Data Sheet
Contents
1. Market Pipe fit series PF Connector series FM U S CLASS Il III DIV 1 GROUPS A B C D E F amp G T6 CLASS Il III DIV 2 GROUPS A B C D E F amp G T5 Not for use in acidic or aliphatic hydrocarbon atmospheres DIP Il Ill 2 EFG T5 Ta 40 to 70 C Must be sealed at the enclosure NI I 2 ABCD T5 Ta 40 to 70 C XP 1 1 ABCD T6 Ta 40 to 70 C 1 2 AEx nA nC IIC T5 Ta 40 to 70 C IP66 DIP Il HI 1 EFG T6 Ta 40 to 70 C 21 AEx tb IIIC T85 C Ta 40 to 70 C 1 AEx d IIC T6 Ta 40 to 70 C 21 AEx tb IIIC T85 C Ta 40 to 70 C FM Canada XP 1 1 ABCD T6 Ta 40 to 70 C DIP Il IHI 2 EFG T5 TA 40 to 70 C DIP 11 HI 1 EFG T6 Ta 40 to 70 C NE I 2 ABCD T5 TA 40 to 70 C 1 1 Ex d IIC T6 Ta 40 to 70 C 1 2 EX NA NC IIC T5 TA 40 to 70 C IP66 IEC IECEx FMG 13 0023X Ex d IIC T6 Gb IP66 IECEx FMG 13 0023X Ex nA nC IIC T5 Gc IP66 Ex tb IIIC T85C Ex tb IIIC T85C Temperature range 40 to 185 F 40 to 70 C Temperature range 40 to 185 F 40 to 70 C NCC IECEx FMG 13 0023X Ex d IIC T6 Gb IP66 IECEx FMG 13 0023X Ex nA nC IIC T5 Gc IP66 Inmetro Ex tb IIIC T85C Ex tb IIIC T85C Temperature range 40 to 185 F 40 to 70 C Temperature range 40 to 185 F 40 to 70 C Certificate number NCC 14 03257X Certificate number NCC 14 03257X Seguran a Seguran a INMETRO ocP 0034 INMETR2. Honeywell U2 Combination Viewing Head and Signal Processors 5 j me i 1 i 4 INTRODUCTION The Honeywell U2 flame monitoring system combines sensing and processing in one package The U2 is available in several models to provide different options Each model includes one two or three sensors which share the same optical axis The U2 can be connected either through a detachable connector or a pipe fitting for installations with conduit Refer to the table below for model numbers and options USER MANUAL APPLICATION Each sensor in the U2 has a different response which is suitable for certain applications The UVTRON tube detector has a peak response at 210 nm and is primarily for gas flame monitoring This UV detector using pulse technology is the best for low NOx gas burners and where a solid state sensor using flicker technology does not provide satisfactory results The solid state UV photodiode has a peak response at 310 nm This sensor is suitable for gas oil and coal The principle of flame monitoring is flicker frequency based User selectable high pass filters are used to reject signals that are from background radiation The solid state IR photodiode has a peak response at 1400 nm This sensor is suitable for low NOx oil and coal burners low excess air oil burners and burners with a limited view from a windbox front plate The principle of flame monitoring is flicker frequency based User selectable high pass f
3. O ocP 0034 Ex d IIC T6 Gb Ta 40 to 70 C Ex d IIC T6 Gb Ta 40 to 70 C Ex nA nC IIC T5 Gc Ta 40 to 70 C Ex nA nC IIC T5 Gc Ta 40 to 70 C Ex tb IIIC T85C Db Ta 40 to 70 C IP66 Ex tb IIIC T85C Db Ta 40 to 70 C IP66 NCC 14 03257 X NCC 14 03257 X KTL IECEx FMG 13 0023X Ex d IIC T6 Gb IP66 IECEx FMG 13 0023X Ex nA nC IIC T5 Gc IP66 Ex tb IIIC T85C Ex tb IIIC T85C Temperature range 40 to 185 F 40 to 70 C Temperature range 40 to 185 F 40 to 70 C Certificate number KTL 14 KB4BO 0575X Certificate number KTL 14 KB4BO 0574X Special conditions of use for IECEx as indicated below NOTES Special Conditions for Safe Use Consult the manufacturer if dimensional information on the flameproof joints is necessary The aluminum surface of the Honeywell U2 flame monitoring system may store electrostatic charge and become a source of ignition in applications with a low relative humidity lt 30 where the aluminum surface is relatively free of surface contamination such as dirt dust or oil Cleaning of the painted surface should 1 2 only be done with a damp cloth The apparatus has flying lead conductors that exit the enclosure A suitably certified Ex d or Ex e terminal box is required to be connected to apparatus enclosure for completing to external supply circuits A WARNING Lockout requires operator action To prevent explosion in hazardous atmospheres do not open housing Not including a
