Flame Detector

FLUS 06/ FLS 09

Instructions for Servicing
and Comissioning

DIN CERTCO: 5F189−2000

DIN
DVGW: NG−2530BL0056

1−8254−8015a/ 02 Combustion and Energy Systems

 Revision Date Alteration Editor

First edition 10.3.2002 A. Schmidt

Alteration 11.3.2002 Completely revised H. Hellmann

Alteration 08.01.2004 Various changes due to type H. Hellmann

completion and manufacturer's data

© 2003
Technical Documentation SAACKE
January 2004

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 & Co. KG, Bremen, Germany.
They are not to be copied or duplicated without prior written
consent.
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Table of contents

1 Validity ................................................................5

2 Commissioning sequence ................................6

3 Preparation of commissioning.........................7

3.1 FLUS 06 settings................................................7

3.2 'Flame out' status ..............................................7

3.3 'Flame existing' status ......................................8

3.4 Functional test of the flame detector...............8

4 Measuring the signal voltage at the

scanner ...............................................................9

5 Flame detection trouble ..................................10

5.1 Trouble during the ignition process ..............10

5.2 Trouble during operation................................11

6 Check the flame trouble shut-down...............12

7 Adaptation of the basic sensitivity of IR-

flame scanners FLS 09....................................14

7.1 How to proceed:...............................................14

Appendix 1..................................................................15

7.2 Adjusting the sensitivity of the flame

scanner FLS 09, FLS 09 (-L), FLS 09 (-S) ......15

Appendix 2..................................................................16

7.3 Special remarks for GLS burners

(Teminox)..........................................................16

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 Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

1 Validity
This specification describes how to use the flame detection system FLUS 06 / FLS 09 that consists of the flame
monitoring unit FLUS 06 or FLUS 06 UV and the flame scanner FLS 09 or FLS 09 UV.

Attention!

The flame detector is a safety system. Operations/manipulations at this system may therefore be carried out by
the manufacturer or authorized persons only. Such operations must not be carried out by others.

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 Trouble identification

2 Commissioning sequence
Setting measures before commissioning the burner
Check whether all electric connections exist and are properly fastened
• Verify the cable layout incl. of the shielding
Flame monitoring unit FLUS 06
• Potentiometer for intensity to left-side limit stop in IR units, whereas right-side limit stop has to be chosen exclusively for UV units;
otherwise provide for the UV-version of FLUS 06
Check of the flame detector for proper operation (point 3.4)
Inspect the flame detector's function (point 2.1).
Flame scanner:
• If possible, alignment of the flame scanner to the first third of the ignition or main flame to be monitored. The flame must be visible over the
entire operation range

- Check whether enough ignition flame is in the sight range of the scanner; if
Burner start required modify the pilot burner settings
- Inspect the sight opening for possible soiling
- Check the alignment of the scanner; if required modify the insertion depth and
no alignment in the burner head;
in case of UV the signal intensity at the measuring outlet of the flame scanner can
Flame 'On' be maximized by a better alignment
- in case of an IR-unit, step-by-step increase of the sensitivity at the FLUS 06
(potentiometer in direction of right-side limit stop).
yes
Optimization of the set values
− In case of IR: in order to achieve an optimum between detection of the flame and the suppression of a possible reflection, the
potentiometer at the flame monitoring unit may be turned in direction of the right-side limit stop only so far that the intensity display
will not be lowered
− In case of UV: the signal intensity at the measuring outlet of the flame scanner can be maximized by a better alignment to the
flame, i.e. the ignition flame in case of a common monitoring of both the ignition and the main flame
− Measure the signal voltage at the scanner (point 4)

Checking measures for flame detection: no

− Safe detection of the flame at all firing rates of the burner
-

− Check of the viewing situation (background radiation)

− In case of IR: if necessary, reduce the basic sensitivity of the scanner (point)

Checking measures for flame 'OUT' display

− During the switch-off test of the burner, a safe 'Flame OUT' indication must be displayed despite
of a possible reflection from the furnace no

Check the setting values by means of a new burner start.

