Flame Detection System FLUS06UV / FLS09UV

Installation Instructions

2008-02-22

1-8254-8046-02 Combustion and Energy Systems

© 2007
Technical Documentation SAACKE

The copyright of this printed technical document as well

as of all drawings personally entrusted to the recipient
belongs at all times to SAACKE GmbH, Bremen,
Germany.
They are not to be copied or duplicated without prior
written consent.
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Combustion and Energy Systems

Contents FLUS06UV / FLS09UV

0 Contents

0 Contents ..................................................................................................................................4
1 General Information................................................................................................................5
2 Safety .......................................................................................................................................5
2.1 Documentation is a part of the product! .................................................................................................. 5
2.2 Symbols................................................................................................................................................... 6
2.3 Safety in General..................................................................................................................................... 6
2.4 Intended Use ........................................................................................................................................... 6
2.5 Limitation of Liability ................................................................................................................................ 7
2.6 Qualified Staff .......................................................................................................................................... 7
2.7 Electrical Hazards ................................................................................................................................... 7

3 Transport, Storage and Packing ...........................................................................................8

3.1 Checking the Delivery ............................................................................................................................. 8
3.2 Reporting Transport Damage.................................................................................................................. 8
3.3 Instructions for Storage ........................................................................................................................... 8
3.4 Disposal of the Packaging....................................................................................................................... 8
3.5 Disposal of the Product ........................................................................................................................... 8

4 Scope of Delivery....................................................................................................................9
5 Flame Scanner ......................................................................................................................10
5.1 Assembling and Installing the New Flame Scanner.............................................................................. 10
5.1.1 SKV 15-400 (Duoblock) / DGL .......................................................................................................... 11
5.1.2 SKV-A................................................................................................................................................ 11
5.1.3 SKVJ 10-25 ....................................................................................................................................... 12
5.1.4 SKVJ 20-55 / JGL 20-70 ................................................................................................................... 14
5.1.5 Teminox GLS Monoblock.................................................................................................................. 16
5.1.6 Teminox GLS Duoblock .................................................................................................................... 17

6 Flame Monitor .......................................................................................................................18

6.1 FLUS 06 UV .......................................................................................................................................... 18
6.2 FLUS06 (Infrared Variant) ..................................................................................................................... 18
6.3 Other Flame Monitors............................................................................................................................ 19

7 Connecting the Flame Scanner with the Flame Monitor...................................................19

8 After Conversion...................................................................................................................20

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FLUS06UV / FLS09UV General Information

1 General Information
This document describes how to retrofit SAACKE burners of the older design to the
flame detection system FLUS 06 UV flame detection system (flame monitor) / FLS
09 UV (flame scanner).

A detailed description follows of how to replace flame detection components that

are no longer available:

Flame monitor: FLUS 03, BAC with FLOS 03, FLOS 03 (standalone)
Flame scanner: FLS 04 / 07 / 08, FLS 09 IR

Note
If the flame detection component you want to replace is not listed here, please
contact SAACKE.

This document serves as a supplement to the Operating Instructions for flame

detection system FLUS 06 UV / FLS 09 UV (1-8254-8011x 1 ) and the
corresponding commissioning instructions (1-8254-8015x1).

2 Safety

2.1 Documentation is a part of the product!

This document is an integral part of the product. It must be retained for the entire
service life of the product. Make this document available to the staff responsible for
the work described in it. Add any updates you receive later from SAACKE to the
document.

Help us improve this documentation!

We appreciate any feedback that improves the quality of our documentation. You
will find our address on the back of this document.

1
The x represents the current revised version of the document.

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Safety FLUS06UV / FLS09UV

2.2 Symbols
Especially important information in this document is highlighted by the
corresponding symbols:

Warning!
The industrial safety symbol identifies safety instructions whose purpose is to
prevent physical injury or death. Follow these safety instructions carefully and be
especially cautious during the work/procedures they refer to.

Warning! Risk of death from electric shock!

The electricity symbol identifies safety instructions whose purpose is to prevent
physical injury or death from electric shock. Follow these safety instructions
carefully and be especially cautious during the work/procedures they refer to.

Caution!
The caution symbol identifies all safety warnings whose purpose is to prevent
damage or destruction of the product and/or other plant components.

Note
This points to information or notes that are especially useful.

