Spark Sensor FM 1-8 - Eng

Spark sensor FM 1/8
Instruction manual
Spark detection and extinguisment system
Imprint
GreCon
Technical Documentation
All rights reserved
Edition: 03.2008
Subjected to technical
modifications.
Table of contents
600648 02 0 3
Table of contents
Conventions 7
Maintenance contract ........................................................................................................... 8
Technical questions and ordering of spare parts ................................................................... 8
Leakage insurance .............................................................................................................. 8
CE Conformity ..................................................................................................................... 9
About this instruction manual ................................................................................................ 9
Scope and target group ................................................................................................... 9
Symbols used in this manual .......................................................................................... 10
Description 11
Functional description ........................................................................................................ 12
Variants ............................................................................................................................. 12
FM 1/8 ........................................................................................................................... 12
FM 1/8 Ex II 1/2D ........................................................................................................... 13
Proper usage ..................................................................................................................... 14
Technical data .................................................................................................................... 15
Spark sensor FM 1/8 and FM 1/8 Ex II 1/2 D .................................................................. 15
Terminal box KELEX Ex II 3/(1) D ................................................................................... 16
Terminal box KELEX Ex II 2/(1) D ................................................................................... 17
Mouting plate screwed-in mounting FM 1/8 and FM 1/8 Ex II 1/2 D ................................. 18
Locking plate screwed-in mounting FM 1/8 and FM 1/8 Ex II 1/2 D ................................. 19
Mouting plate welded-on mounting FM 1/8 and FM 1/8 Ex II 1/2 D .................................. 20
Locking plate welded-on mounting FM 1/8 and FM 1/8 Ex II 1/2 D .................................. 21
Securing bracket for screwed-in and welded-on mounting FM 1/8 and FM 1/8 Ex II 1/2 D 22
Mounting plate for purge air adapter SPA ....................................................................... 23
Screwed-in mounting FM 1/8 .............................................................................................. 24
Installation dimensions ............................................................................................... 25
Screwed-in mounting FM 1/8 Ex II 1/2D .............................................................................. 27
Welded-on mounting FM 1/8 and FM 1/8 Ex ....................................................................... 28
Air purge adapter SPA FM 1/8 ........................................................................................... 31
SPA FM 1/8 incl. weld-on sensor mounting SPA ......................................................... 31
SPA FM 1/8 incl. screwed-in sensor mounting SPA .................................................... 31
Air purge adapter SPA FM 1/8 ex ....................................................................................... 32
Table of contents
4 600648 02 0
Mounting 39
Information on positioning ................................................................................................... 40
General instructions ............................................................................................................ 42
Mounting a FM 1/8 ......................................................................................................... 42
Mouting an FM 1/8 Ex II 1/2D ......................................................................................... 42
Mounting tools .................................................................................................................... 43
Mounting the screwed-in mounting FM 1/8 and FM 1/8 Ex .................................................. 44
Mounting the weld-on mounting FM 1/8 and FM 1/8 Ex ....................................................... 46
Mounting the air purge adapter SPA FM 1/8 ....................................................................... 47
Mounting weld-on mounting SPA .................................................................................... 47
Mounting the screwed-in mouting SPA and SPA EX ....................................................... 48
Mounting the support SPA .............................................................................................. 49
Mounting the support SPA Ex ......................................................................................... 49
Mounting the flange ........................................................................................................ 49
Setting the throttle check valve ....................................................................................... 50
Installation of the terminal boxes on the mounting plate ....................................................... 51
Fastening to mounting plate ........................................................................................... 51
Pipe mouting of the assembled mouting plate ................................................................ 52
Wall 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 ........................................................................................................ 54
Screwed-in mounting ..................................................................................................... 55
Mouting plate for welded-on mouting .............................................................................. 56
Mounting plate for screwed-in mounting .......................................................................... 57
Mounting FM 1/8 with sensor mounting bracket ................................................................. 58
Locking plate for welded-on mounting ........................................................................... 58
Locking plate for screwed-in mounting .......................................................................... 60
Mouting plate for welded-on mounting ............................................................................ 62
Mounting plate for screwed-in mounting .......................................................................... 64
Mounting bracket SPA ................................................................................................... 66
Electrical installation 69
Mounting instructions for the electrical installation ............................................................... 70
Electrical installation FM 1/8 ............................................................................................... 71
Connection to the control console of the type CC 700 - 724 ............................................ 71
Connection to the control console of the type CC 7XXX ................................................. 72
Electrical connection FM 1/8 Ex II 1/2D ............................................................................... 74
Connection to the control console of the type CC 700 - 724 ............................................ 74
Connection to the control console of the type CC 7XXX ................................................. 76
Table of contents
600648 02 0 5
Maintenance 79
General maintenance instructions ....................................................................................... 80
Carrying out maintenance work and function tests ............................................................... 81
Safety 83
Safety instructions .............................................................................................................. 84
Basic rules for a safety-conscious operation .................................................................. 84
Safety of the system ....................................................................................................... 85
Explosion protection .................................................................................................. 85
Table of contents
6 600648 02 0
600648 02 0 7
Conventions
Conventions
8 600648 02 0
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 a
VdS-approved manufacturer and installation-company of spark extinguishment systems. We
therefore recommend that you sign a GreCon service contract. This will guarantee reliable
servicing and maintenance at regular intervals. This will ensure reliability and a long life of your
installation.
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 spare
parts on the following phone numbers:
Heinz Eberlie +49 51 81 / 79 - 327
Hans Staudach +49 51 81 / 79 - 305
Hotline:
On weekdays: 4pm-10pm +49 171 / 306 98 25
Daily: 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 to
external 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 against
damage caused by leakage from a spark extinguishment system.
We suggest you contact your responsible insurance company immediately to arrange suitable
cover.
Conventions
600648 02 0 9
CE Conformity

