D-GF 150

pending
pending

■ Controlling and Monitoring of Gas, Oil and Combined Burners of any

Capacity
■ Integrated Gas Valve Proving System
■ Separated Outputs for Gas- and Oil Fuel Valves
■ Quick Fuel Change „on the fly“ without Burner Shutdown
■ Data Interface
■ Adjustable Pre-purge Timer
■ Integrated Flame Monitor with adjustable Treshold
■ Approved according to EC Gas Appliance- and Pressure Equipment
Directive

Burner Control for

Gas and Oil Burners D-GF 150
Flame Sensor D-LE 103
 D-GF 150
Burner Control for
Gas and Oil Burners
■ Application
The DURAG D-GF 150 Burner Control
System controls and monitors gas and oil
burners of any capacity. The control func-
tions of this system cover the tasks of pre-
purge, ignition and solenoid valve control,
through to the enabling of the output reg-
ulation. Thanks to its flexibility, the pro-
gram sequence for pre-purge, ignition, fuel
supply and air supply may be adjusted to
the requirements of the plant, with simulta-
neous consideration given to applicable
guidelines. These units may be used in ap-
plications ranging from large power sta-
tions to small remote heating plants, or in
chemical processes or thermal flue gas
combustion systems.
By employing microprocessors with
corresponding software and hardware, this
burner management system offers im-
proved evaluation capability and a height-
ened degree of safety and availability. In
combination with flame sensors from ei-
ther the D-LE 103 or D-LE 603 series, the
burner management system is fully suited
to monitor flames of different fuels and
combustion techniques, in single burner or
multi-burner systems. Different UV and IR
flame sensors are available to optimally
adapt the flame monitoring system to local
conditions. The response threshold (sensi-
tivity) of the flame monitoring system in the
burner control may be set to one of ten dif-
ferent levels using a rocker switch on the
front panel of the burner control.
2
■ General Program
Sequence
The types of fuels and burners found in
the field require different functional se-
quences and safety times, which are elec-
tronically controlled and monitored by the
burner control system. By observing the ap-
plicable guidelines, one may choose from
the following program sequences, depend-
ing on the current operating conditions of
the combustion system:
■ Fuel gas in master burner mode
■ Fuel gas in slave burner mode
■ Fuel oil in master burner mode
■ Fuel oil in slave burner mode
Beside these standard functions the
D-GF 150 Burner Control employs for the
first time also the following new functions:
■ Integrated gas valve proving system
■ Separated Outputs for controlling gas-
and oil fuel valves
■ Quick fuel change „on the fly“ without
burner shut-down
■ Data Interface
■ Program halt for burner optimisation
■ Program Sequence in
Master Burner Mode
The „master burner“ program se-
quence is generally the normal mode of op-
eration. Once the program starts up, the
blower motor is activated. Air pressure
must build up within the next 30 seconds.
This is monitored by the air pressure moni-
tor. If air pressure is present, the air damper
is moved to the "open" position. Afterward,
the selected pre-purge of 30 s to a maxi-
mum of 20 min starts. Once the set pre-
purge period expires, the air damper is
moved to the „ignition position“. The three-
second ignition delay period then starts. Af-
ter activation of the ignition transformer,
the pre-ignition period begins. Ignition-
and pilot fuel valves are opened after 2 sec-
onds, and the ignition safety time starts. If a
flame was generated during the ignition
safety time, the main fuel valve of the se-
lected fuel is opened after a delay period of
5 seconds. The ignition fuel valve is closed
after an overlap period. 5 seconds later, the
operational state is reached and the burner
control system activates regulating output.
If, during operation, a controlled shutdown
is triggered via the monitor chain, the sys-
tem checks whether the flame in the burn-
er is extinguished once the fuel supply is
cut off. The period of time for the flame OFF
signal is 10 seconds. A blower post-run of 5
seconds follows the flame OFF signal.
Application of the D-GF 150 Burner
Control
 D-GF 150
Burner Control for
Gas and Oil Burners

