the device into the system control
Integrate the relay switch contacts of the flame scanner into the safety-oriented system control. You must observe and comply with the requirements of the DIN EN 298 and the regional
requirements.
In addition, you must ensure that the function or neutral position of the respective
contact is checked regularly - in accordance with the requirements - by the superordinate control system and/or burner sequencer.
Ensure signal detection
NOTICE
In unfavourable conditions, the energy of the ignition spark can interfere with the ionisation
signal in such a way that it is not possible to perform a measurement.
T o prevent this, a time section of approx. 0.5 s before expiry of the ignition safety time, in which
a secure signal detection can take place, is to be set on the system control.
41
5 Commissioning
Perform leak test
NOTICE
The regional requirements for the leak test must be observed and complied with.
Perform functional test
Perform the functional test as follows:
1 Check the pilot light of the of the flame scanner with the fuel feed closed off (flame off).
NOTICE
The flame scanner pilot lamp is only visible with the bar graph option.
If there is no bar graph included with the delivery , alternatively check the flame relay (NO)
for correct function
– The pilot light must be off, and the relay contact must be open.
2 Ignite the flame.
– The pilot light must be lit, and the relay contact must be closed.
3 Extinguish the flame.
– The pilot light must go out, and the relay contact must open again.
If the functional test was successful, the flame scanner has been correctly
commissioned.
- Otherwise, the fuel supply is to be closed immediately.
- Check electrical connections and the configuration of the system control.
- Disconnect the pilot burner from the system control.
- Do not place the pilot burner into operation.
- Contact the manufacturer.
42
5 Commissioning
5.3.1 Adjusting the GFI 48 Flame Quality and Flame Stability
The following graphic shows the air volume flow to be adjusted in [m3/h] in dependence on the
desired gas pre-pressure in [mbar] and/or the thermal power in [kW]. The gas pre-pressure is
to be recorded at the measurement socket for gas.
Fig. 5-16 Air volume flow to be set
1 Gas pre-pressure in [mbar] 4 Stability field in free self-sustaining com-
bustion
2 Thermal power in [kW] 5 Ideal line
3 Air volume flow in [m3/h]
Reference value table
The reference value table shows the values of the air pressure in [mbar] for the air volume flow
in [m3/h] determined in the diagram.
Outer tube
length
1,000 mm
(39,37 in)
2,000 mm
(78,74 in)
3,000 mm
(118,11 in)
4,000 mm
(157,48 in)
Combustion air
30 m3/h
(39.23 yd3/h)
6 mbar
(0.087 psi)
8 mbar
(0.11 psi)
10 mbar
(0.14 psi)
12 mbar
(0.17 psi)
40 m3/h
(52.31 yd3/h)
10 mbar
(0.14 psi)
14 mbar
(0.20 psi)
18 mbar
(0.26 psi)
22 mbar
(0.32 psi)
50 m3/h
(65.39 yd3/h)
15 mbar
(0.21 psi)
21 mbar
(0.30 psi)
28 mbar
(0.40 psi)
34 mbar
(0.49 psi)
60 m3/h
(78.47 yd3/h)
20 mbar
(0.29 psi)
28 mbar
(0.40 psi)
37 mbar
(0.53 psi)
45 mbar
(0.65 psi)
43
5 Commissioning
5.3.2 Adjusting the GFI 70 Flame Quality and Flame Stability
The following graphic shows the air volume flow to be adjusted in [m3/h] in dependence on the
desired gas pre-pressure in [mbar] and/or the thermal power in [kW]. The gas pre-pressure is
to be recorded at the measurement socket for gas.
Fig. 5-17 Air volume flow to be set for GFI 70
1 Gas pressure in [mbar] 4 Stability field in free self-sustaining com-
bustion
2 Thermal power in [kW] 5 Ideal line
3 Air volume flow in [m3/h]
Reference value table
The reference value table shows the values of the air pressure in [mbar] for the air volume flow
in [m3/h] determined in the diagram.
