BFI Automation CFC 2000L Original Operating Instructions

Compact flame controller

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Original Operating Instructions

Compact Flame Controller

OE-Converter

Type:

Document-No.:

BFI Automation Mindermann GmbH

D-42579 Heiligenhaus / Germany

Phone +49 (2056) 98946-0 Fax +49 (2056) 98946-42

http://www.bfi-automation.de

CFC 2000L

BA CFC2000L EN Rev10

Software settings

see

HB CFC Com1 EN

Ruegenstrasse 7

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Page 1 Original Operating Instructions Compact Flame Controller OE-Converter Type: CFC 2000L Document-No.: BA CFC2000L EN Rev10 Software settings Document-No.: HB CFC Com1 EN BFI Automation Mindermann GmbH Ruegenstrasse 7 D-42579 Heiligenhaus / Germany Phone +49 (2056) 98946-0 Fax +49 (2056) 98946-42 http://www.bfi-automation.de...
Page 3: Table Of Contents
Content General aspects Introduction Warning notes Copyright protection Disposal information Warranty Obligation of the operating company Liability disclaimer Declaration of conformity Address of the manufacturer Safety Intended use Requirements on persons Safety instructions Safety devices 2.4.1 Fundamental aspects 2.4.2 Safety devices on the compact flame controller Safety instructions in case of maintenance and troubleshooting 2.5.1 Fundamental aspects...
Page 4 Content Description Type plate Functional description Hardware settings 5.3.1 The frequency filter 5.3.2 Safety switch-OFF time of the safety channel Factory settings Operation of the Compact Flame Controller Test of the Compact Flame Controller Care and Maintenance Failures Order data Accessories 10-1...
Page 5: General Aspects
General aspects General aspects Introduction These operating instructions are a helpful guide for ensur- ing the successful and safe operation of the compact flame controller. They contain important information on how to operate the controller safely, correctly and effi- ciently. Observing the operating instructions will help to prevent hazards, reduce costs of repair and downtimes and increase the reliability and life of the device.
Page 6: Warning Notes
General aspects Warning notes The following warning notes are used in these operating instructions: This warning level indicates an imminent hazardous situa- tion. If the hazardous situation is not prevented, this will result in death or severe injury. Follow the instructions that accompany this warning to prevent the risk of death and severe personal injury.
Page 7: Copyright Protection
These operatint instructions have to be treated as confi- dential. They may only be used by authorised staff. Ac- cess by third parties may only be granted upon written agreement of BFI Automation. All documents are protected in keeping with the German copyright law.
Page 8: Warranty
 non-performance of specified maintenance work It is recommended that the operator of the device con- cludes a service contract with BFI Automation. This guar- antees that the device is regularly checked by our service staff and ensures that any required wearing and spare...
Page 9: Obligation Of The Operating Company
General aspects Obligation of the operating company The compact flame controller may cause hazards if it is operated inappropriately or in an improper condition. The operating company is under the obligation to operate the machine in proper state only. The operating company has to secure hazardous areas that exist between BFI de- vices and the customer's own equipment.
Page 10: Liability Disclaimer
BFI Automation for consequential damages. BFI Automation is liable for possible errors or omissions with the exclusion of additional claims entered into in the framework of the warranty obligations conceded to in the contract.
Page 11: Declaration Of Conformity
General aspects Declaration of conformity...
Page 12: Address Of The Manufacturer
General aspects Address of the manufacturer BFI Automation Mindermann GmbH Ruegenstrasse 7 D-42579 Heiligenhaus Germany Tel. +49 (2056) 98946-0 Fax. +49 (2056) 98946-42 E-mail: info@bfi-automation.de Internet: www.bfi-automation.de...
Page 13: Safety
Compact Flame Controller are flame de- tections for selective and continuous burner monitoring in industrial steam generators, single and multi-burner fur- naces. The CFC 2000L may only be operated with fibre optic cables that were supplied by BFI Automation. Danger when improperly used ! The device may cause hazards if it is not used as in- tended and/or for any other purposes.