GreCon products are labelled with the CE mark and meet the requirements
of the following CE standards:
CE-standard 89/336/EWG Electromagnetic Compatibility
amended by CE mark standard (93/68/EWG)
CE-standard 73/23/EWG Low-Voltage
amended by CE mark standard (93/68/EWG))
CE-standard 94/9/EG Ex-Protection
amended 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 your
installation.
This manual is to be used by those persons who operate the system and carry out maintenance
and repairs on it.
Operators have to be trained by GreCon employees.
Conventions
10 600648 02 0
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 from
damage.
This symbol indicates safety instructions for protection of persons against injury.
This symbol indicates safety instructions for protection against electric voltage.
600648 02 0 11
Description
Description
12 600648 02 0
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 to
the 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 different
variants. In the following, the different variants of the spark sensor FM 1/8 with their specific
properties 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 1/8
Welded-on mounting FM 1/8
Purge air adapter SPA FM 1/8
Mounting plate for screwed-in mounting
Mounting plate for welded-on mounting
Mounting plate SPA
Locking plate for screwed-in mounting
Locking plate for welded-on mounting
Locking bracket for screwed-in and welded-on
mounting
Description
600648 02 0 13
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 short
Connector protection cap
Optional components: terminal box KELEX Ex II 2/(1) D
Usable fastening materials: welded-on mounting Ex
Screwed-in mounting Ex II 1/2D
Purge air adapter SPA FM 1/8 Ex
Mounting plate for welded-on mounting
Mounting plate SPA
Locking bracket for screwed-in and welded-on
mounting
Description
14 600648 02 0
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 manufacturer
accepts no liability for any damage or impaired function of the system, resulting from
this.
The manufacturer accepts no liability for any damage caued by impropre usage.
Proper usage includes observance of the instruction manual as well.
Description
600648 02 0 15
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: BS7
CE 0044 II 1/2 D T80C TV 03 ATEX 2267X x
IP 65/65 ID-Nr.: 58154015EX SN:..................../.....
GreCon Alfeld (Leine) Funkenlschanlage Typ: BS7
CE 0044 II 1/2 D T80C TV 03 ATEX 2267X x
IP 65/65 ID-Nr.: 58154015EX SN:..................../.....
Labelling place: ................................................. rating plate glued on housing
Description
16 600648 02 0
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 with 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 BS7 Typ:
CE 0044 II 3/(1) D T74C TV 02 ATEX 1838X x
IP 65 ID-Nr.: 5815885EX SN:............................
IP 65 ID-Nr.: 5815885EX SN:............................
Labelling place: ................................................. e.g. labelling of circuit board and additional rating
plate on the housing.
(Fig.4 Pos. A/B/C: rating plate / information sign)
Description
600648 02 0 17
Terminal box KELEX Ex II 2/(1) D
1
3
2
1
1
3
5
,
7
5
14,5 52
A
B
CC
Fig.3: KELEX with hole size
2 Connection console
Dimensions (L x W x D): .................................. 80 mm x 125 mm x 57 mm
Material: ............................................................ Aluminium
Labelling: ..........................................................
IP 65 ID-Nr.: 5815886EX SN:............................
IP 65 ID-Nr.: 5815886EX SN:............................
Labelling place: ................................................. e.g. labelling of circuit board and additional rating
plate on the housing.
(Fig. 5 Pos. A/B/C: rating plate / information sign)
Description
18 600648 02 0
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
Description
600648 02 0 19
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
Description
20 600648 02 0
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
Description
600648 02 0 21
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
Description
22 600648 02 0
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
Description
600648 02 0 23
Mounting plate for purge air adapter SPA
Fig. 9: Mounting plate for SPA
Description
24 600648 02 0
Screwed-in mounting FM 1/8
Fig. 10: Example 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
Description
600648 02 0 25
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
Description
26 600648 02 0
X (2:1)
X
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
23 23
Fig. 12: Installation dimensions if screwed-in sensor mounting and a mounting plate is used
Description
600648 02 0 27
Screwed-in mounting FM 1/8 Ex II 1/2D
A B C
D E F G
Fig. 13: Example 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).
Description
28 600648 02 0
Welded-on mounting FM 1/8 and FM 1/8 Ex
Fig. 14: Weld-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
Description
600648 02 0 29
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
Description
30 600648 02 0
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
Description
600648 02 0 31
Air purge adapter SPA FM 1/8
Fig. 17: SPA FM 1/8 incl. weld-on sensor mounting SPA
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 zone
outside: ex free zone
SPA FM 1/8 incl. screwed-in sensor mounting SPA
Mouting place: .................................................. inside: ex free zone
outside: ex free zone
Description
32 600648 02 0
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 / 21
outside: zone 21 / 22 / Ex free zone
SPA FM 1/8 Ex incl. screwed-in-mounting SPA
Mounting place: ................................................ inside: zone 20/21
outside: zone 21/22 / Ex free zone
Description
600648 02 0 33
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 adapter
Connection 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 connection
of the air purge adapter
Connection pipe: .............................................. Copper pipe 8 mm
Labelling: .......................................................... weldable 1/2D 581499.001Ex
screwable 3/3D 581499.40EX
screwable 1/2D 581564EX
Labelling place: ................................................. e.g. identification number glued on support
Description
34 600648 02 0

