Lamtec GFI 48 Operating Instructions Manual
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Lamtec GFI 48 Operating Instructions Manual

Ignition and pilot burner
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Operating Instructions
Ignition and Pilot Burner
GFI 48 / 70 / 89 and Ex Variants
Sensors and Systems for Combustion Engineering
www.lamtec.de

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Summary of Contents for Lamtec GFI 48

  • Page 1 Operating Instructions Ignition and Pilot Burner GFI 48 / 70 / 89 and Ex Variants Sensors and Systems for Combustion Engineering www.lamtec.de...

  • Page 3: Table Of Contents

    3.6.1 Technical data for the GFI 48 pilot burner ......12 3.6.2 Technical data for the GFI 70 pilot burner .
  • Page 4 Table of Contents Correcting Faults ............54 General Data .

  • Page 5: Important Information About The Manual

    Important Information about the Manual Important Information about the Manual Purpose/Applicability of the Document These instructions facilitate the safe and efficient handling of the pilot burner GFI and its variants. Target Group These instructions must have been read carefully and completely before commencing with any work.
  • Page 6 General Safety Instructions General Safety Instructions Classification of the Safety Instructions and Warnings The following symbols are used in this document to draw the user's attention to important safe- ty information. They are located at points where the information is required. It is essential that the safety information is observed and followed, and that applies particularly to the warnings.

  • Page 7: General Safety Instructions

    General Safety Instructions 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.

  • Page 8: Product-Specific Dangers

    General Safety Instructions 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.
  • Page 9 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 Appli- ances Directive 2009/142/EC. •...

  • Page 10: Proper Use - Conditions Of Use

    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. Installation Notes WARNING! All following warnings must be observed to avoid personal injury and damage to property and the environment..

  • Page 11: Product Description

    • 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 •...

  • Page 12: 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.

  • Page 13: Equipment

    (IFM) IFM= ionisation flame scanning either ignition transformer or IFM 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).

  • Page 14: Installation And Connection Materials

    Product Description 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. Important Information about the Product 3.5.1 Life Cycle...

  • Page 15: Technical Data

    Product Description 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.
  • Page 16 Product Description Fig. 3-11 Side view of GFI48 pilot burner design C Fig. 3-12 Dimensions of GFI48 pilot burner design C Dimension outer tube length (customer-specific) Outer tube diameter 48.3 mm x 2 mm (1.90 x 0.078 in) Housing length versions A and B Housing dimensions Air supply connection 1 inch (BSPP inner threads)

  • Page 17: Technical Data For The Gfi 70 Pilot Burner

    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 Ex- Zone II Fig.
  • Page 18 Product Description Fig. 3-17 Side view of GFI70 pilot burner design C Fig. 3-18 Dimensions of GFI70 pilot burner design C Dimension outer tube length (customer-specific) Outer tube diameter 70 mm x 2 mm ( 2.75 x 0.078 in) Housing length versions A and B Housing dimensions Air supply connection 1 1/2 inch (BSPP inner threads)

  • Page 19: Technical Data For The Gfi 89 Pilot Burner

    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 Ex- Zone II Fig.
  • Page 20 Product Description Fig. 3-23 Side view of GFI89 pilot burner design C Fig. 3-24 Dimensions of GFI89 pilot burner design C Dimension outer tube length (customer-specific) Outer tube diameter GFI89: 88.9 mm x 2 mm ( 3.5 x 0.078 in) Housing length versions A and B Housing dimensions Air supply connection...

  • Page 21: Common Technical Data For Gfi 48/70/89 Pilot Burner

    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.
  • Page 22 Product Description Versions A and B: Integrated flame scanner ≤ 2% Intrinsic error Electrical safety Contact protection by means of protective impedances Min. impedance of the connected 1 MΩ measuring device 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.
  • Page 23 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 (1 x 17 AWG) 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...
  • Page 24 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.

  • Page 25: Special Version Thermal Rating With High Power Versions

    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...
  • Page 26 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)

  • Page 27: Technical Data External Housing Ex-Zone I

    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:...

  • Page 28: Technical Data For Nw48/70/89 Sliding Flange

    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.

  • Page 29: Design And Functions

    Construction of pilot burner versions A and B 1 Outer tube 2 Air housing 3 Gas block 4 Connection enclosure Fig. 4-1 Main components of LAMTEC GFI pilot burner Connections: Gas and air supply 1 Air supply connection 2 Gas supply connection Fig.

  • Page 30: Functional Description

    Design and Functions 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! ...