■ Slave Burner Program Step Description Remarks Duration LEDs

Program Sequence Standby

position 12345678
The „slave burner“ program sequence Ps10
Air pressure off Air pressure must go to 0 unlimited







distinguishes itself in two respects from
that of "master burner". After start-up, the Ps11
 Stand by unlimited 







program begins immediately with the igni- Ps12  Air pressure build-up Air pressure must signal 1 max 30 s 






tion delay period, the pre-purge period,
and the moving of the air dampers is omit- Pre-purge Master Burner only !
ted. The subsequent steps in the program
are sequenced as in the master burner Ps20
Open air damper Go to pre-purge position max 10 min






mode. In the "slave burner" program se- Ps21
Pre-purge Stray light test 30 s .. 20 min






quence, the regulation output is activated
Ignition of
once the operational state has been Ignition Burner
reached, but it is not signalized by the stan-
Ps30
Close air damper Go to ignition position max 10 min 





dard LED.
Ps31
Ignition delay Stray light test 3s


Ps32
Pre-ignition Ignition Transf. ZTR starts 2s


■ Gas Valve Proving Ps33
OPEN IGNITION VALVE Overlap ZTR + ZMV 1. SZ –1 s


System Ps34
Ignition safety time,

ignition burner ZTR off 1s






The D-GF150 Burner Control is Ps35
Main-valve delay Ignition flame stabilised 5s





equipped with a gas-valve proving system.
Ignition of Main
This function is activated by means of inter- Burner
nal hook switches. When operating with
Ps40
Program halt ZMV ZMV active alone unlimited 




gas, the main fuel valves of the gas supply
can be tested for tightness. This function re- Ps41
OPEN MAIN VALVE Overlap ZMV + HMV 2. SZ –1 s




quires the installation of two gas valves in Ignition safety time main ZMV off, main flame
Ps42
1s+4s





series and of one gas pressure sensor be- burner and regulator delay stabilised
tween both gas valves. Ps43  OPERATING POSITION Regulator release unlimited


1

A section between the supply-side and
the burner-side gas valve constitutes a Switch-off
pressure test space. This test space is first
Ps50
Switch-off Remaining fuel burns 5 s (15 s*)






emptied via activation of the burner-side
gas fuel valve. By an internal hook switch Ps51  Flame off Flame must extinguish max 30 s 





the testing time can be adjusted to either *D-GF150-10 only
5s or 30 s. In this period the gas pressure be- Gas Valve Gas only! LED5 flashes
tween the gas valves must not change. The Leakage Test
gas, required for this test, is released into Ps60
Emptying of the gas line Open GVB (burner side) 5s





the furnace after the test.
Ps61
Test for pressure P0 Test input GDR= 0 5 s or 30 s




Ps62
Filling of the gas line Open GVG (gas side) 5s 



■ Fuel Change Over Ps63
Test for pressure P1 Test input GDR= 1 5 s or 30 s 



Fuel Change LED1 flashes

In the operating position, a quick
change of the fuel is possible. For that pur- Ps70
Close air damper Go to ignition position max 10min 



pose, the monitor chain inputs for gas Ps71
Drive ignition lance in 5s 




(WKG) and oil (WKO) must be changed dur-
Ps72
Pre-ignition ZTR starts 5s 



ing operation (Ps43). For 1 second a simul-
taneous activation or deactivation of the Ps73
Overlap ZMV + ZTR Open ZMV 5s 


fuel selection inputs is permitted. After the Ps74  Accept fuel mode Ignition burner active, 5s 




change of the monitor inputs, the ignition main fuel valve closed.
position is approached, the ignition burner
LED ist off  LED is off
is activated, the old fuel is stopped and the D-GF 150 Program Sequence  LED flashes  LED is on or off
new fuel is started by opening the corre-
sponding fuel valves. The change over be-
tween two valves takes place in 11s.