Outer tube
length
1,000 mm
(39,37 in)
2,000 mm
(78,74 in)
3,000 mm
(118,11 in)
4,000 mm
(157,48 in)
Combustion air
60 m3/h
(78.47 yd3/h)
6 mbar
(0.087 psi)
8 mbar
(0.11 psi)
10 mbar
(0.14 psi)
12 mbar
(0.17 psi)
90 m3/h
(117.71 yd3/h)
10 mbar
(0.14 psi)
14 mbar
(0.20 psi)
18 mbar
(0.26 psi)
22 mbar
(0.32 psi)
120 m3/h
(156.95 yd3/h)
15 mbar
(0.21 psi)
21 mbar
(0.30 psi)
28 mbar
(0.40 psi)
34 mbar
(0.49 psi)
195 m3/h
(255.04 yd3/h)
20 mbar
(0.29 psi)
28 mbar
(0.40 psi)
37 mbar
(0.53 psi)
45 mbar
(0.65 psi)
44
5 Commissioning
5.3.3 Adjusting the GFI 89 flame quality and flame stability
The following graphic shows the air volume flow to be adjusted in [m3/h] in dependence on the
desired gas pre-pressure in [mbar] and/or the thermal power in [kW]. The gas pre-pressure is
to be recorded at the measurement socket for gas.
Fig. 5-18 Air volume flow to be set for GFI 89
1 Gas pressure in [mbar] 4 Stability field in free self-sustaining com-
bustion
2 Thermal power in [kW] 5 Ideal line
3 Air volume flow in [m3/h]
Reference value table
The reference value table shows the values of the air pressure in [mbar] for the air volume flow
in [m3/h] determined in the diagram.
Outer tube
length
1,000 mm
(39,37 in)
2,000 mm
(78,74 in)
3,000 mm
(118,11 in)
4,000 mm
(157,48 in)
Combustion air
120 m3/h
(156.95 yd3/h)
5 mbar
(0.07 psi)
8 mbar
(0.11 psi)
10 mbar
(0.14 psi)
12 mbar
(0.17 psi)
160 m3/h
(209.27 yd3/h)
9 mbar
(0.13 psi)
13 mbar
(0.18 psi)
17 mbar
(0.24 psi)
21 mbar
(0.30 psi)
200 m3/h
(261.58 yd3/h)
14 mbar
(0.20 psi)
19 mbar
(0.27 psi)
24 mbar
(0.34 psi)
29 mbar
(0.42 psi)
240 m3/h
(313.90 yd3/h)
20 mbar
(0.29 psi)
26 mbar
(0.37 psi)
32 mbar
(0.46 psi)
38 mbar
(0.55 psi)
45
5 Commissioning
5.3.4 Connect Pressure-Measuring Equipment for Gas and Air
Suitable are pressure-measuring instruments with a measuring range from 0......>200 mbar.
1 Unscrew grub screws 2...3 revolutions out of the
measuring instrument inlet connection.
2 Connect air pressure measuring device to "A" (Air).
3 Connect gas pressure measuring device to "G"
(Gas).
NOTICE
The test measurement sockets should be closed again once the measurement has been completed.
5.3.5 Evaluate the Flame Stability using the Ionisation Current
General information about Ionisation Flame Monitoring
Following factors are essential regarding the safety of Ionisation Flame Monitoring:
• The reliable monitoring of a gas flame is achieved if the flame monitoring can be optimally
adapted to the gas combustion plant.
• The following must be taken into account. In the ionisation process, flame and burner are
also used as parts of the electrical circuit to form an optimal ionisation current. It is therefore essential that the boiler and burner are properly grounded.
• Of decisive importance for the height of the ionisation current is the fuel, the burner setting
and the electrode arrangement.
• The ionisation current increases with the calorific value of the gas. The prerequisite
for the formation of optimum values is given if, in relation to the setting of the burner:
– a stable flame is created
– the burner is operated with a low excess of air , so that an optimum Combustion occurs.
Flame quality and stability are evaluated by measuring the ionisation current. An ampermeter
is connected to the flame monitor for this purpose.
NOTICE
Measuring circuits must feature a secure disconnect according to EN 61140 "Protection
against electric shock " for active parts; for this reason, use only measurement and evaluation
devices which have a double or reinforced insulation.
NOTICE
Work on electrical systems or equipment may be performed only by a certified electrician or
trained personnel managed and supervised by a certified electrician according to the
electrical engineering regulations.
46
5 Commissioning
Measurement sockets with limited designated purpose for short-time measurement.
Risk of explosion if improperly used for continuous measurement.