2.3 Safety in General

The "Safety" chapter gives you an overview of the safety aspects you must pay
attention to in order to work with the product safely. Any individual who assembles,
installs, mounts, commissions, operates and/or does maintenance on the product
described must read and follow the instructions in this chapter carefully to avoid
physical injury and material damage. Your safety is at stake.

In addition to these general safety instructions you will find specific safety
instructions in the product documentation related to individual actions or
procedures.

Only if you follow all of the safety instructions will you be able to provide the best
possible protection for yourself, your colleagues and the environment by ensuring
that the product functions safely and reliably.

In addition to this, it is imperative that you comply with the accident prevention and
safety regulations of the country you are working in.

2.4 Intended Use

The product supplied must only be used in a coherent plant configuration. A plant
configuration is coherent if the product supplied is the equivalent of the plant
component it replaces or it is used according to the manufacturer's specifications.
You can verify this by checking the technical data given in this document.

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FLUS06UV / FLS09UV Safety

2.5 Limitation of Liability

SAACKE shall not be held liable for damage resulting from any use of the product
other than its intended one, from ignoring the documentation or from operation by
inadequately qualified staff. The risk in this case lies with the operator / plant
authorities alone.

2.6 Qualified Staff

Warning!
Risk of physical injury and damage from incorrect operation!
The plant authorities must ensure that only qualified and authorized staff works
with the product.

Qualified staff in the context of this documentation are individuals who have the
training that enables them to handle the product described and are authorized by
the plant authorities to assemble, install, mount, commission, operate and/or do
maintenance on the product.

2.7 Electrical Hazards

Warning! Risk of death from electric shock!

Damaged lagging or live components that are not covered correctly present a risk
of death from electric shock!

Warning! Risk of death from electric shock!

Carelessness can lead to an electric shock.
This is why when you work with electrical equipment, you must always first:
1. Disconnect each piece of equipment from the mains.
2. Secure it to prevent it from being switched back on.
3. Check that the equipment is de-energized.
4. Ground the equipment and short-circuit it.
5. Cover other components/equipment nearby that are energized.
6 Secure the danger zone, for example by blocking it off and/or putting up a
conspicuous danger sign that no one can overlook.
Transport

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Transport, Storage and Packing FLUS06UV / FLS09UV

3 Transport, Storage and Packing

3.1 Checking the Delivery

SAACKE products are packed and checked before they leave the factory.

When the product is delivered, first check whether the packaging is intact. This
would be the first indication that it has been transported correctly.

Check the product for transport damage.

3.2 Reporting Transport Damage

If damage has occurred during transport, follow these procedures:

Record the transport damage on the freight documents and take a

photograph and/or make a sketch of it.
Have the person responsible for the delivery (for example the truck driver)
confirm that the damage was noticed by signing the freight documents.
Report the transport damage right away to SAACKE or whichever company
supplied the product.

3.3 Instructions for Storage

Only store the product in its undamaged original packaging.

Keep all components, especially electrical, pneumatic and hydraulic components,

dry, free of dust and at their correct temperature during storage. The relative
humidity must be below 80%.

3.4 Disposal of the Packaging

Dispose of all packaging correctly and ecologically.

When you do it, comply with the waste disposal regulations of the country in which
you are working.

3.5 Disposal of the Product

At the end of its service life the product must be disposed of correctly and
ecologically. When you do it, comply with the waste disposal regulations of the
country in which you are working.

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FLUS06UV / FLS09UV Scope of Delivery

4 Scope of Delivery
Flame scanner FLS 09 UV including adapter
Connection socket for extension cable

Casing cover (only with flame scanners for burner model SKVJ 10-25)
This document

The following additional items, depending on which flame detection system is used

Flame monitor FLUS 06 UV

Diode
Relay
Special extension cable (for marine plants only)
Wiring diagram for flame monitor
– 2-6575-149117-10/... for marine plants
– 2-6575-149117-20/... for land installations

Caution!
If the devices currently being used or their connection do not match the devices
and connection options found in the accompanying wiring diagram, the new flame
detection system must not be installed without consulting with SAACKE!
If this is the case, please send the circuit diagrams with the configuration to
SAACKE in Bremen.

