Spark Sensor FM 1-8_eng

8/10/2019 Spark Sensor FM 1-8_eng

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Spark sensor FM 1/8

Instruction manual

Spark detection and extinguisment system


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Imprint

GreConTechnical Documentation

All rights reserved

Edition: 03.2008

Subjected to technicalmodifications.


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Table of contents

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Mounting 39

Information on positioning ................................................................................................... 40General instructions ............................................................................................................ 42

Mounting a FM 1/8 ......................................................................................................... 42Mouting an FM 1/8 Ex II 1/2D ......................................................................................... 42

Mounting tools .................................................................................................................... 43Mounting the screwed-in mounting FM 1/8 and FM 1/8 Ex .................................................. 44Mounting the weld-on mounting FM 1/8 and FM 1/8 Ex ....................................................... 46Mounting the air purge adapter SPA FM 1/8 ....................................................................... 47

Mounting weld-on mounting SPA .................................................................................... 47Mounting the screwed-in mouting SPA and SPA EX ....................................................... 48Mounting the support SPA .............................................................................................. 49Mounting the support SPA Ex ......................................................................................... 49

Mounting the flange ........................................................................................................ 49Setting the throttle check valve ....................................................................................... 50Installation of the terminal boxes on the mounting plate ....................................................... 51

Fastening to mounting plate ........................................................................................... 51Pipe mouting of the assembled mouting plate ................................................................ 52Wall mouting of the assembled mouting plate ................................................................ 52

Wall mounting of the terminal box KELEX II 2/(1) D or KELEX II 3/(1) D .............................. 53 Mounting FM 1/8 without sensor mounting bracket .............................................................. 54

Welded-on mouting ........................................................................................................ 54Screwed-in mounting ..................................................................................................... 55Mouting plate for welded-on mouting .............................................................................. 56Mounting plate for screwed-in mounting .......................................................................... 57

Mounting FM 1/8 with sensor mounting bracket ................................................................. 58Locking plate for welded-on mounting ........................................................................... 58Locking plate for screwed-in mounting .......................................................................... 60Mouting plate for welded-on mounting ............................................................................ 62Mounting plate for screwed-in mounting .......................................................................... 64Mounting bracket SPA ................................................................................................... 66

Electrical installation 69

Mounting instructions for the electrical installation ............................................................... 70Electrical installation FM 1/8 ............................................................................................... 71

Connection to the control console of the type CC 700 - 724 ............................................ 71Connection to the control console of the type CC 7XXX ................................................. 72

Electrical connection FM 1/8 Ex II 1/2D ............................................................................... 74Connection to the control console of the type CC 700 - 724 ............................................ 74Connection to the control console of the type CC 7XXX ................................................. 76


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Maintenance 79

General maintenance instructions ....................................................................................... 80Carrying out maintenance work and function tests ............................................................... 81

Safety 83

Safety instructions .............................................................................................................. 84Basic rules for a safety-conscious operation .................................................................. 84Safety of the system ....................................................................................................... 85

Explosion protection .................................................................................................. 85


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Table of contents

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Conventions

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Maintenance contract

According to German insurance regulations (Verband der Schadenversicherer (VdS)), Spark

Extinguishment Systems must be serviced regularly by a VdS-approved company. GreCon is aVdS-approved manufacturer and installation-company of spark extinguishment systems. Wetherefore recommend that you sign a GreCon service contract. This will guarantee reliableservicing and maintenance at regular intervals. This will ensure reliability and a long life of yourinstallation.

For further information, please contact our Service Department.

Technical questions and ordering of spare parts

Our Service Department is ready to deal with any technical questions and takes orders for spareparts on the following phone numbers:

Heinz Eberlie +49 51 81 / 79 - 327Hans Staudach +49 51 81 / 79 - 305

Hotline:On weekdays: 4pm-10pm +49 171 / 306 98 25Daily: 12am - 12am Only for those customers who have signed a

GreCon support contract*

* In order to conclude a GreCon support contract, please contact our Service Department.

Leakage insurance

Even Spark Extinguishment Systems may produce uncontrolled water outlet when subjected toexternal mechanical influences or unusual electrical disturbances (e. g. lightning strikes).

In general, insurance companies will add to the existing policies, at no additional cost, cover againstdamage caused by leakage from a spark extinguishment system.

We suggest you contact your responsible insurance company immediately to arrange suitablecover.