Do not use measurement sockets for continuous measurements!
Perform short-time measurement only with suitable measuring device and under continuous
supervision.
NOTICE
To improve the evaluation of the flame stability, a needle instrument is more suitable than a
digital measuring device.
An amperemeter with a range of measuring of 0-300 mV is suitable.
10 mV correspond to 1A. .
NOTICE
Sensitive electronics!
Risk if faulty switching when handling measuring device plugs. An accidental contact of a
connected measuring terminal with the enclosure ground or with another contact can occur
here. This can trigger a faulty switching in the system control (e.g. by extinguishing the flame
signal).
For this reason, the flame monitor monitor must be deactivated during connecting and disconnecting of the measuring terminals, e.g. by disconnecting the supply voltage.
DANGER!
47
5 Commissioning
Designs A and B: Connect measuring instrument for ionisation current measurement
Use pointer amperemeter with a measuring range of 0-300 mV. 10 mV correspond to 1A.
Fig. 5-19 Connect amperemeter to measuring terminals
Procedure:
1 Deactivate flame monitor.
2 Connect measuring instrument to the flame monitor.
3 Activate flame monitor.
Designs C: Connect measuring instrument for ionisation current measurement
Procedure:
1 Deactivate external flame monitor.
2 Connect measuring instrument to the external flame monitor.
3 Activate external flame monitor.
Perform measurement:
Flame quality and flame stability are set by regulating the gas and air pressure.
An even and stable flame signal is always preferable to a high, but fluctuating flame signal..
Procedure:
1 Ignite the flame.
2 Read the measured values.
3 Set the flame to maximum flame quality while observing the measured value.
– Even needle deflection = high stability
– Uneven needle deflection = low stability
Stop the measurement
Procedure:
1 Deactivate the flame monitor
2 Disconnect measuring instrument.
3 Screw off pressure gauges.
4 Screw grub screws into the measurement sockets up to the limit stop.
5 For versions A and B: Close the protective caps of the measuring sockets.
48
6 Maintenance
6 Maintenance
Observe the safety regulations!
NOTICE
Wear personal safety equipment.
Face protection
Insulating safety gloves
Safety shoes
All activities described in this chapter must be performed by qualified, authorised personnel
only under observance of requirements from the following regulating bodies:
Official Journal of the European Union L 96/309, Directive 2014/34/EU of 26 February
2014 relating to equipment and protective systems intended for use in potentially
explosive atmospheres (recast)
EN 60079-0:2014-06 (VDE 0170-1:2014-06) Explosive atmospheres – Part 0:
Equipment – General requirements
WARNING!
DANGER!
For ignition attempts for maintenance purposes, there is a risk of flashing
caused by residual gas in the gas tube or gases in the environment.
For pilot attempts, secure the hazard area in front of the pilot burner mouth.
Clear the pilot burner with purge air from residual gas as necessary.
The ignition should ideally only be tested in installed status.
WARNING!
Opening the housing of the integrated power unit Ex-Zone II is not permitted!
This does not affect the opening of the tube to replace the wearing parts.
49
6 Maintenance
6.1 Consumables
Replace wear parts
The replacement of parts that are subject to normal wear is not deemed to be repair work and
may be performed by authorised personnel of the system operator.
The decision as to when wear parts are to be replaced is the responsibility of the system operator.
The following events can make the replacement of wear parts necessary:
• Malfunctions become more frequent.
• Device fails due to a defect.
• Device working under adverse conditions.
• Abnormalities during the course of proper maintenance.
NOTICE
It is not necessary to repair ignition breakdown paths.
NOTICE
Use only original replacement parts when replacing wear parts.
Original replacement parts are available from the manufacturer; for contact data, see chapter
6.4 Customer Service Information
The following is a list of the wear parts that are to be replaced during maintenance and
as needed:
Fig. 6-1 Wear parts on the GFI pilot burner
1 Nozzle for natural gas/propane
2 Electrodes with spacer/centre holder and plug sockets for the electrode rods
3 Spacer and centre holder for the electrode rods
4 Electrode rods
50
6 Maintenance
6.2 Maintenance Preparation
Under regular operating conditions, the maintenance is limited to a semi-annual
inspection of the device. With increased load due to extreme operating conditions
(e.g. temperature, vibration, contamination, etc.), the inspection must be performed monthly .