If the spark sensor FM 1/8 with the SPA FM 1/8 is used, the used mounting
depends on the properties of the installation site.
The mounting bracket to be used depends on the ambient temperature
and the wall thickness of the transport pipe. For wall thicknesses smaller
than or equal to 3mm ,a screwed-in mounting should be used. If the wall
thickness of the transport pipe is larger than 3mm, a weld-on mounting has
to 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 glued
mountings also. Here, it must be rememberd that the glueing may only be
done 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 of

400 mm onwards, since otherwise, there is a fear of zone dragging.
Description
600648 02 0 35
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
Description
36 600648 02 0
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
Description
600648 02 0 37
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
Description
38 600648 02 0
600648 02 0 39
Mounting
Mounting
40 600648 02 0
Information on positioning

These instructions only refer to transport pipes. If you wish to use the
sensors somewhere else, please contact the GreCon agent responsible for
your company.He/ she will give you information on how to position the
sensors 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 the
corresponding 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 optics
system.
Installation for a horizontal pipe
Fig. 24: Installation for a horizontal pipe
Mounting
600648 02 0 41

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.
Mounting
42 600648 02 0
General instructions
For mounting a spark sensor FM 1/8, follow one of the following lists depending on the variant used.
In addition to the limitations made in the section Technical data, for transport pipes with a wall
thickness larger than 3 mm as well as a diameter smaller than 250 mm, weld-on mounting should
be used.
Mounting a FM 1/8

Mounting a screwed-in, weld-on mounting FM 1/8 or air purge adapter SPA FM 1/8
Mounting the FM 1/8 without / with sensor mounting bracket
Installation of the terminal box KELEX II 3/(1) D
Electrical installation in accordance with projects documents
Mouting an FM 1/8 Ex II 1/2D