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Conventions

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CE Conformity

GreCon products are labelled with the CE mark and meet the requirementsof the following CE standards:

CE-standard 89/336/EWG Electromagnetic Compatibilityamended by CE mark standard (93/68/EWG)

CE-standard 73/23/EWG Low-Voltageamended by CE mark standard (93/68/EWG))

CE-standard 94/9/EG Ex-Protectionamended by CE mark standard (93/465/EWG)

The harmonized standards are listed in the Declaration of Conformity.

About this instruction manual

Scope and target group

This instruction manual applies to the spark sensor FM 1/8 and all variants.

Please pay also attention to product documentations describing other systems installed in yourinstallation.

This manual is to be used by those persons who operate the system and carry out maintenanceand repairs on it.

Operators have to be trained by GreCon employees.


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Conventions

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Symbols used in this manual

This symbol indicates useful tips or special information.This symbol indicates all important information on how to protect the product fromdamage.

This symbol indicates safety instructions for protection of persons against injury.

This symbol indicates safety instructions for protection against electric voltage.


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Description


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Description

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Functional description

Spark sensors detect sparks in the infrared range. Spark sensors are sensitive to daylight.

Via a terminal box, a prefabricated three conductor cable serves to connect the spark sensors tothe control console. This console checks whether there is a broken wire or a short- circuit. Further-more, it automatically verifies whether the sensors function correctly (automatic sensor test).

Variants

In order to be able to use the spark sensor at many different plates, it is available in differentvariants. In the following, the different variants of the spark sensor FM 1/8 with their specificproperties and components are represented.

FM 1/8

Use in dust explosive atmosphere: impossible

Required components: spark sensor FM 1/8,terminal box KELEX Ex II 3/(1)D

Optional components: -

Usable fastening materials: screwed-in mounting FM 1/8Welded-on mounting FM 1/8Purge air adapter SPA FM 1/8Mounting plate for screwed-in mountingMounting plate for welded-on mountingMounting plate SPALocking plate for screwed-in mountingLocking plate for welded-on mountingLocking bracket for screwed-in and welded-onmounting


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Description

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FM 1/8 Ex II 1/2D

Use in dust-explosive atmosphere: Material flow: Zone 20 / 21 / 22 Ambience: Zone 21 / 22

Required components: spark sensor FM 1/8 Ex II 1/2D,Terminal box KELEX Ex II 3/(1)D,Sensor mounting bracket shortConnector protection cap

Optional components: terminal box KELEX Ex II 2/(1) D

Usable fastening materials: welded-on mounting ExScrewed-in mounting Ex II 1/2DPurge air adapter SPA FM 1/8 ExMounting plate for screwed-in mounting

Mounting plate for welded-on mountingMounting plate SPALocking plate for screwed-in mountingLocking plate for welded-on mountingLocking bracket for screwed-in and welded-onmounting


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Description

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Proper usage

The systems described in this manual can only be used together with GreCon spark

extinguishment systems.Do not make any unauthorised modifications at the system on your own. The manufactureraccepts no liability for any damage or impaired function of the system, resulting fromthis.

The manufacturer accepts no liability for any damage caued by impropre usage.

Proper usage includes observance of the instruction manual as well.


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Description

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Technical data

Spark sensor FM 1/8 and FM 1/8 Ex II 1/2 D

Fig. 1: spark sensor FM 1/8

Supply voltage: ................................................. + 20 V 2%

Current consumption: ...................................... 10 mA 2%

Spectral response: ........................................... 780 - 1100 nm

Ambient temperature: ....................................... - 20C to + 70C

Protection class: .............................................. IP 65

Viewing angle: .................................................. 100

Material: ............................................................ aluminium die cast

Labelling: .......................................................... Ex free: none

Ex II 1/2D: GreCon Alfeld (Leine) Funkenlschanlage Typ: BS7CE 0044 II 1/2 D T80C TV 03 ATEX 2267X

IP 65/65 ID-Nr.: 58154015EX SN:.................... /.....

GreCon Alfeld (Leine) Funkenlschanlage Typ: BS7

CE 0044 II 1/2 D T80C TV 03 ATEX 2267X

IP 65/65 ID-Nr.: 58154015EX SN:.................... /.....