Page 14: Requirements On Persons
Safety Requirements on persons Work on/with the device may only be performed by per- sons authorized to do so based on their training and quali- fication. Furthermore, such persons have to have been commissioned by the operating company. Do not allow any persons who are being apprenticed, ed- ucated, instructed or on a general training programme to work on the device without the constant supervision of an experienced person.
Page 15: Safety Instructions
Safety Safety instructions The following instructions on accident prevention have to be observed when operating the compact flame controller. Only operate the device if it is in a proper state !  Do not remove or disable safety devices.  Check for externally noticeable damage and defects prior to using the device ! Immediately notify the appro- priate authority/person of any changes that occur (in- cluding changes in operating performance).
Page 16: Safety Devices
Safety Safety devices 2.4.1 Fundamental aspects Check the safety equipment and locking devices on the device for safe operational condition. Only operate the device if all safety devices are present and enabled. The operating company or operator of the compact flame controller is responsible for the proper op- eration of the device.
Page 17: Safety Instructions In Case Of Maintenance And Troubleshooting
 Operating and auxiliary materials as well as exchanged parts have to be disposed of in a safe and eco-friendly way.  Spare parts supplied by BFI Automation or approved of by BFI Automation only may be used.
Page 18: Electrical / Electronic Devices
Safety 2.5.2 Electrical / electronic devices Danger to life caused by electrical current! Contact with live wires or components presents a danger to life ! Before working on electrical components, disconnect the compact flame controller from the mains power supply! In keeping with the electrical regulations, work on electri- cal / electronic parts / components may only be carried out by electrical specialists.
Page 19: Technical Data
Technical data Technical data General characteristic features  Flame scanner with integrated amplifier and flame re-  Tested by the German Technical Inspection Associa- tion TÜV, approved by IECEx  For continuous, intermittent and 72-hours operation  Type UV, UV1: For monitoring gas and oil-fired burn- ers in the UV range ...
Page 20: Electrical System, Optical And Mechanical Data
Technical data Electrical system, Optical and Mechanical Data Spectral sensitivity 280 to 420 nm 190 to 550 nm 300 to 1050 nm 300 to 2700 nm 1050 to 2700 nm Angle of view 3 ° with SKL Self-monitoring Fully electronic, per 800 ms Operating voltage 24 V DC...
Page 21 Technical data Electrical connection Standard housing dust-tight Harting plug Ex-proof housing terminal compartment in housing Housing dimension Standard housing* 122 x 120 x 80 mm (4.8 x 4.72 x 3.15 inch) Ex-proof housing 232 x 232 x 166.5 mm (9.13 x 9.13 x 6.55 inch) for 1 device* 276 x 276 x 218 mm for 2 or 3 devices*...
Page 22: Weight
Technical data Weight Housing [kg] [lbs] Standard Ex-proof for 1 device approx. 7.0 approx. 15.43 for 2 or 3 devices approx. 13.0 approx. 28.66 Dimensions Standard 1 x Ex 2 or 3 x Ex [mm] [inch] [mm] [inch] [mm] [inch] Length 6.69 15.75...
Page 23: Device Design - Block Diagram Cfc2000
Technical data Device Design – block diagram CFC2000 µP & J1-3 Sensor Fault output Pre-amplifier Data output RS232 Band-pass filter Flame relay DC voltage part Monitor relay Frequency part Relay contact with fuse F3 Modulation part J1-3 Monitor channel switch-off time Monitor channel Frequency tap selection Switchover to channel 2 (external)
Page 24 Technical data...
Page 25: Transport, Installation And Connection
The legal regulations as well as adjustment instructions of the plant operator have to be observed! Scope of delivery  Compact Flame Controller CFC 2000L  Operating instruction BA CFC 2000L EN  Harting cable terminal box kit (not with ex-proof hous- ing) Accessories (optional) ...
Page 26: Packaging
Transport, Installation and Connection Report any damage After arrival of the device and accessories, notify the ship- ping agent, the insurance company and BFI Automation immediately in case of any damage caused by transport or inadequate packaging. Take steps to minimise and prevent further damage.