Shut down the system control and secure it against inadvertent or accidental
restarting.
CAUTION!
Residual heat on all parts of the system and the ignition burner.
Risk of contact burns.
Allow the system and ignition burner to cool down before removal.
51
6 Maintenance
6.3 Perform Maintenance
Procedure:
CAUTION!
Residual heat on all parts of the system and the pilot burner.
Risk of contact burns.
Allow the system and pilot burner to cool down before removal.
1 Shut down the system and secure it from being switched on again.
2 Allow the pilot burner to cool down completely.
3 Shut off the gas and air supply.
4 Depressurise the gas and air supply systems and disconnect them.
5 Have the closures for the combustion chamber opening ready.
6 Disconnect the electrical connections and ensure that there is no voltage present.
7 Loosen the grub screws.
8 Pull the pilot burner out of the flange.
Remove the device
1 Mark the position in which the outer tube is
inserted in the feed-through flange.
2 Loosen the grub screws of the feed-through
flange.
3 Pull the pilot burner out of the feed-through flange.
NOTICE
If the location conditions permit, it makes sense to remove the device together with the feedthrough flange.
Advantage: The position of the outer tube in the feed-through flange is maintained without any
changes.
Alternatively, the outer tube with feed-through flange and air enclosure can remain on the
combustion chamber so that only the electrodes need to be pulled out of the outer tube.
Requirement for this: The outer tube is short enough that the electrode rods can be removed
from the outer tube without twisting.
Fig. 6-2 Leave outer tube and feed-through flange on the combustion chamber
52
6 Maintenance
Replace wear parts
1. Separate air enclosure and gas block, then pull off outer tube.
Fig. 6-3 Step 1 - Replace wear parts on the pilot burner
2. Loosen in-hex screw of the spacer and centre holder.
Fig. 6-4 Step 2 - Replace wear parts on the pilot burner
3. Slide the spacer and centre holder forward so that their plug sockets
release the electrode rods.
Fig. 6-5 Step 3 - Replace wear parts on the pilot burner
4. Bend the electrode rods to the side slightly. Slide the spacer and centre holder back far
enough
that a socket wrench can be placed on the nozzle.
Fig. 6-6 Step 4 - Replace wear parts on the pilot burner
5. Unscrew nozzle and remove flame stabiliser
53
6 Maintenance
Fig. 6-7 Step 5 - Replace wear parts on the pilot burner
NOTICE
During the mounting process, the nozzle with the flame stabiliser must be tightened at 20 Nm.
6. Loosen in-hex screws of all spacer and centre holders.
Pull off all spacer and centre holders from the electrode rods and from the inner tube.
Fig. 6-8 Step 6 - Replace wear parts on the pilot burner
7. Replace all wear parts.
Fig. 6-9 Step 7 - Replace wear parts on the pilot burner
8. Then re-assemble everything and ensure that the distance of the spacer and
centring holder in relation to one another.
Fig. 6-10 Step 8 - Replace wear parts on the pilot burner
54
6 Maintenance
9. Make sure the electrodes are in the correct position.
Ignition electrode (short): left
ionisation electrode (long): right
Re-tighten all hexagon screws.
Fig. 6-11 Step 9 - Replace wear parts on the pilot burner
10. Mount the outer tube again and perform electrode test, see chapter 5.2 Assembly check
ionisation electrode.
Mount the device again
Procedure:
1 Install the pilot burner again, see also chapter 5.2 Assembly
2 Connect gas and air supply again.
3 Connect electrical connections again.
4 Perform leak test, see also chapter 5 Commissioning
5 Perform functional test, see also chapter 5 Commissioning
55
6 Maintenance
6.4 Customer Service Information
Please contact LAMTEC Service/Support if you have any questions.
LAMTEC GmbH & Co.KG
Sensors and Systems for Combustion
Technology
Wiesenstraße 6
D-69190 Walldorf
Hotline: +49 (0) 6227 / 6052-33
email: support@lamtec.de
6.5 Warranty and Delivery Terms
The manufacturer's warranty conditions apply. Warranty claims are refused if changes have
been made to the device or it has been interfered with in any way during the warranty period.