Note the set values, the measured values and the production number of the FLUS 06 and the FLS 09
as well as the maximum scanner temperature in the Commissioning Documentation.

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 Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

3 Preparation of commissioning
Check whether the optical flame scanner has been positioned correctly.
Before connecting the flame monitoring unit to the auxiliary energy, check whether the connections at the connector
block of the flame monitoring unit have been realized according to the connection diagram.
Inspecting the flame detector's function

3.1 FLUS 06 settings

Attention!
A direct current ammeter 0…20 mA can be connected to terminals 7 and 8 of the FLUS 06 for the measurement
of the evaluated flame intensity. If no ammeter is connected, these terminals must be bridged in order to
activate the intensity indicator at the unit.

The intensity potentiometer for the evaluation of the flame intensity must be adjusted accordingly.

IR-flame scanners FLS 09

Left position: symbol large flame = small amplificaton

Right position: symbol small flame = high amplification

Should there be no reaction at the first burner start, the right side limit stop adjustment can be chosen for a stable flame
detection. Until switch-off tests have been successfully carried out, it must be assured that- in addition to the flame
detector - there are sufficient means to react in case of a flame that does not burn correctly or even extinguishes.

As soon as the burner has been adjusted correctly, the sensitivity must be reduced again to a value that guarantees a
stable and safe operation.

UV-flame scanners FLS 09 UV

Attention!
Use flame scanner FLS 09 UV with type FLUS 06 UV only;
with type FLUS 06 intensity setting to right position: small flame

3.2 'Flame out' status

After having switched on the auxiliary energy, the flame detector is ready for operation after abt. 10 seconds.

The following reading must appear:

- display 'Flame out' LED (red) lights up

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 Trouble identification

3.3 'Flame existing' status

For a check of the monitoring parameters during the firing plant operation, the flame scanner must be installed properly
at the correct place.

If the flame burns properly, the display must change as follows:

- display 'Flame out': LED (red) goes out
- display 'Flame existing': LED (green) lights up

During that time, the LED changes its radiation intensity antivalently in the cycle rhythm of the monitoring electronics.

3.4 Functional test of the flame detector

When there is no burner flame, proper operation of the flame detector can be checked as follows:

1. The flame detector is electrically completely installed and supplied with voltage.

2. Simulation of a flame radiation in front of the sight window of the flame scanner. This can be done with a pocket-
lighter or an other modulated light source (not mains frequency) with sufficient intensity, e.g. when moving
spread fingers between the light source and the flame scanner, the light of a lamp can be sufficiently modulated.

3. The analysis unit must switch on its outlet contacts. This is proved by the red LED going out and the lighting-up
of the green LED. The two-stage intensity indicator lights up (bridge of terminal 7-8 or external display
connected). In case of problems, the outlet contact should be checked at first. In case of a longer modulation (>
5 seconds), you can note the change between the two processing channels when the green 'Flame existing'
LED becomes brighter or darker in a certain rhythm.

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 Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

4 Measuring the signal voltage at the scanner

This point is not possible at present with flame scanners of type series FLS 09-S (heavy fuel oil/ships).

The flame radiation can be measured between the blue wire (mass) and the pink wire (measuring line) of the scanner
connection line. For this purpose, a standard volt-free measuring instrument e.g. a manual multimeter that corresponds
with the directive EN 61010 with a measuring resistance > 5 MΩ must be used.

The measured voltages can be in the range of:

a few mV AC up to abt. 0.3 V AC in an UV-unit and up to abt. 3 V AC in an IR-unit.

The table below specifies the values with which the scanner evaluates signals as flame signal.
For an optimum suppression of background radiation, the values measured after burner shut-down should be clearly
below the specified values.
For a sure recognition of the flame, the double value should be sufficient with a stable signal. In case of an instable
flame recognition, higher values can be required.
In a FLS 09 (IR) it is possible to open the casing and to modify the sensitivity by means of DIP-switches (see Chapter
7). The minimum value for the FLAME ON signal is modified accordingly.
For technical reasons, this is not possible with scanners of type FLS 09 UV. In normal cases, the casing must not be
opened.