Page 27: Space Requirement
Transport, Installation and Connection Space requirement See following illustration. Standard housing Item SI unit US unit [mm] [inch] G1“ G1“ 5.98 4.72 4.17 3.46...
Page 28 Transport, Installation and Connection Ex-proof housing for 1 OE-Converter For use in hazardous area Zone 1 Item SI unit [mm] US unit [inch] 9.11 0.511 0.472 9.11 8.11 10.51 11.89 2.16 2.75...
Page 29: Installation
Transport, Installation and Connection Installation All installation and connection work may be carried out by qualified and approved specialist staff only ! The legal regulations as well as adjustment instructions of the plant operator have to be observed! Optical alignment device Union nut SW55 Fibre optic cable Heating insulator...
Page 30 Transport, Installation and Connection Recommendation: For adjustment, use the optical adjustment aid (available as an option) as shown in the figure below. The best set- ting is obtained when a large visual field is achieved. correct incorrect Risk of damage to the eyes from infrared and ultraviolet radiation and from escaping gases during visual flame monitoring! Wear filtering protective goggles !
Page 31 The entire mechanical peripheral system can be supplied by BFI Automation. OE-Converter 5 3-Way valve Fibre optic cable 6 Double nipple...
Page 32: Works Setting Of The Compact Flame Controller
Transport, Installation and Connection 4.7.1 Works setting of the compact flame controller Danger to life caused by combustion or explosion ! Incorrect installation or adjustment may result in uncon- trolled combustion or explosions! Observe the adjustment instructions of the plant operator! Adjustment work may be carried out only by qualified and approved specialist staff! Compact flame controllers with variable sensitivity set-...
Page 33: Adaption Of The Compact Flame Controller To The Firing Installation
Transport, Installation and Connection 4.7.2 Adaption of the compact flame controller to the firing installation Danger to life caused by combustion or explosion ! Incorrect installation or adjustment may result in uncon- trolled combustion or explosions! Observe the adjustment instructions of the plant operator! Adjustment work may be carried out only by qualified and approved specialist staff! All alignments and settings must be carried out, when...
Page 34: Connection
Transport, Installation and Connection Connection 4.8.1 Electrical connection Danger to life caused by electrical current! Electrcal current may lead to injuries or to death! The safety instructions and local safety regulations have to be observed during connection! Have electrical connections made only by authorised spe- cialist personnel! For connection data, please refer to the chapter Technical data and to the following terminal diagram.
Page 35: Connection Diagram Oe-Converter
Transport, Installation and Connection 4.8.2 Connection diagram OE-Converter A – Harting device plug (pin contacts) B – Harting cable connection box (socket contacts) Connection of standard compact flame controller Internal External Con- Conduc- Function Burner Power supply tact tor colour control display Flame relay lead...
Page 36 Transport, Installation and Connection Pin/Terminal Description colour BFI Special cable KW6 Flame relay: Root white Flame relay ‘Flame ON’ brown Flame relay ‘Flame OFF’ pink Power supply +24 V DC green Power supply 0V (GND) yellow Current output 0(4)-20 mA gray Sensitivity switchover channel 2 blue...
Page 37: Laying The Special Cable Kw6 For Standard Housing
Transport, Installation and Connection 4.8.3 Laying the special cable KW6 for standard housing Item Plastic insert Inner PUR jacket Crimp contact Contact insert Outer PUR jacket Union nut Thread Single core Outer shielding 15 mm (0.59 inch) No contact chamber may remain bare ! 20 mm (0.78 inch) All contact chambers in the contact insert have to be fitted 55 mm (2.16 inch)
Page 38: Laying The Special Cable Kw6 For Ex-Proof Housings
Transport, Installation and Connection 4.8.4 Laying the special cable KW6 for Ex-proof housings The outer braided shield shall be clamped between clamp collar I & II on the scanner side. Assembly: First the cable and the clamp collars must be fixed with screwed cap I.
Page 39: Storage