Mounting a weld-on mounting FM 1/8 Ex or an air purge adapter SPA FM 1/8 Ex. (only in
connection with weld-on mounting SPA or a screwed-in mounting Ex II 1/2D)
Mounting a FM 1/8 with sensor mounting bracket
Installation of the Ex-terminal box on the mounting plate SPA
Mounting the terminal box KELEX Ex II 3/(1) D or Ex II 2/(1) D
Electrical installation in accordance with projects documents
Mounting
600648 02 0 43
Mounting tools
Fig.. 27: Mounting fixture
A Locking for mounting screwed-in mounting
B Mounting screwed-in mounting and weld-on mounting
Abb. 28: Mounting device SPA
A Wing
B Twist grip
C Theaded rod
D O-ring
Mounting
44 600648 02 0
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 so
that the opening material does not fall into the
pipe.
Insert the two o-rings into the inner slots (B) of
the support (A).
Place the individual parts on the mounting
device.
Please observe the following order:
1 = nut
2 = washer, round
3 = washer, with slot
4 = support
Fig. 29: Example of screwed in mounting
For mounting the screwed-in mounting EX II 1/2D,
2 is replaced by a silicone sealing and sensor
mounting bracket.
Mounting
600648 02 0 45

Insert the support and the ring (with slot) into
the hole.
Pull the mounting device back until the thread
of 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 it
using a wrench.
Pull the mounting tool out of the screwed-in
mounting.
Abb. 30: Mounting the screwed in mounting
Mounting
46 600648 02 0
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 inner
slots of the weld-on mounting.
Define the installation site.

Mark the wall thickness on the weld-on
mounting (1). The wall thickness corresponds
to the weld depth. Thus, the weld-on mounting
is even with the pipe wall.
Place the weld-on mounting on the mounting
tool (2).
Secure the weld-on mounting against shifting
on the mounting tool by tightening the wing
screw or socket screw.
Insert the weld-on mounting into the hole so
that its marking is even with the outer side of
the pipe.

Locate the weld-on mounting by means of two
welding points.
Remove the mouting device (2).
Weld the mounting by creating a circular seam
using the step-back welding process.
Fig. 31: Mounting a weld on mounting
Insert both the two delivered o-rings into the
inner slots of the screwed-in mounting.
The weld-on mounting has to be mounted in the pipe such that the guide
slot for the washer is directed to the outside.
Mounting
600648 02 0 47
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.
pipe.

Insert the mounting into the hole.
Locate the weld-on mounting by means of two
welding points.
Remove the mouting device (2).
Weld the mounting by creating a circular seam
using the step-back welding process.
Fig. 32: Weld-on mounting SPA
Alternatively, the mounting can be glued at the installation site with Loctite
5221. Follow the processing instructions for the glue.
Mounting
48 600648 02 0
Mounting the screwed-in mouting SPA and SPA EX

For mounting the screwed-in-mounting, a wrench (wrench
size 50mm) is necessary.
pipe.
Push the individual parts of the screwed-in
mounting loosely on the mounting tool in the
following order.
1. Ring nut
2. Compression sealing (or metal plate and
silicone sealing in the ex-zone)
3. Metal ring with slots
4. Support (screwed-in mounting)
Locate the support on the wrench!
By turning the twist grip in a clockwise
direction, the o-ring is queezed. It expands to
the side and holds the screwed-in mounting.

Insert the screwed-in mounting and the meatal
ring with slots into the bore hole and pull the
mounting tool towards yourself when the metal
ring with slots touches the inner wall of the
pipe.
Place the compression sealing ring, or in the
Ex zone the silicone sealing and then the
metal ring on the screwed-in mounting.
Now turn the ring nut on the support and
tighten it by means of the wrench (wrench size
50).

Turn the twist grip of the mounting tool back.
The o-ring expands and you can take out the
wrench.
If the screwed-in mounting is not tightend
enough, insert the wing of the mounting tool
into the slots of the mounting and tighten it
again with the wrench.
Fig. 33: Mounting the screwed-in mounting SPA
Mounting
600648 02 0 49
Mounting the support SPA

Place the support on the mounting.
Attach the support by means of three socket screws
located laterally (1).
Place the compressed air hose on the compressed
air connection on the flow control valve of the
support and tighten the cap nut (2).
Fig. 34: Support SPA Ex-free zone
Mounting the support SPA Ex