D-GF 150 Dimensions

3
D-GF 150
Burner Control for
Gas and Oil Burners

Line Diagram: Gas Operation with

Pre-purge (Master Burner)

D-GF 150

Safety Time Start Ignitor: 3 s or 5 s

Safety Time Start Main 3 s or 5 s

Burner:

Safety Time Main Burner: 1 s

Analogue Output: 0 or 4-20 mA

DVGW
Approvals : DIN-CERTCO
(UL, C-UL, FM)*

D-GF 150-10

Safety Time Start Ignitor: 4 s or 10 s

Safety Time Start Main 10 s or 15 s

Burner:

Safety Time Main Burner: 1 s or 3 s

Analogue Output: 4-20 mA

Approvals : (UL, C-UL, FM)*

*pending

D-GF 150 Order Information

D-GF 150 Connection Diagram

4
 D-GF 150
Burner Control for
Gas and Oil Burners

■ Survey of D-LE 103 Flame Sensors

Suitable for fuels All flame sensors have been tested according to EN 230 (oil)
Flame Photo Spectral range and EN 298 (gas). They are approved for continuous operation
Sensor element (nm) without capacity limit and 72h operation according to TRD
Gas Oil Coal Wood 604.
Low voltage Monitoring of gas and oil flames in single burner installations
D-LE 103 UL-xx UV cell 190 - 260 ++ + (increased viewing angle of 12°).

GaP with
D-LE 103 UAF-xx 280 - 410 O ++ Monitoring of gas and oil flames in single burner installations.
UV-filter
GaP without Monitoring of oil flames in single burner installations as well as oil
D-LE 103 UA-xx 190 - 520 + ++ O + burners where additional fuels are burned.
UV-filter
D-LE 103 IS-xx Si 300 - 1100 ! ++ ++ + Monitoring of oil and wood dust flames.

Monitoring of oil and wood dust flames as well as gas flames from
D-LE 103 IG-xx Ge 780 - 1800 O ++ ++ ++ pilot or main burners in single burner installations.

xx = P: Axial plastic plug cable connection Explanation of symbols:

IP 67 / NEMA 4X ++ The flame sensor is ideally suitable for this fuel considering its flame detection and flame selectivity.
xx = MP: Axial metal plug cable connection + The flame sensor is well suited to this fuel, although under certain conditions it may show an increased flame simulation signal.
This is especially possible with combination operation (e.g. oil and gas).
IP 54 / NEMA 3S
O The flame sensor is conditionally suited to this fuel. The monitoring characteristics depend mainly upon the combustion
xx = CG: Cable connection with M20x1.5 cable gland technique.
IP 65 / NEMA 4X ! Due to local regulations the flame sensor might not be approved for monitoring of gas flames.
This information is based on years of experience in a great proportion of combustion systems. Variations due to differing flame
behaviour, caused by special combustion techniques cannot be taken into account or excluded.

■ D-LE 103 UL / UA / UAF ■ D-LE 103 IS / IG
Ultraviolet Flame Infrared Flame Sensors
Sensors These IR flame sensors have a spectral
These flame sensors have a spectral
range of either 190 to 260 nm, 190 to 520 nm
or 280 to 410 nm, depending on the model.
All blue-burning flames, e.g. gas flames
whose portion of visible light is low, may be
monitored by these flame sensors.
sensitivity of either 300 to 1100 nm or 780 to
1800 nm, depending on the model. Only
those signals are processed which corre-
spond to flame flickering. Thus flame moni-
toring is not influenced by ambient light, as
far as constant light is concerned. Flames
whose UV radiation is absorbed by dust, wa-
ter vapour or other materials may be moni-
tored in the infrared range. A waste incinera-
tor would be an example of such an applica-
tion. IR flame sensors with a sensitivity of up
to 1800 nm have proven themselves in mon-
itoring gas and oil combustion systems em-
ploying NOx reduction techniques such as
flue gas recirculation.