The device is shipped as specified in the purchase order information. LAMTEC's terms and
conditions of delivery and service and the general terms and conditions of delivery and service
of the electrical and electronic engineering industry apply.
56
7 Correcting Faults
7 Correcting Faults
Observe the safety regulations!
NOTICE
Wear personal safety equipment.
Face protection
Insulating safety gloves
Safety shoes
WARNING!
All activities described in this chapter must be performed by qualified, authorised personnel
only under observance of requirements from the following regulating bodies:
Official Journal of the European Union L 96/309, Directive 2014/34/EU of 26 February
2014 relating to equipment and protective systems intended for use in potentially
explosive atmospheres (recast)
EN 60079-0:2014-06 (VDE 0170-1:2014-06) Explosive atmospheres – Part 0:
Equipment – General requirements
For ignition attempts for maintenance purposes, there is a risk of flashing
caused by residual gas in the gas tube or gases in the environment.
For pilot attempts, secure the hazard area in front of the pilot burner mouth.
Clear the pilot burner with purge air from residual gas as necessary.
The ignition should ideally only be tested in installed status.
Opening the housing of the integrated power unit Ex-Zone II is not permitted!
This does not affect the opening of the tube to replace the wearing parts.
7.1 General Data
Act correctly when an error occurs
Critical operating state when an error occurs.
Risk of death from deflagration or explosion.
Shut off the gas supply immediately.
Stop operation.
Shut down the system.
Secure the system against being restarted.
DANGER!
WARNING!
DANGER!
57
7 Correcting Faults
7.2 Fault Finding and Troubleshooting
Fault Causes Fault rectification
No ignition flame forms.
There is no combustion air present or the combustion air is insufficient.
Possible cause
- Fan not running. Check fan.
Ensure that the fan is
being activated correctly by the system control.
- An actuator is closed (air
flap, ball valve, valve).
- An actuator is faulty (air
flap, ball valve, valve).
- Air line clogged. Check line air line.
- Air line or fan incorrectly
dimensioned.
- Combustion air is
contaminated.
- Gas does not comply with
the specifications.
- Gas/air ratio does no
comply with the
specifications.
No fuel gas reaches the ignition burner.
Open actuator.
Check/replace actuator.
Correct the dimensioning of the tube length,
tube diameter, fan power.
Clean or replace air filter.
If air filter is missing, retrofit this.
Gas must comply with the specifications of the
ignition burner (see type plate and technical
specifications).
Set the gas and air operating pressures correctly (see chapter 5.3 Commissioning ).
Possible cause
- An actuator is closed (ai
flap, ball valve, valve).
- An actuator is faulty (air
flap, ball valve, valve).
- Gas pressure not
sufficient.
- In the tubing there is
residual inert gas (N2).
Open actuator.
Check/replace actuator.
Correct the dimensioning of the tube length,
tube diameter, fan power.
Flush the gas line by repeating ignition attempt
until flame ignites.
58
7 Correcting Faults
Fault Causes Fault rectification
No ignition flame forms.
No ignition sparks occur.
Possible cause
The flame monitor switches to fault
condition during operation.
- No supply voltage on the
ignition burner.
- Ignition electrode is
burnt down.
- Distance between ignition
electrode and ground is
not correct or there is an
accidental ground pres
ent.
- Ignition electrode is
contaminated.
- An insulator is broken. Replace insulator with spacer and centre
- Ignition transformer is
defective.
Ignition flame has been extinguished.
Check supply voltage.
Ensure that the ignition burner is being correctly activated by the system control.
Replace ignition electrode.
Check the distance between ignition electrode
and ground and correct, if necessary.
Rectify contamination using steel wool or sandpaper until the electrode is bare.
holder.
Replace ignition transformer.
Possible cause
- Pressure in combustion
chamber fluctuating.
- Gas and air pressures
fluctuating.
- Main flame is influenced
by flows in the combus
tion chamber or due to
external deflection.
- No combustion air in the
combustion chamber.
Provide for differential pressure control on the
gas and air side.
Correct the installation position and power of
the ignition burner.
59
7 Correcting Faults
Fault Causes Fault rectification
The ignition flame forms but goes
out after the ignition safety time
expires.
Ionisation monitoring not functioning
Possible cause
- Ionisation electrode is
burnt down.
- An insulator is broken. Replace insulator with spacer and centre
- Flame monitor is con
nected incorrectly or is
incorrectly activated.