Labelling place: ................................................. rating plate glued on housing


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Description

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Terminal box KELEX Ex II 3/(1) D

1

3

2

1 0 8

6 14,5 50,5

A

B

C

Fig.2: KELEX w ith hole size

1 Connection sensor 1

2 Connection console


Dimensions (L x W x D): .................................. 80 mm x 120 mm x 57 mm



Material: ............................................................ Makrolon

Labelling: .............................................. ............

GreCon Alfeld (Leine) Funkenlschanlage BS7Typ:

CE 0044 II 3/(1) D T74C TV 02 ATEX 1838X

IP 65 ID-Nr.: 5815885EX SN:............................


CE 0044 II 3/(1) D T74C TV 02 ATEX 1838X

IP 65 ID-Nr.: 5815885EX SN:............................

Labelling place: ................................................. e.g. labelling of circuit board and additional ratingplate on the housing.(Fig.4 Pos. A/B/C: rating plate / information sign)


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Description

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Terminal box KELEX Ex II 2/(1) D

1

3

2

1 1 3

5 , 7

5

14,5 52

A

B

C C

Fig.3: KELEX w ith hole size

1 Connection sensor 12 Connection console


Dimensions (L x W x D): .................................. 80 mm x 125 mm x 57 mm



Material: ............................................................ Aluminium

Labelling: ................................................ ..........


CE 0044 II 2/(1) D T70C TV 04 ATEX 2678X

IP 65 ID-Nr.: 5815886EX SN:............................


CE 0044 II 2/(1) D T70C TV 04 ATEX 2678X

IP 65 ID-Nr.: 5815886EX SN:............................

Labelling place: ................................................. e.g. labelling of circuit board and additional ratingplate on the housing.(Fig. 5 Pos. A/B/C: rating plate / information sign)


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Description

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Mouting plate screwed-in mounting FM 1/8 and FM 1/8 Ex II 1/2 D

1

2 1

2

Fig. 4: Mounting plate, screwed-in mounting

1 Diagonal screwed-in position for KELEX II 3/(1)D

2 Diagonal screwed-in position for KELEX II 2/(1) D

Material (material number): .............................. 1.4305

Labelling: .......................................................... mounting plate Ex: 581564EX.01

Labelling place: ................................................. marked on component with a laser


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Description

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Locking plate screwed-in mounting FM 1/8 and FM 1/8 Ex II 1/2 D

Fig. 5: Locking plate, screwed-in mounting


Labelling: .......................................................... locking plate Ex: 581564EX.02



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Description

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Mouting plate welded-on mounting FM 1/8 and FM 1/8 Ex II 1/2 D

1

2 1

2

Fig. 6: Mounting plate, welded-on mounting







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Description

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Locking plate welded-on mounting FM 1/8 and FM 1/8 Ex II 1/2 D

Fig. 7: Locking plate, welded-on mounting


Labelling: .......................................................... locking plate Ex: 58156615EX.05



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Description

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Securing bracket for screwed-in and welded-on mounting FM 1/8 and FM 1/8 Ex II 1/2 D

Fig. 8: Securing bracket for screwed-in and welded-on mounting


Labelling: .......................................................... 581564EX.04



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Description

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Mounting plate for purge air adapter SPA

Fig. 9: Mounting plate for SPA





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Description

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Screwed-in mounting FM 1/8

Fig. 10: E xample of screwed-in mounting

1 = support 3b = Washer Ex

2 = Washer, slotted 4 = nut

3a = Washer without slot 5 = O-ring

Screwed-in mounting FM 1/8

Hole diameter for mounting: ............................. 32 mm


Labelling: .......................................................... none


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Description

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Installation dimensions

120

3 0

5 4

84

1 1 5

5 0

90

135

4 0

23

Fig. 11: Installation dimensions if screwed-in sensor mounting FM 1/8 is used


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Description

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2:1

KELEX II 3 (1)D 120x80x57

108

13


130

8 0

5 2

5 0

, 5

2 0 0

2 5 0

6 9

57

8 0

75

7 , 5

2 9

, 5

4 2

5 0

4 2

135

4 0

2323

Fig. 12: Installation dimensions if screwed-in sensor mounting and a mounting plate is used


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Description

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Screwed-in mounting FM 1/8 Ex II 1/2D

A B C

D E F G

Fig. 13: E xample of screwed-in mounting

A = washer with slot E = support

B = Silicone sealing F = grooves for O-rings

C = Locking plate G = Locking groove

D = Nut

Screwed-in mounting FM 1/8 Ex II 1/2D

Hole diameter for mounting: ............................. 32 mm


Labelling: .......................................................... 581564EX

Labelling place: ................................................. marked on component (C) with a laser

Screwed-in sensor mounting EX must not be mounted on bend places(e.g.pipes).