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Flame Scanner FLUS06UV / FLS09UV

5 Flame Scanner
First check which flame scanner is currently installed in your burner. To do this,
proceed as follows:

Write down the current position of the installed flame scanner so you will be able to
reproduce it later.
This is necessary to be able to align the new flame scanner optimally without great
effort.

Pull out the flame scanner.

A model designation is printed on the flame scanner.

If the model designation on the flame scanner is “FLS 09 UV,” you can
replace it with the new flame scanner without any additional conversion
measures.
If the model designation on the flame scanner is not “FLS 09 UV,” you must
replace the flame scanner. Make sure that you follow all instructions in
section 5.1. This section includes specific information arranged by burner
model describing which additional steps are required to install the new
flame scanner in your burner.

Note
In both cases make sure you observe chapter 6 and 8.

5.1 Assembling and Installing the New Flame Scanner

The following sections contain an overview arranged by burner model describing
which steps are required to replace the flame scanner.

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FLUS06UV / FLS09UV Flame Scanner

5.1.1 SKV 15-400 (Duoblock) / DGL

No conversion measures are required for the burner.

A special adapter for the flame scanner is included in the scope of delivery of the
flame detection system.

Assemble the flame scanner and the adapter as shown in the drawing below.

H001 H002
Fig. 1: Assembly of flame scanner and adapter for SKV 15-400 Duoblock
(left: variant for one flame scanner; right: variant for two flame scanners)

1 Adapter 6 Fastening screw

2 Flame scanner 7 Clamping screw
4 Mount 8 Nut for clamping screw
5 Position screw

Replace the old flame scanner with the combination of flame scanner and adapter.

5.1.2 SKV-A
No conversion measures are required on the burner.

Replace the old flame scanner with the new flame scanner.

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Flame Scanner FLUS06UV / FLS09UV

5.1.3 SKVJ 10-25

Included in the scope of the flame detection system is a new cover for the burner
casing and, depending on the order, one or two special adapters for the flame
scanner.

Assemble the flame scanner and the adapter as shown in the drawing below.

H003
Fig. 2: Assembly of flame scanner and adapter for SKVJ 10-25

1 Flame scanner 7 Nut for clamping screw

3 Adapter 8 Clamping screw
4 Mount 9 Allen screw for adapter
5 Position screw 10 Gasket
6 Fastening screw

Mount the combination of flame scanner and adapter on the casing cover included
in the scope of the delivery.

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FLUS06UV / FLS09UV Flame Scanner

H004
Fig. 3: Conversion measures for SKVJ 10-25 (variant for two flame scanners)

1 Flame scanner with adapter

2 Casing cover

Replace the old casing cover with the new casing cover.

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Flame Scanner FLUS06UV / FLS09UV

5.1.4 SKVJ 20-55 / JGL 20-70

It may be necessary 2 to perform the following conversion measures on the burner:

Extend the breakthrough for the flame scanner an additional 4 mm. As you do this,
tilt the edge to an angle of 75° (see following drawing, C).

H005
Fig. 4: Conversion measures for SKVJ 20-55 / JGL 20-70

A New diameter
B Old diameter

Suitable tools to assist with these tasks:

Files (round and semi-round)

Round grinding tool
Drill Ø 28
Milling inserts for drilling machine

The threaded bore holes (M4) will be reused.

A special adapter for the flame scanner is included in the scope of delivery of the
flame detection system.

Assemble the flame scanner and the adapter as shown in the illustration below.

2
Depending on the burner’s year of manufacture, it is possible the conversion measures described here
have already been performed in the factory. You should therefore first check whether the conversion
measures described here need to be done!

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FLUS06UV / FLS09UV Flame Scanner

H003
Fig. 5: Assembly of flame scanner and adapter for SKVJ 20-55 / JGL 20-70

1 Flame scanner 7 Nut for clamping screw

3 Adapter 8 Clamping screw
4 Mount 9 Allen screw for adapter
5 Position screw 10 Gasket
6 Fastening screw

Replace the old flame scanner with the combination of flame scanner and adapter.

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Flame Scanner FLUS06UV / FLS09UV

5.1.5 Teminox GLS Monoblock

No conversion measures are required for the burner.

A special adapter for the flame scanner is included in the scope of delivery of the
flame detection system.

Assemble the flame scanner and the adapter as shown in the drawing below.