Put some adequate sealing material on the lower
slot of the support (e.g. Loctite 5221).
Place the support on the mounting.
Attach the support by means of three socket screws
located laterally (1).
Create a compressed-air supply by means of a
8mm copper conduit connected to the cutting ring
screwing (2).
Fig. 35: Support SPA Ex zone
Mounting the flange

Place the delivered o-ring into the intended slot of the support and attach the flange.
Tighten the flange by means of four socket screws to the support. The holes are not
arranged symmetrically so that the air channels of the two parts are even.
Place the other two delivered o-rings into the inner slots of the flange.
Mounting
50 600648 02 0
Setting the throttle check valve

First, set the valve in such a manner that as little air
as possible flows through it. There should be a slight
air 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 optimum
compressed air consumed for the given conditions.
The objective is to get the optimum relationship
between degree of fouling and compressed air
consumption.
Fig. 36: Throttle check valve
Mounting
600648 02 0 51
Installation of the terminal boxes on the mounting plate
Fastening to mounting plate

1
2
1 2
1
2
1
2
Fig. 37: Fastening on the mounting plate
Mounting
52 600648 02 0
Pipe mouting of the assembled mouting plate
When using a screwed-in mounting or a purge air adapter, the mounting plate can be mounted
directly on the pipe. In this case, the mounting plate is placed in front of the washer (without slot) on
the support of the screwed-in mounting or is placed between the support SPA and the mounting
SPA.
A
B
A
B
AA
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 and
dowels.
Fig. 39: Mounting for horizontal and vertical pipes
Mounting
600648 02 0 53
Wall mounting of the terminal box KELEX II 2/(1) D or KELEX II 3/(1) D
Fig.. 40: Wall 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.
Mounting
54 600648 02 0
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).
Mounting
600648 02 0 55
Screwed-in mounting
1
2
Fig. 42: Mouting of FM 1/8 with screwed-in mouting

Mounting
56 600648 02 0
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 several
times.
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.
Mounting
600648 02 0 57
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.
Mounting
58 600648 02 0
Mounting FM 1/8 with sensor mounting bracket
1
2
3
4
A
A
Fig. 45: Installation of FM 1/8 Ex with locking plate for welded-on holder
Mounting
600648 02 0 59

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 the
sensor.
Mounting
60 600648 02 0
2
3
1
A
A
Fig. 46: Installation of FM 1/8 Ex with locking plate for screwed-in holder
Mounting
600648 02 0 61

Fasten the locking bracket with a screw to the locking plate.
sensor.
Mounting
62 600648 02 0
Mouting plate for welded-on mounting
1
2
3
4
A
A
Fig. 47: Installation of FM 1/8 Ex with mounting plate for welded-on mounting
Mounting
600648 02 0 63

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.
sensor.
Mounting
64 600648 02 0

2
3
1
A
A
Fig. 48: Installation of FM 1/8 Ex with mounting plate for screwed-in mounting
Mounting
600648 02 0 65

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.
sensor.
Mounting
66 600648 02 0
Mounting bracket SPA
Fig. 49: Installation of FM 1/8 Ex with mounting plate SPA
Mounting
600648 02 0 67