- The distance between the
ionisation electrode and
ground is not correct or
there is an accidental
ground present.
- The insulating property of
the insulators is impaired
due to overheating of the
ignition burner.
- The ignition flame is not
located in the coverage
area of the ionisation
electrode.
- The ignition spark inter
feres with the ionisation
feedback.
- The operating voltage
and basic voltage are
simultaneously switched
on.
Flame monitor is faulty. Have the manufacturer inspect the flame moni-
Replace ionisation electrode
holder.
Check electrical connection of the flame moni-
tor.
Ensure that the flame monitor is being correctly
activated by the system control.
Correct the distance between ionisation electrode and ground by bending the ionisation
electrode or replace the ionisation electrode.
Ensure that the ignition burner is continually
flushed with combustion air to reduce the heat
effect.
Adjust the gas and air operating pressures correctly (see chapter 5.3 Commissioningsection
"Adjust the flame quality and flame stability".
Ensure that the system control
switches off the ignition spark before the ignition safety time expires (-0.5 s).
Ensure that the system control switches on the
operating voltage 5 s after the basic voltage.
tor and replace, if necessary.
60
7 Correcting Faults
Fault Causes Fault rectification
The flame monitor switches to fault
condition during operation.
Despite the closed gas valve, the
flame monitor outputs a flame
signal.
The ignition flame has been extinguished.
Possible cause
- Pressure in combustion
chamber fluctuating.
- Gas and air pressures
fluctuating.
- Main flame is influenced
by flows in the combus
tion chamber or due to
external deflection.
- No combustion air in the
combustion chamber.
The gas valve is leaky, so
that a small flame arises.
Provide for differential pressure control on the
gas and air side.
Correct the installation position and power of
the ignition burner.
Replace leaky gas valve.
7.3 Repair
WARNING!
Safety-relevant components!
Risk of malfunction if repaired improperly.
Only have repairs done by the manufacturer.
Do not attempt to make repairs yourself.
7.4 Information About the Repair Service
Please contact LAMTEC Service/Support if you have any questions.
LAMTEC GmbH & Co.KG
Sensors and Systems for Combustion
Technology
Wiesenstraße 6
D-69190 Walldorf
Hotline: +49 (0) 6227 / 6052-33
email: support@lamtec.de
61
8 Decommissioning and Storage
8 Decommissioning and Storage
Observe the safety regulations!
NOTICE
Wear personal safety equipment.
Face protection
Insulating safety gloves
Safety shoes
WARNING!
All activities described in this chapter must be performed by qualified, authorised personnel
only under observance of requirements from the following regulating bodies:
Official Journal of the European Union L 96/309, Directive 2014/34/EU of 26 February
2014 relating to equipment and protective systems intended for use in potentially
explosive atmospheres (recast)
EN 60079-0:2014-06 (VDE 0170-1:2014-06) Explosive atmospheres – Part 0:
Equipment – General requirements
DANGER!
For ignition attempts for maintenance purposes, there is a risk of flashing
caused by residual gas in the gas tube or gases in the environment.
For pilot attempts, secure the hazard area in front of the pilot burner mouth.
Clear the pilot burner with purge air from residual gas as necessary.
The ignition should ideally only be tested in installed status.
WARNING!
Opening the housing of the integrated power unit Ex-Zone II is not permitted!
This does not affect the opening of the tube to replace the wearing parts.
62
8 Decommissioning and Storage
8.1 Decommissioning
Take the pilot burner out of operation and remove
CAUTION!
Residual heat on all parts of the system and the pilot burner.
Risk of contact burns.
Allow the system and pilot burner to cool down before removal.
Procedure:
1 Shut down the system and secure it from being switched on again.
2 Allow the pilot burner to cool down completely.
3 Shut off the gas and air supply.
4 Depressurise the gas and air supply systems and disconnect them.
5 Disconnect the electrical connections and ensure that there is no voltage present.
6 Loosen the grub screws.
7 Pull the pilot burner out of the flange.
8.2 Storage
Procedure:
1 Perform a complete maintenance, see chapter 6.3 Perform Maintenance, to ensure that
the ignition burner is operationally ready for the next use.