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Description

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Welded-on mounting FM 1/8 and FM 1/8 Ex

Fig. 14: W eld-on sensor mounting

1 = O-ring 2 = slot for washer

Weld-on sensor mounting FM 1/8

Diameter of required hole: ................................ 40 mm


Labelling: .......................................................... none

Weld-on sensor mounting FM 1/8 Ex

Diameter of required hole: ................................ 40 mm


Labelling: .......................................................... 581568EX



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Description

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120

3 0

5 4

84

90

5 0

1 1 5

135

4 0

23

Fig. 15: Installation dimensions if weld-on sensor mounting FM 1/8 is used


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Description

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108

13


130

8 0

5 2

5 0

, 5

2 0 0

2 5 0

6 9

2 9

. 5

4 2

7 . 5

4 2

5 0

8 0

57

75

X (2:1)

X

135

4 0

23

Fig. 16: Installation dimensions if weld-on sensor mounting and a mounting plate is used


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Description

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Air purge adapter SPA FM 1/8

Fig. 18: SPA FM 1/8 incl. screwed-in sensor mounting SPA,

Legend

1 = flange for FM 1/8

2 = Support, not Ex with throttle valve

3 = Weld-on sensor mounting SPA

4 = Screw-in sensor mounting SPA

4a = Compression seal

SPA FM 1/8 incl. weld-on sensor mounting SPA

Mouting place: .................................................. inside: ex free zoneoutside: ex free zone

SPA FM 1/8 incl. screwed-in sensor mounting SPA

Mouting place: .................................................. inside: ex free zoneoutside: ex free zone


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Description

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Air purge adapter SPA FM 1/8 ex

Fig. 19: SPA FM 1/8 Ex incl. weld-on sensor mounting -SPA

1a 2 4

b a

Fig. 20: SPA FM 1/8 Ex with screwed-in sensor mounting-SPA

Legend

1a = flange for FM 1/8

1b = Flange ex for FM 1/8 with connection for locking plate

2 = Support Ex with cutting ring screwing

3 = Weld-on sensor mounting SPA

4 = Screw-in sensor mounting SPA

4a = Silicone sealing

4b = Metal plate

SPA FM 1/8 Ex incl. weld-on sensor mounting SPA

Mounting place: ................................................ inside: zone 20 / 21outside: zone 21 / 22 / Ex free zone

SPA FM 1/8 Ex incl. screwed-in-mounting SPA

Mounting place: ................................................ inside: zone 20/21outside: zone 21/22 / Ex free zone


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Description

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Air purge adapter SPA FM 1/8

Compressed air consumption: ......................... 0-35 l/min at 1.5 bar (reference value)

Minimum operating pressure: ........................... 1,5 bar referred to the compressed air connection

of the air purge adapterConnection pipe: .............................................. compressed air hose 8 mm


Labelling: .......................................................... none

Air purge adapter SPA FM 1/8 Ex

Compressed air consumption: ......................... 0-35 l/min at 1.5 bar (reference value)

Minimum operating pressure: ........................... 1,5 bar referred to the compressed air connectionof the air purge adapter

Connection pipe: .............................................. Copper pipe 8 mm


Labelling: ................................................ .......... weldable 1/2D 581499.001Exscrewable 3/3D 581499.40EXscrewable 1/2D 581564EX

Labelling place: ................................................. e.g. identification number glued on support


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Description

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If the spark sensor FM 1/8 with the SPA FM 1/8 is used, the used mountingdepends on the properties of the installation site.The mounting bracket to be used depends on the ambient temperatureand the wall thickness of the transport pipe. For wall thicknesses smallerthan or equal to 3mm ,a screwed-in mounting should be used. If the wallthickness of the transport pipe is larger than 3mm, a weld-on mounting hasto be used.

At the installation site, the welded-on mounting SPA can be used in non-explosive environments and at ambient temperatures below 70C as gluedmountings also. Here, it must be rememberd that the glueing may only bedone with a special glueing and sealing putty(Loctite 5221).