Attach the connector protection cap with two screws and four insulating disks to the spark
sensor (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 spark
sensor. By means of a third screw attach the sensor mounting bracket to the air purge
adapter.
sensor. The insulating disks have to be inserted such that the bead fits into
the hole.
Mounting
68 600648 02 0
600648 02 0 69
Electrical installation
Electrical connection
70 600648 02 0
Mounting instructions for the electrical installation
For the electrical installation and cable installation, different factors have to be considered. It is
prohibited to kink the cables. This would result in cable cuts. The reference value for bendings is a
radius 10 times the cable diameter. Furthermore, when mounting the sensor outdoors, make sure
that there is a drip down loop on the cable for rain water. Otherwise, moisture could penetrate into
the device.
Fig. 50: Correct and incorrect cable bendings
Fig. 51: Hanging wound up cable
1 Wound up cable
2 Cable tie (or something similar)
3 screwed cable gland
4 Sensor / Housing of electro-component
Furthermore, it has to be considered that the cable ends are not unnecessarily subjeted to tensile
force. Wound up cables should be hanged at proper places in order to unload the cable ends from
the weight of the wound up cable. Too high tensile forces on the cable ends could result in kinks in
the cable.
600648 02 0 71
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
72 600648 02 0
Connection to the control console of the type CC 7XXX
I01
I01T
3
I01
I01T
4
I02T
I02
19
I02T
I02
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 module
possible connecting terminals
Line module
Fig. 53: Connection of a spark sensor FM 1/8
600648 02 0 73
3 4 19 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
FM 1/8
A B C
1 2 3
I01
I01T
I01
I01T I02T
I02
I02T
I02
Line module
Line module
Fig.54: Connection of two spark sensors FM 1/8
74 600648 02 0
Electrical connection FM 1/8 Ex II 1/2D
Connection to the control console of the type CC 700 - 724
IO 71
MFB
A B
A B C
C
KELEX II 3/(1)D
KELEX 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
Console Console
Fig. 55: Connecting an FM 1/8 Ex II 1/2D
600648 02 0 75
IO 71
MFB
A B
A B C
C
KELEX II 3/(1)D
KELEX 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
FM 1/8
A B C
1 2 3
3 3 3 1
on S1
Console Console
Fig. 56: Connecting two spark sensors FM 1/8 Ex II 1/2D
76 600648 02 0
Connection to the control console of the type CC 7XXX
Test
GND
3
Test
GND
4
Test
GND
19
Test
GND
20
KELEX II 3/(1)D
KELEX 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
Line module
Line module
Fig. 57: Connection of a spark sensor FM 1/8 Ex II 1/2D and FM 1/8 VEx II 1/2D
600648 02 0 77
KELEX II 3/(1)D
KELEX II 2/(1)D
FM 1/8 FM 1/8
A A
A A A1
B B
B B B
C C
C C C A2
1 1
1 1 1
2 2
2 2 2
3 3
3 3 3 1
on S1
3 4 19 20
I01
I01T
I01
I01T I02T
I02
I02T
I02
Line module
Line module
Fig. 58.: Connection of two spark sensors FM 1/8 Ex II 1/2D and FM 1/8 VEx II 1/2D
78 600648 02 0
600648 02 0 79
Maintenance
Maintenance
80 600648 02 0
General maintenance instructions

This chapter describes maintenance measures and function tests you have
to carry out in the given intervalls.
The explained maintenance measures comprise preventive measures as
well as cleaning of the system components. Maintenance measures carried
out regularly make your spark extinguishment system more safe and
reliable.
All maintenance measures and function tests are to be carried out by

specially trained personnel only.
You must enter all maintenance measures carried out in the operators log
and sign them.
Maintenance
600648 02 0 81
Carrying out maintenance work and function tests

Before carrying out the required maintenance measures, switch off the lines
at the control console.
Function tests carried out at the control console:
Every four hours, the control console automatically checks the correct
functioning of the sensors. The console simulates alarms in the sensors
and then tests their reaction. If the console finds out that the monitoring
function of a sensor does not work correctly, it will display this error. The
test 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 this
function test for each monitoring line separately. The manual test and the
automatic test are identical. The result of the manual test appears on the
display 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.
Maintenance
82 600648 02 0
600648 02 0 83
Safety
Safety
84 600648 02 0
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 you
against 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 received
specific 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 plant
shut down.
Work safety
If you have to carry out the required work on ladders or working platforms, please protect yourself
from falling.
Safety
600648 02 0 85
Safety of the system
Qualified personnel
Installation, maintenance and service work is to be carried out by qualified and trained personnel
only.
Comissioning
Commissioning is to be done bz GreCon sercice engineers only or bz personnel authoriyed bz
GreCon to do so.
Maintenance of the system
A GreCon Spark Extinguishment System is part of the system-safety installation. Operate the spark
extinguishing system only in a technically impeccable condition.
According to German insurance regulations (Verband der Schadenversicherer (VdS)), Spark
Extinguishment Systems must be serviced at least once a year by a VdS-approved company. If the
system 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 cannot
eliminate by yourself, please contact either the GreCon Service Department or a GreCon agent
near your site.
Choice of installation site
Considering technical prerequisites, installation sites have to be chosen in a way that the system
can be reached easily for maintenance work. (see VDS Directive 2106 Edition 5/2003, Paragraphs
3.2 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.

Spark Sensor FM 1-8 - Eng

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Spark sensor FM 1/8

Screwed-in mounting SPA FM 1/8 Ex may only be used from a pipe-width of

All maintenance measures and function tests are to be carried out by

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