Infrared flame scanner FLS 09 (IR) Ultraviolet flame scanner FLS 09 UV

Switch Connection Connection

Sx/1 Sx/2 Position pink/blue pink/blue
OFF OFF 1 45 mV~
FLS 09 (-S) ON OFF 2 30 mV~ Factory setting
25 mV~
OFF ON 3 20 mV~
FLS 09, FLS 09 (-L) ON ON 4 15 mV~ Factory setting

Background noise without signal typical 1 (<2) mV~ 6 (<8) mV~

See chapter 7

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 Trouble identification

5 Flame detection trouble

Attention!
If a FLS 09 UV is used, the sensitivity at the FLUS 06 must be set to right-side limit stop or an UV-type FLUS 06
must be used.

Check the proper operation of the unit as described in 3.4.

Excessive temperature rise

Care must be taken to ensure that the maximum admissible ambient temperature of 60 °C is not exceeded in the area
where the unit is installed. If higher temperatures must be expected, appropriate cooling measures must be provided. It
must be ensured that the scanner casing is not heated up over this value e.g. by radiation heat from the boiler.
Especially, an accumulation of heat after the burner fan has been switched off must be avoided. Overheating primarily
leads to a loss of sensitivity or a damage of the sensor element and can even cause the total failure of the unit.

If in case of an excessive temperature rise, there are difficulties with the flame detection when re-starting
the burner, in no case the sensitivity of the flame detector should be increased at once. At first,
wait for the cooling down of the flame scanner.

5.1 Trouble during the ignition process

Troubles during the ignition process can have 2 causes.

1. The ignition flame is detected insufficiently only.

• Check the sight opening of the flame scanner for possible soiling
• Check whether the ignition flame is burning steadily
• Check if there is sufficient ignition flame to be seen in the sight area of the scanner; if required modify
the pilot burner settings
• Measure the flame radiation that is absorbed by the scanner (pint 4); optimize the alignment inclusive of
the insertion depth in the burner head where required
• in case of an IR-type, increase the sensitivity at the FLUS 06 when necessary

2. Interfering irradiation prevents a stable detection

• The red LED goes out and the green LED lights up. The green LED, however, does not change its
brightness in intervals of abt. 3 seconds. That means that there is a common-mode fault (the signal exists
in both evaluation channels simultaneously). This is mainly caused by the interfering radiation from the
ignition transformer and/or its connected lines.

- Check the shielding and the PE for correct connection

- Ground the ignition transformer correctly
- Check the layout of the cables and de-intwist/separate them when necessary

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 Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

5.2 Trouble during operation

Troubles during operation can have 2 causes.

1. The main flame is not detected sufficiently.

• Check the sight opening of the flame scanner for possible soiling
• Check whether the main flame is burning steadily, i.e. it can be seen by the flame scanner over the
complete operation range of the burner
• Measure the flame radiation that is absorbed by the scanner (point 4); optimize the alignment inclusive
of the insertion depth in the burner head where required
• in case of an IR-type, increase the sensitivity at the FLUS 06 when necessary
2. Interfering irradiation prevents a stable detection

• The red LED goes out and the green LED lights up. The green LED, however, does not change its
brightness in intervals of abt. 3 seconds. That means that there is a common-mode fault (the signal exists
in both evaluation channels simultaneously).

- Check the shielding and the PE for correct connection

- Check the layout of the cables and de-intwist/separate them when necessary

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 Trouble identification

6 Check the flame trouble shut-down

For special attention in case of infrared-type flame scanners FLS 09 (IR) !

As for all flame detection systems on an infrared basis, the specialty of the 'background radiation' (e.g. a
glowing brickwork) in the furnace must be considered. Shutdown tests should therefore be carried out
when the boiler is warm.