Screwed-in mounting SPA FM 1/8 Ex may only be used from a pipe-width of400 mm onwards, since otherwise, there is a fear of zone dragging.


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Description

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135

84

5 0

4 0

5 4

150

4 0

23

5 0

5 2

6 7

84

Fig. 21: Installation dimensions when using an SPA in the Ex free zone and in the Ex zone


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Description

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60

135

4 0

6 7

5 0

84

8 0

64

2 5 0

Fig. 22: Installation dimensions when using an SPA and a terminal box in the Ex free zone


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Description

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150

4 0

64

2 5 0

5 2

6 7

5 0

84

8 0

23

Fig. 23: Installation dimensions when using an SPA and a terminal box in the Ex zone


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Description

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Mounting


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Mounting

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Information on positioning

These instructions only refer to transport pipes. If you wish to use thesensors somewhere else, please contact the GreCon agent responsible foryour company.He/ she will give you information on how to position thesensors correctly.

False alarm produced by light incidence

Incident light, e.g. via defective or open pipes, inspection flaps or windows,can cause false alarms.

Seal the transport pipe against incident light in order to prevent false alarms.

In the case of transport pipe being equipped with flaps for taking samples, disable thecorresponding line while taking samples.

Protecting the sensor optics system against dirt

Do not mount the spark sensor at the bottom of the transport pipe !Material deposits or extinguishing water flowing back contaminate the lower sensor opticssystem.

Installation for a horizontal pipe

Fig. 24: Installation for a horizontal pipe


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Mounting

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Protecting the sensor optics system against wear

Installation in pipe bends

Fig. 25: Installation in, behind or in front of bends

A Transportation direction

B min.2000mm

Do not mount spark sensors directly in pipe bends!Generally, you have to mount them behind or in front of bends.

Installation behind a fan

Fig. 26: Installation behind a fan

A min. 1500

Do not mount the spark sensors directly in the blow direction of the fan!Sparks produced by the fan can cause spark alarms.


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Mounting

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Mounting tools

Fig.. 27: M ounting fixture

A Locking for mounting screwed-in mountingB Mounting screwed-in mounting and weld-on mounting

Abb. 28: Mounting device SPA

A WingB Twist gripC Theaded rodD O-ring


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Mounting

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Mounting the screwed-in mounting FM 1/8 and FM 1/8 Ex

Define where to mount the sensor.

Drill a hole into the pipe: 32 mm.

Remove the circular cutter very carefully sothat the opening material does not fall into thepipe.

Insert the two o-rings into the inner slots (B) ofthe support (A).

Place the individual parts on the mountingdevice.

Please observe the following order:

1 = nut2 = washer, round3 = washer, with slot4 = support

Fig. 29: E xample of screwed in mounting

For mounting the screwed-in mounting EX II 1/2D,2 is replaced by a silicone sealing and sensormounting bracket.


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Mounting

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Insert the support and the ring (with slot) intothe hole.

Pull the mounting device back until the threadof the support juts out of the hole and the ring(with slots) touches the inner wall.

Push the round washer against the outer wall.

Screw the nut on the support and tighten itusing a wrench.

Pull the mounting tool out of the screwed-inmounting.

Abb. 30: M ounting the screwed in mounting


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Mounting

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Mounting the weld-on mounting FM 1/8 and FM 1/8 Ex

Before mounting, make sure that the o-rings are not yet situated in the innerslots of the weld-on mounting.

Define the installation site.


Mark the wall thickness on the weld-onmounting (1). The wall thickness correspondsto the weld depth. Thus, the weld-on mountingis even with the pipe wall.

Place the weld-on mounting on the mountingtool (2).

Secure the weld-on mounting against shiftingon the mounting tool by tightening the wingscrew or socket screw.

Insert the weld-on mounting into the hole sothat its marking is even with the outer side ofthe pipe.

Locate the weld-on mounting by means of twowelding points.

Remove the mouting device (2).

Weld the mounting by creating a circular seamusing the step-back welding process.

Fig. 31: M ounting a weld on mounting

Insert both the two delivered o-rings into theinner slots of the screwed-in mounting.

The weld-on mounting has to be mounted in the pipe such that the guideslot for the washer is directed to the outside.


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Mounting

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Mounting the air purge adapter SPA FM 1/8

Mounting weld-on mounting SPA

The weld-on mounting is made of high-grade steel 1.4301.Use adeqate electrodes for the welding process.