  • Page 31: Commissioning

    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...
  • Page 32 Commissioning Mounting position DANGER! Due to the pilot burner falling due to vibrations for overhead assembly with sliding flange!  Overhead assembly is only permitted with welded flange! Fig. 5-1 Possible installation situations 1 Mounting angle in relation to the hori- 3 Not permissible with sliding flange.
  • Page 33 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 arranged grub screws for securing the outer tube. 1 Seal 4 x M12 screws (GFI48/GFI70) 4 x M16 screws (GFI89) 4 washers 4 screw nuts...
  • Page 34 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.
  • Page 35 Commissioning Before the installation: Check the ionisation electrode DANGER! 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. ...
  • Page 36 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.
  • Page 37 Commissioning 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. Fig. 5-7 Mount the pilot burner Tighten the grub screws in a cross-wise pattern to secure the pilot burner.
  • Page 38 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.

  • Page 39: Electrically Connecting The Gfi Pilot Burner

    Commissioning 5.2.1 Electrically Connecting the GFI Pilot Burner Design A: Electrically connect the pilot burner Connect the pilot burner cables as follows Wire colour Function Phase Neutral conductor Ignition transformer N Ignition transformer L gn/ye Protective conductor Fig. 5-10 Connect pilot burner version A Design B: Electrically connect the pilot burner Wire colour Function...
  • Page 40 Commissioning Design C: Connect earth cable Connection thread Ring terminal lug Spring washer Earthing bolt Fig. 5-12 Connect version C earth cable Design C: Ignition and ionisation cables 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!
  • Page 41 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 Wire colour Function Phase Neutral conductor Ignition transformer N Ignition transformer L gn/ye Protective conductor...
  • Page 42 Commissioning Commissioning 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: ...
  • Page 43 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: 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.

  • Page 44: Adjusting The Gfi 48 Flame Quality And Flame Stability

    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 [m /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.

  • Page 45: Adjusting The Gfi 70 Flame Quality And Flame Stability

    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 [m /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.

  • Page 46: Adjusting The Gfi 89 Flame Quality And Flame Stability

    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 [m /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.

  • Page 47: Connect Pressure-Measuring Equipment For Gas And Air

    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"...
  • Page 48 Commissioning DANGER! 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.
  • Page 49 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 1μA. Fig. 5-19 Connect amperemeter to measuring terminals Procedure: Deactivate flame monitor. Connect measuring instrument to the flame monitor. Activate flame monitor.

  • Page 50: Maintenance

    Maintenance Maintenance 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: ...

  • Page 51: Consumables

    Maintenance 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 op- erator.

  • Page 52: Maintenance Preparation

    Maintenance 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.

  • Page 53: Perform Maintenance

    Maintenance 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. Shut down the system and secure it from being switched on again. Allow the pilot burner to cool down completely.
  • Page 54 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.
  • Page 55 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.
  • Page 56 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.

  • Page 57: Customer Service Information

    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...

  • Page 58: Correcting Faults

    Correcting Faults 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: ...

  • Page 59: Fault Finding And Troubleshooting

    Correcting Faults 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 Open actuator.
  • Page 60 Correcting Faults Fault Causes Fault rectification No ignition flame forms. No ignition sparks occur. Possible cause - No supply voltage on the Check supply voltage. ignition burner. Ensure that the ignition burner is being cor- rectly activated by the system control. - Ignition electrode is Replace ignition electrode.
  • Page 61 Correcting Faults Fault Causes Fault rectification The ignition flame forms but goes out after the ignition safety time Ionisation monitoring not functioning expires. Possible cause - Ionisation electrode is Replace ionisation electrode burnt down. - An insulator is broken. Replace insulator with spacer and centre holder.

  • Page 62: Repair

    Risk of malfunction if repaired improperly. Only have repairs done by the manufacturer. Do not attempt to make repairs yourself. 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...

  • Page 63: Decommissioning And Storage

    Decommissioning and Storage 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: ...

  • Page 64: Decommissioning

    Decommissioning and Storage 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: Shut down the system and secure it from being switched on again.

  • Page 65: Disposal Notes

    Disposal Notes Disposal Notes NOTICE Improper or inadequate recycling harms the environment. Please observe the regional dispos- al regulations.  The device itself is to be recycled as electronic waste to returned to the burner or boiler manufacturer.

  • Page 66: Eu Declaration Of Conformity

    EU Declaration of Conformity EU Declaration of Conformity...
  • Page 67 EU Declaration of Conformity...

  • Page 68: Order Information

    Order Information 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...
  • Page 69 Order Information...
  • Page 70 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 info@lamtec.de Telefax: +49 (0) 6227 6052-57 www.lamtec.de Printed in Germany | Copyright  2019...

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Gfi 89Gfi 70

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