Transport, Installation and Connection Storage Do not unpack the packed compact flame controller and accessories. The following conditions apply to storage:  Store in a dry place. Maximum relative humidity 60%. Ensure that the packages are not stored outdoors. In addition, It has to be assured that the floor in the storage area will remain dry throughout the storage pe- riod.
Page 40 Transport, Installation and Connection 4-16...
Page 41: Description
Description Description Type plate The type plate is located on the device housing and con- tains the device type designation and the serial number. Functional description For flame radiation analysis the compact flame controller is using the integral method in the respective spectral range.
Page 42: Hardware Settings
Description Hardware settings The safety concept of the compact flame controller is based on two-channel signal processing. The evaluation channel processes the flame signal under processor control so that the settings can be changed by the BFI software. The safety channel is configured with SMD technology. Settings can only be changed on the printed circuit board.
Page 43: Safety Switch-Off Time Of The Safety Channel
5.3.2 Safety switch-OFF time of the safety channel The safety switch-OFF time of the safety channel (hard- ware) is set by means of a jumper. The settings are as fol- lows: Jumper 1 bridged: 1 second Jumper 2 bridged: 3 seconds Jumper 3 bridged: 5 seconds If a switch-OFF time of 2 seconds is required, the jumper must be inserted in position 2 (3 seconds) and the switch-...
Page 44: Factory Settings
Factory settings The following hard- and software settings are made by BFI Automation:  Current output -> 4..20mA  Current-Relay-Function -> on  Switch-off time -> 1 s  Frequency filter -> 60 Hz  Switch-off threshold -> 750 ...
Page 45: Operation Of The Compact Flame Controller
Operation of the Compact Flame Controller Operation of the Compact Flame Controller Danger of injury and material damage if improperly used! Improper use of the compact flame controller can lead to injury or even death and to material damage! Operation of the compact flame controller only by author- ised and qualified special personnel! Observe the operating instructions! The response of the compact flame controller depends on...
Page 46 Operation of the Compact Flame Controller...
Page 47: Care And Maintenance
Care and Maintenance Care and Maintenance The compact flame controller is maintenance-free. For cleaning, use a moist cloth to wipe the housing from the outside only and clean the lens in regular intervals. Take care not to scratch the lens!
Page 48 Care and Maintenance...
Page 49: Failures
Failures Failures Problem: Display: Cause: Remedy: No Flame No mA output signal Compact flame Check voltage supply ON signal controller not func- Yellow LED OFF Replace compact flame controller after the tioning Green LED OFF Check electrical connection burner was No data communica- started tion...
Page 50 Failures...
Page 51: Order Data
Order data Order data The compact flame controller is available from BFI Auto- mation GmbH under the following order data: Compact flame controller in standard housing zone 2 Part-No. OE-Converter CFC 2000 UV 6013-2033-00 OE-Converter CFC 2000 UV1 6013-2003-00 OE-Converter CFC 2000 IR 6013-2043-00 OE-Converter CFC 2000 IR2 6013-2063-00...
Page 52 Order data 3 compact flame controller in Ex-proof housing GUB03 zone 1 Part-No. OE-Converter CFC 2000 UV LEX3 7013-2034-12 OE-Converter CFC 2000 UV1 LEX3 7013-2004-12 OE-Converter CFC 2000 IR LEX3 7013-2044-12 OE-Converter CFC 2000 IR2 LEX3 7013-2064-12 OE-Converter CFC 2000 IR3 LEX3 7013-2084-12...
Page 53: Accessories
Accessories Accessories Communication and software Part-No. Software CFC Com1 and data 6040-4901-00 interface cable, 1.5 m IRDA/USB2.0 data interface ca- 6040-4810-10 ble, 1.5 m IRDA/USB2.0 data interface ca- 6040-4810-13 ble, 3 m Additional accessories Part-No. Power supply 5002 6010-5002-00 Special cable KW6, yard good 6060-0680-00 Swivel mount 1“...
Page 54 Accessories LWL for UV HT (High tempera- 5055-1xxx-10 tur), -60…300°C, stainless steel hose LWL-EX for UV HT (High tem- 5055-2xxx-20 peratur), -60…300°C, stainless steel hose LWL for X-IR, -60…200°C 5051-1xxx-00 LWL-EX for X-IR, -60…200°C 5051-2xxx-00 Y-LWL for X-IR, -60…200°C 5051-3xxx-00 LWL for X-IR HT (High tempera- 5052-1xxx-10 tur), -60…300°C, stainless steel...
Page 55 Accessories 10-3...

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