Insert the mounting into the hole.

Locate the weld-on mounting by means of twowelding points.

Remove the mouting device (2).

Weld the mounting by creating a circular seamusing the step-back welding process.

Fig. 32: Weld-on mounting SPA

Alternatively, the mounting can be glued at the installation site with Loctite5221. Follow the processing instructions for the glue.


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Mounting

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Mounting the screwed-in mouting SPA and SPA EX

For mounting the screwed-in-mounting, a wrench (wrench

size 50mm) is necessary.




Push the individual parts of the screwed-inmounting loosely on the mounting tool in the

following order.1. Ring nut2. Compression sealing (or metal plate andsilicone sealing in the ex-zone)3. Metal ring with slots4. Support (screwed-in mounting)

Locate the support on the wrench!By turning the twist grip in a clockwisedirection, the o-ring is queezed. It expands tothe side and holds the screwed-in mounting.

Insert the screwed-in mounting and the meatalring with slots into the bore hole and pull themounting tool towards yourself when the metalring with slots touches the inner wall of thepipe.

Place the compression sealing ring, or in theEx zone the silicone sealing and then themetal ring on the screwed-in mounting.

Now turn the ring nut on the support and

tighten it by means of the wrench (wrench size50).

Turn the twist grip of the mounting tool back.The o-ring expands and you can take out thewrench.

If the screwed-in mounting is not tightendenough, insert the wing of the mounting toolinto the slots of the mounting and tighten itagain with the wrench.

Fig. 33: M ounting the screwed-in mounting SPA


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Mounting

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Setting the throttle check valve

First, set the valve in such a manner that as little airas possible flows through it. There should be a slightair flow tangible before the purge air adapter.

Observe the degree of fouling at the sensor visual

Open the valve a little in case of excess fouling,to facilitate a greater air flow.

In this manner, feel your way to the optimumcompressed air consumed for the given conditions.

The objective is to get the optimum relationshipbetween degree of fouling and compressed airconsumption.

Fig. 36: Throttle check valve


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Mounting

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Installation of the terminal boxes on the mounting plate

Fastening to mounting plate

12

1 2

Fig. 37: Fastening on the mounting plate




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Mounting

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Pipe mouting of the assembled mouting plate

When using a screwed-in mounting or a purge air adapter, the mounting plate can be mounteddirectly on the pipe. In this case, the mounting plate is placed in front of the washer (without slot) onthe support of the screwed-in mounting or is placed between the support SPA and the mountingSPA.

A

B

A

B

A A

Fig. 38: Mounting for horizontal and vertical pipes

A Sensor

B Terminal box mounted on mounting plate

Wall mouting of the assembled mouting plate

For wall mouting of the mouting plate, please use the two holes ( 5mm) of the mouting plate.Theses holes are used to attach the mounting plate to the wall by means of adequate screws anddowels.

Fig. 39: Mounting for horizontal and vertical pipes


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Mounting

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Wall mounting of the terminal box KELEX II 2/(1) D or KELEX II 3/(1) D

Fig.. 40: W all mounting

The terminal boxes can be directly mounted to the wall..

Use the housing as a template in order to mark the boreholes.Drill a corresponding number of dowel holes.

Provide each hole with a corresponding dowel.

Fasten the components with the help of screws that are screwed in dowels.


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Mounting

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Mounting FM 1/8 without sensor mounting bracket

Welded-on mouting

Fig. 41: Mouting of FM 1/8 with welded-on mouting

Insert sensor optics into the mounting by pushing and simultaneously distorting it (1).

Screw the connector to the connection terminal on the spark sensor (2).


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Mounting

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Screwed-in mounting

1

2

Fig. 42: Mouting of FM 1/8 with screwed-in mouting




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Mounting

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Mouting plate for welded-on mouting

1

2 3

Fig. 43: Installation of FM 1/8 with mounting plate for welded-on holder

Remove the bracket at the top of the mounting plate by bending it back and forth severaltimes.

Push the mounting plate from the side onto the welded-on mounting.

Fix the mounting plate with a welding spot on the welded-on mounting.




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Mounting

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Mounting plate for screwed-in mounting

2

11

Fig. 44: Installation of FM 1/8 with mounting plate for screwed-on holder

Remove the bracket at the top of the mounting plate by bending it back and forth several

times.Insert sensor optics into the mounting by pushing and simultaneously distorting it (1).



