Lamtec GFI 48, GFI 89, GFI 70 Operating Instructions Manual
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
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