Schematic Diagram of D-LE 103 Dimensional Drawing of D-LE 103 Flame Sensors

5
 ■ Technical Data
D-GF 150
■ D-GF 150 Burner Control
Mains Voltage
Mains Frequency
Flame Intensity
Current Output
Relay Outputs (max. 250 Vac/1A)
The electro-mechanical relay contacts meet the requirements of the
VDE 0116 for safety equipment.
Semiconductor Outputs
(max. 250Vac/0,1A)
06/2003 - All specifications subject to change without notice · Änderungen vorbehalten
Inputs (115/230 Vac)
Perm. Ambient Temperature
Protection (EN 60529)
Weight
DURAG Industrie Elektronik
GmbH & Co KG
Kollaustr. 105
D-22453 Hamburg, Germany D-70469 Stuttgart, Germany
Tel. +49 40 554 218-0 Tel. +49 711 135 788-0
Fax +49 40 584 154 Fax+49 711 135 788-5
■ D-LE 103 Flame Sensor
115/230 VAC +10% ... -15% Supply Voltage 20 VDC (from Burner Control)
50/60 Hz ±10% Spectral Sensitivity (depending 190-1800 nm
on type of flame sensor)
0/4..20 mA / 750 Ohms
Permissable Ambient
Ignition Fuel Valve 20°C to +60°C (0°F to 140°F)
Temperature
Pilot Fuel Valve Viewing Pipe Connection G 1¼“
Main Fuel Valve Gas (Supply Side) Purge Air Connection G ½“
Main Fuel Valve Gas (Burner Side) Optical Viewing Angle 6°
Main Fuel Valve Oil Protection (EN 60529):
Close Air Damper Cable Version (-CG) IP65 / NEMA 4X
Open Air Damper Standard Plug Version (-P) IP67 / NEMA 4X
Release Regulation Metal Plug Version (-MP) IP54 / NEMA 3S
Alarm Weight approx. 1.5 kg (3.3 lb.)
Ignition Transformer Extensive descriptions of these units with specifications, setting in-
structions, dimensions and connection plans are available upon
request.
Ready for Operation
Blower ■ Available Accessories
Insert Ignition Lance
Flame ON
■ AM 150
Expansion module for the D-GF 150 Burner Control with following
Internal Flame ON features: alphanumeric display, first-out annunciator, MODBUS-
Interface and more
External Flame ON
Pre-Purge in Operation ■ D-ZS 087 - 20
Ignition in Operation Digital display for optimal alignment of flame sensors through
Gas Valve Leackage Test in pulse frequency measurement and for storing pulse peak values
Operation
Master Burner / Non Master ■ D-ZS 118
Optical adjustment auxiliary unit for alignment of the ball-type
Burner Mode
adjustment flange on the scanner tubes
Air Pressure Sensor
Program Halt ■ D-ZS 077-10
Gas Pressure Sensor UV-C test light source 230 V / 50 Hz
External Flame Monitor
Monitor Chain Gas ■ D-ZS 093
Monitor Chain Oil UV-A, UV-B and IR test light source 230 V / 50 Hz
Limiter Chain
External Reset
■ D-ZS 033 - I
Ball-type adjustment flange for D-LE 103
Feedback Signal Air Damper
Open
Feedback Signal Air Damper ■ D-ZS 117 - I
Closed Heat insulator with electrical disconnection
-20°C to +60°C
IP20 ■ D-ZS 133 - I
Ball-type valve for closing the viewing pipe
1.5 kg
www.durag.de
Georg Hegwein VEREWA Umwelt- und ORFEUS Combustion DURAG, Inc. DURAG India
GmbH & Co. KG Prozessmesstechnik GmbH Engineering GmbH Southridge Business Center 102, Sophia's Choice,
Am Boschwerk 7 Kollaustr. 105 An der Pönt 53a 1355 Mendota Heights Rd. #200 St. Mark's Road,
D-22453 Hamburg, Germany D-40885 Ratingen, Germany Mendota Heights, Bangalore - 560 001,
Tel. +49 40 554 218-0 Tel. +49 2102 9974-0 Minnesota 55120, USA India
Fax +49 40 584 154 Fax +49 2102 9974-41 Tel. +1 651 451-1710 Tel. +91 80 5112 0223
Fax +1 651 457-7684 Fax +91 80 5112 0224