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Mounting

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Mounting FM 1/8 with sensor mounting bracket

Locking plate for welded-on mounting

1

23

4

A

A

Fig. 45: Installation of FM 1/8 Ex with locking plate for welded-on holder


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Mounting

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Put the connection cable through the screwed cable gland of the connector protection cap.

Attach the connector protection cap with two screws =to the spark sensor (3).

Push the locking plate from the side onto the spark sensor (4).

Fasten the locking bracket with 2 screws and 4 insulating washers on the plug protection cap.

Fasten the locking bracket with a screw to the locking plate. .

The insulating disks seperate the electric potentials from the pipe and thesensor.


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Mounting

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Locking plate for screwed-in mounting

2

3

1

A

A

Fig. 46: Installation of FM 1/8 Ex with locking plate for screwed-in holder


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Mounting

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Mouting plate for welded-on mounting

1

2

34

A A

Fig. 47: Installation of FM 1/8 Ex with mounting plate for welded-on mounting


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Mounting

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Bend the locking bracket on the mounting plate through 90 as can be seen on the drawing.

Push the mounting plate with the terminal box on it from the side onto the spark sensor (4).


Fasten the locking bracket with a screw to the mounting plate.



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Mounting

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Mounting plate for screwed-in mounting

23

1

A A

Fig. 48: Installation of FM 1/8 Ex with mounting plate for screwed-in mounting


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Mounting

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Bend the locking bracket on the mounting plate through 90 as can be seen on the drawing.






Fasten the locking bracket with a screw to the locking plate.



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Mounting

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Mounting bracket SPA

Fig. 49: Installation of FM 1/8 Ex with mounting plate SPA


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Mounting

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Attach the connector protection cap with two screws and four insulating disks to the sparksensor (3).

Place the sensor mounting bracket from above on the spark sensor(4).

Attach the sensor mounting bracket with two screws and two insulating disks to the sparksensor. By means of a third screw attach the sensor mounting bracket to the air purgeadapter.

The insulating disks seperate the electric potentials from the pipe and thesensor. The insulating disks have to be inserted such that the bead fits into

the hole.


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Mounting

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Electrical connection

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Electrical installation FM 1/8

Connection to the control console of the type CC 700 - 724

IO 71

IO 71

MFB

MFB

A

A

B

B

A

A

B

B

C

C

C

C

KELEX 3/(1) D

KELEX 3/(1) D

FM 1/8

FM 1/8 FM 1/8

A

A A

A

A

A

A

A1

A1

B

B B

B

B

B

B

B

B

C

C C

C

C

C

C

C

C

A2

A2

1

1 1

1

1

1

1

1

1

2

2 2

2

2

2

2

2

2

3

3 3

3

3

3

3

3

3

1

1

on S1

on S1

Console

Console

on S1

Console

Console

Fig. 52: Connection of one or two spark sensors FM 1/8


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Connection to the control console of the type CC 7XXX

I01I01T

3I01I01T

4

I02TI02

19

I02TI02

20

KELEX II 3/(1) D

FM 1/8

A

A A A1

B

B B B

C

C C C A2

1

1 1 1

2

2 2 2

3

3 3 3 1

on S1

Line modulepossible connecting terminals


Fig. 53: Connection of a spark sensor FM 1/8


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Electrical connection FM 1/8 Ex II 1/2D

Connection to the control console of the type CC 700 - 724

IO 71MFB

A B A B C

C

KELEX II 3/(1)DKELEX II 2/(1)D

FM 1/8

A

A A A1

B

B B B

C

C C C A2

1

1 1 1

2

2 2 2

3

3 3 3 1

on S1

ConsoleConsole

Fig. 55: Connecting an FM 1/8 Ex II 1/2D


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IO 71MFB

A B A B C

C


FM 1/8

A

A A A1

B

B B B

C

C C C A2

1

1 1 1

2

2 2 2

3

FM 1/8

A B C1 2 3

3 3 3 1

on S1

ConsoleConsole

Fig. 56: Connecting two spark sensors FM 1/8 Ex II 1/2D


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Connection to the control console of the type CC 7XXX