H006
Fig. 6: Assembly of flame scanner and adapter for Teminox GLS Monoblock

1 Flame scanner 6 Allen screw for adapter

3 Gasket 8+9 Clamping screw and nut
4 Mount 10 Adapter
5 Position screw

Replace the old flame scanner with the combination of flame scanner and adapter.

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FLUS06UV / FLS09UV Flame Scanner

5.1.6 Teminox GLS Duoblock

No conversion measures are required for the burner.

A special adapter for the flame scanner is included in the scope of delivery of the
flame detection system.

Assemble the flame scanner and the adapter as shown in the drawing below.

H007
Fig. 7: Assembly of flame scanner and adapter for Teminox GLS Duoblock

1 Adapter 10 Flange body

2 Flame scanner 11 Fastening screw
4 Mount 12 Washer
5 Position screw 14 Gasket
6 Allen screw for adapter 15 Allen screw
7+8 Clamping screw and nut

Replace the old flame scanner with the combination of flame scanner and adapter.

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Flame Monitor FLUS06UV / FLS09UV

6 Flame Monitor
First check which flame scanner is currently used in your burner.

A model designation is printed on your flame monitor.

6.1 FLUS 06 UV
If a model FLUS06UV flame monitor is being used, no additional steps are required
in terms of the flame monitor. In this case, continue with chapter 7.

6.2 FLUS06 (Infrared Variant)

If you have been using a model FLUS 06 flame monitor (infrared variant), you do
not need to replace the flame monitor. However, you must adjust the sensitivity of
the flame monitor to the new flame scanner.

H008
Fig. 8: Flame monitor FLUS 06 (infrared variant)

A LED “Flame off” (red)

B LED “Flame present / ready for operation” (green)
C Potentiometer for intensity setting
large flame = minimum intensity, small flame = maximum intensity
D Intensity indicator

Turn the potentiometer clockwise as far as it will go (maximum intensity).

You can find more detailed information on flame monitor FLUS 06 in the Technical
Manual for the flame detection system (1-8254-8011x 3 ) and in the corresponding
commissioning instructions (1-8254-8011x3).

Next proceed with chapter 7.

3
The x represents the current revised version of the document.

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FLUS06UV / FLS09UV Connecting the Flame Scanner with the Flame Monitor

6.3 Other Flame Monitors

All other flame monitors must be replaced.

Remove the old flame monitor from the control cabinet.

Install the flame monitor in the control cabinet. Observe the wiring diagram
included in the scope of delivery as you do so.

Next proceed with chapter 7.

7 Connecting the Flame Scanner with the Flame Monitor

Connect the new flame scanner with the flame monitor. Use the connection line on
the flame scanner to do this.

Note
If this connection line is not long enough to bridge the distance between the flame
monitor and flame scanner, use a suitable extension cable (five-core, shielded
cable, maximum length 100 m).
A connection socket is included with delivery for connecting the flame scanner to
the extension cable.
A special extension cable (25 m) is included in the scope of delivery for marine
plants.

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After Conversion FLUS06UV / FLS09UV

8 After Conversion
Finally, the flame scanner that has just been installed must be optimally aligned
before starting the burner again.

Use the previously noted position of the old flame scanner to do this. Reproduce
this position for the flame scanner you have just installed.

On the part of the flame scanner that protrudes from the burner, there is a mark to
make alignment easier for you. The ratio between this mark and the flame scanner
lens is shown in the following drawing:

H009
Fig. 9: Ratio between mark and flame scanner lens

1 Lens
2 Mark (opposite the lens)

Place the flame scanner and flame monitor in operation according to the
commissioning instructions (1-8254-8015x 4 ).

4
The x represents the current revised version of the document.

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FLUS06UV / FLS09UV After Conversion

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a
SAACKE GmbH
Südweststrasse 13 · 28237 Bremen
GERMANY
Phone: +49 - 421- 64 95 0
Fax: +49 - 421- 64 95 224
E-Mail: info@saacke.de
www.saacke.com

b
SAACKE Service GmbH
Südweststrasse 13 · 28237 Bremen
GERMANY
Phone: +49 - 421- 64 95 0
Fax: +49 - 421- 64 95 244
E-Mail: service@saacke.de
www.saacke.com

SAACKE-Hotline: +49-421-64 95 201