The breakaway or extinguishment of the flame must be reproduced. For this purpose, the fuel supply to the burner that
is monitored by the flame scanner must be shut-off.
It must be checked whether the flame detector gives the signal to close the safety shut-off system within a time of tV out ≤
1 s after the flame extinguishment:

• The green LED goes out.

• The red LED lights up.

With the infrared-type flame scanners FLS 09 (IR) care must always be taken that the sensitivity of the flame detector is
only set as high as necessary to monitor the flame safely and reliably over the complete range of operation of the
burner.

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Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

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 Trouble identification

7 Adaptation of the basic sensitivity of IR-flame scanners FLS 09

For special attention in case of infrared-type flame scanners FLS 09 (IR) !

As for all flame detection systems on an infrared basis, the specialty of the 'background radiation' (e.g. a
glowing brickwork) in the furnace must be considered. Shutdown tests should therefore be carried out
when the boiler is warm.

7.1 How to proceed:

In case of problems with the flame detection, with shutdown tests or extraneous light troubles, in addition to a modified
alignment of the flame scanner, it is also possible to modify the basic sensitivity of the scanner.

The flame scanner must be opened

by qualified persons only!

Please proceed as follows:

1. Deenergize the flame detector FLUS 06.

2. Open the flame scanner cautiously by loosening the 3 screws.

3. Two switches are located on the back of the circuit board. These switches must in all cases be adjusted
symmetrically as described in point 7.2. The setting should always be modified step by step only.

4. Mount the flame scanner again thoroughly. Place the sensor located on the back of the circuit board in
direction of the sight opening of the scanner. Besides, a wrong alignment of the sensor to the sight opening
is prevented by the asymmetrical arrangement of the three screws.

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 Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

Appendix 1

7.2 Adjusting the sensitivity of the flame scanner FLS 09, FLS 09 (-L), FLS 09
(-S)

Normally, the settings made in our factory

should not be modified!

Adjustment is made by means of the switches S1 and S2.

For this purpose, the scanner casing must be opened.
The FLUS 06 must at first be deenergized.

Sensitivity

OFF ON OFF ON
1
35% min
S1
S2

<1> 4
1
S1
S2

S1
<2> FLS09 (-S) factory setting 4 50%
1
S1
S2

4 S2
<3> 80%
1
S1
S2

<4> FLS09 or FLS09 (-L) factory setting

4
100% max.

Attention!

FLS 09, FLS 09 (-L) long casing

The settings <4> and <3> are applicable.
The settings <2> and <1> are ingenious for the flame detection under very
favorable conditions only.
L. side

FLS 09 (-S) heavy fuel oil-/marine design

For reasons of the possible coke formation, settings <1> and <2> are applicable.
The internal equalization in our factory is different from that of the FLS 09.

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 Trouble identification

Appendix 2
7.3 Special remarks for GLS burners (Teminox)
for mounting the IR-flame scanner FLS 09-L (long version)

C
D
A

E
F

A- Mounting depth
B- Connection cable
C- Clip
D- Scanner mount
E- Burner casing
F- Gas ring
G- Light entry opening

Optimum mounting conditions were tested for the GLS burners of type series 75 - 125. For an optimum flame
detection in combination with an optimum extraneous light suppression already by constructive means, a
mounting depth (towering-out of the FLS 09-L) of 4 - 6 cm into the mounting opening at the 'burner neck'
at abt. 10 -11 o'clock.
Problems with the ignition load recognition can occur due to a constriction of the ignition gas supply
piping (e.g. from 15 mm to 12 mm). This would result in the fact that the ignition flame burns too faintly
and the ignition load would be set accordingly. Compared with the basic load and the ignition flame,
this ignition load will then result in a decisive loss of intensity for the flame detection.

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Instructions for servicing and commissioning
FLUS 06 / FLS 09 flame monitoring

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 Compact Burner SKV/SKVG
A 68...134
for heavy fuel oil, light oil and gas

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