2 Seal off the connections for gas and air supply to prevent contamination.
3 Store the ignition burner in the original packaging together with these
operating instructions under appropriate storage conditions, see chapter 3.6 Technical
Data.
63
9 Disposal Notes
9 Disposal Notes
NOTICE
Improper or inadequate recycling harms the environment. Please observe the regional disposal regulations.
The device itself is to be recycled as electronic waste to returned to the burner or boiler
manufacturer.
64
10 EU Declaration of Conformity
10 EU Declaration of Conformity
65
10 EU Declaration of Conformity
66
11 Order Information
11 Order Information
Sliding flange Order no.
GFI48 sliding flange with O-ring seal and grub screws, DN50 PN6, 1.4571 646R1151
GFI48 two-hole sliding flange with O-ring seal and grub screws, 1.4571 646R1152
GFI70 sliding flange with O-ring seal and grub screws, DN65 PN6, 1.4571 646R2151
GFI89 sliding flange with O-ring seal and grub screws, DN80 PN6, 1.4571 646R3151
Commissioning / maintenance / service Order no.
Inspection diode for GFI 646R0100
Spare parts Order no.
For GFI48: Ionisation and ignition electrodes with spacer and centring holder for the electrode rods 646R1115
For GFI48: Spacer and centre holder with insulator for the electrode rods 646R1116
For GFI70: Ionisation and ignition electrodes with spacer and centring holder for the electrode rods 646R2115
For GFI70: Spacer and centre holder with insulator for the electrode rods 646R2116
For GFI89: Ionisation and ignition electrodes with spacer and centring holder for the electrode rods 646R3115
For GFI89: Spacer and centre holder with insulator for the electrode rods 646R3116
Nozzle for natural gas GFI48 646R1105
Nozzle for propane gas GFI48 646R1106
Nozzle for natural gas GFI70 646R2105
Nozzle for propane gas GFI70 646R2106
Nozzle for natural gas GFI89 646R3105
Nozzle for propane gas GFI89 646R3106
Flame stabiliser for GFI48 material 1.4301/1.4305 646R1100
Flame stabiliser for GFI70 material 1.4301/1.4305 646R2100
Flame stabiliser for GFI89 material 1.4301/1.4305 646R3100
Ignition transformer for GFI ignition systems, 230VAC / 8kV 646P1040
Ignition transformer for GFI ignition systems, 120VAC / 8kV 646P1041
Ionisation flame scanning (IFM) F130i, SIL3, 230 VAC power supply voltage, for DIN rail, continuous operation 659G1001
Ionisation flame scanning (IFM) F130i, SIL3, 120 VAC power supply voltage, for DIN rail, continuous operation 659G1002
Accessories Order no.
Connection cable with mating connector for plug connection 646R0150
Double nipple 3", material: 1.4408 646R9001
Double nipple 1" outer/outer, stainless steel 646R9015
Hexagon reducing double nipple NPT 3/4" on R 1/2", material: 1.4571 646R9030
Hexagon reducing double nipple NPT 11/4" on R 1", material: 1.4571 646R9031
Stainless steel manometer 0..160 mbar (0 ... 2.32 psi), housing Ø 63mm (2,48 in), connection G1/8" vertical 646R9040
Sliding nipple with O-ring seal and 3" external thread, 1.4301, for GFI48 646R9055
Needle valve 1 1/4" NPT internal thread, material 1.4571 646R9058
Needle valve 3/4" NPT internal thread, material 1.4571 646R9059
Ball valve for gas 1/2" internal/external, with DVGW approval, brass 646R9060
Ball valve (Mini) Ballofix for gas 3/4" internal/external, brass 646R9065
Ball valve (stainless steel) 3" IG/IG with lever, DN80 646R9069
Air regulation sleeve 1" internal/internal, black cast iron 646R9102
Air regulation sleeve 1 1/2" internal/internal, black cast iron 646R9103
67
11 Order Information
68
The information in this publication is subject to technical changes.
LAMTEC Meß- und Regeltechnik
für Feuerungen GmbH & Co. KG
Wiesenstraße 6
D-69190 Walldorf
Telefon: +49 (0) 6227 6052-0
Telefax: +49 (0) 6227 6052-57
info@lamtec.de
www.lamtec.de
Printed in Germany | Copyright 2019
Publication no. DLT7126-19-aEN-007
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