TestGND

3

TestGND

4

TestGND

19

TestGND

20


FM 1/8

A

A A A1

B

B B B

C

C C C A 2

1

1 1 1

2

2 2 2

3

3 3 3 1

on S1

Line modulepossible connecting terminalsLine modulepossible connecting terminals

Fig. 57: Connection of a spark sensor FM 1/8 Ex II 1/2D and FM 1/8 VEx II 1/2D


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FM 1/8 FM 1/8

A A

A A A1

B B

B B B

C C

C C C A 2

1 1

1 1 1

2 2

2 2 2

3 3

3 3 3 1

on S1

3 4 19 20I01I01T

I01I01T I02T

I02I02TI02



Fig. 58.: Connection of two spark sensors FM 1/8 Ex II 1/2D and FM 1/8 VEx II 1/2D


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Maintenance


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Maintenance

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General maintenance instructions

This chapter describes maintenance measures and function tests you haveto carry out in the given intervalls.The explained maintenance measures comprise preventive measures aswell as cleaning of the system components. Maintenance measures carriedout regularly make your spark extinguishment system more safe andreliable.

All maintenance measures and function tests are to be carried out byspecially trained personnel only.

You must enter all maintenance measures carried out in the operators logand sign them.


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Maintenance

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Carrying out maintenance work and function tests

Before carrying out the required maintenance measures, switch off the linesat the control console.

Function tests carried out at the control console:

Every four hours, the control console automatically checks the correctfunctioning of the sensors. The console simulates alarms in the sensorsand then tests their reaction. If the console finds out that the monitoringfunction of a sensor does not work correctly, it will display this error. Thetest serves to determine whether the sensors will function correctly if a real

alarm occurs.The operating menu of the control console serves to manually activate thisfunction test for each monitoring line separately. The manual test and theautomatic test are identical. The result of the manual test appears on thedisplay as well.

Maintenance interval: monthly

Remove the sensor from its mounting.

Check whether the optics system fits tightly and whether it is defective or worn.

Check whether the mounting is defective or worn.Check whether the cable glands are leakproof and whether they function correctly.


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Maintenance

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Safety

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Safety instructions

The reliable GreCon Spark Extinguishment Systems correspond to the latest state of the art, are

manufactured in accordance with the accepted rules of engineering and are safe and reliable. It is,however, required that you observe various safety instructions for all activities which will protect youagainst injury and the system against damage.

Therefore, please read the safety instructions and this manual carefully.

Basic rules for a safety-conscious operation

Documentation

Always keep the documentations at hand.

Operation

Ensure that the Spark Extinguishment System is exclusively operated by personnel who receivedspecific training to do so by GreCon service engineers during commissioning.

Rules

For any activities please observe the rules valid in your location, e.g. rules of the public utilities.

Production stop

Mouting, maintenance and replacement of components may only be done with the production plantshut down.

Work safety

If you have to carry out the required work on ladders or working platforms, please protect yourselffrom falling.


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Safety

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Safety of the system

Qualified personnel

Installation, maintenance and service work is to be carried out by qualified and trained personnelonly.

Comissioning

Commissioning is to be done bz GreCon sercice engineers only or bz personnel authoriyed bzGreCon to do so.

Maintenance of the system

A GreCon Spark Extinguishment System is part of the system-safety installation. Operate the sparkextinguishing system only in a technically impeccable condition.

According to German insurance regulations (Verband der Schadenversicherer (VdS)), SparkExtinguishment Systems must be serviced at least once a year by a VdS-approved company. If thesystem is extremely dirty or if it is charged up to 100%, you have to service it several times a year.

Eliminate any trouble immediately after its appearance. In case there is a trouble that you cannoteliminate by yourself, please contact either the GreCon Service Department or a GreCon agentnear your site.

Choice of installation site

Considering technical prerequisites, installation sites have to be chosen in a way that the systemcan be reached easily for maintenance work. (see VDS Directive 2106 Edition 5/2003, Paragraphs3.2 and 4.8). Compliance is required with the conditions according to the Technical Data.

Explosion protection

For spark sensors in dust explosive atmosphere the following applies: The housing of the sensor may only be opened in a zero voltage condition.

The connector may be pulled only when the system is switched off for at least 3 seconds.

For terminal boxes in dust explosive atmosphere the following applies:

Only open the housing after the plant has been switched off for at least 3 seconds.

Dust layers larger than 3 mm must be removed. Terminal boxes may only be wiped moistly.


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Spark Sensor FM 1-8_eng

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