4. after the FFRT flame failure response time expires unless Flame On is detected The U2 includes a self check relay which should always be energized whenever the U2 has power The self check relay is de energized failsafe when an internal fault is detected The self check relay is factory wired in series with the flame relay One additional contact is provided for alarm purposes Self Checking There is a small processor in all viewing heads and it is possible that it could fail and produce erroneous viewing head pulses The self check circuitry guards against such an HONEYWELL U2 PROGRAMMING INTERFACE TECHNIQUES TAP PRESS FINGER ON BUTTON AND REMOVE SCROLL RAMP HOLD FINGER ON THE OR BUTTON READ ONLY Pee aT WRITE ONLY I i 1 l 1 2400 4800 FO1 9600 19200 Gua 38400 57600 115200 TDO3 RTO01 PRESS FINGER ON GLASS AND MOVE FINGER IN CIRCLES TWIRL HELP occurrence There are several tasks that require intelligent interaction between the viewing heads and the signal processor If all of the interactions do not occur properly the flame relay will open User Interface A touch wheel located on the back of the U2 is used for operator interface The configuration menu is simple and easy to follow Full character 4 digital scrolling LED displays are visible in the dark or sunlight Individual sensor LEDs 3 total located below the display flash to indicate the output of
5. ally different at different loads This is one of the reasons for choosing an optimum sighting initially that will maximize signal swing due to changing loads ACCESSORIES The following accessories are available for use with the U2 Orifice Disks kit M 702 6 Used to reduce the signal brightness in cases where the signal brightness is too strong Located immediately in front of the lens it will reduce the amount of signal to the sensors Bag assembly contains orifice disks and retaining rings Orifice disks come with 3 8 1 4 3 16 and 1 8 inch diameter holes Contact your distributor or Honeywell for guidance in using orifice disks Locking coupler with purge port R 518 CL12 PG Adapter is a 1 in NPTM locking quick disconnect cam and groove coupler with 1 2 in NPT purge port Used with R 518 PT12 and R 518 PT12L insulating locking coupler adapters 66 2071EP 01 Insulating locking coupler adapters R 518 PT12 and R 518 PT12L 1 in NPTM Ultem adapters insulate the viewing head from heat and are used with the R 518 CL12 PG purge air adapter or the R 518 CL12 HTG locking coupler The R 518 PT12L has a quartz lens Swivel mounts M 701 1 M 701 2 M 701 2 FLG M 701 2 SS M 701 3 M 701 3P M 701 4 All have 1 in NPTF viewing head connections on one end with varying process connections including 2 in pipe slip on 2 in NPTF 2 in flanged 2 in NPT in stainless steel construction 4 5 in flanged with 3 bolt
6. ame emits As well sour gas H2S can readily absorb 200nm UV wavelengths reducing the amount of ultraviolet radiation reaching the detector Care should be taken to select the proper viewing head for the fuel used Additionally the contaminants that mask UV can be diluted by providing a strong flow of air through the sight pipe to clear a viewing path through the attenuating material Refer to the Purge Air section of this manual It may also be desirable to sight the detector at an area containing fewer masking agents such as near the burner nozzle or near the entrance of the combustion air Increasing 66 2071EP 01 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS the viewing area of the detector by shortening the sight pipe or by increasing the diameter of the sight pipe can also reduce the attenuating effect of masking agents With low NOx gas burners the UV radiation is usually much less in intensity and spread out Relatively high readings can be obtained from all over the furnace when many burners are on This is particularly true when flue gas recirculation is used There will however be a relatively stronger signal near the root of the flame and the more intense spot should be located during the aiming or sighting process The root or intense spot may be further out than with the standard gas burner so it is imperative that a swivel mount be used when making sighting adjustments As an example of proper sightin
7. d 66 2071EP 01 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS M33313 Fig 1 Connector Pinout NOTES Itis recommended to use shielded pairs of cable However any cable can be used as long as ana log output and communication cables are individ ually shielded Honeywell offers C12S cable with 12 conductors for use with the U2 18 AWG is recommended Wiring must be in conduit or tray as permitted by code Hazardous location wiring must meet area classifications Mounting and Sighting Mounting is 1 in NPT F Refer to Fig 7 for suggested U2 mounting Before beginning the actual installation determine the best location for mounting the viewing head based upon the following factors Pressure The U2 lens will withstand 500 psi If the U2 will be exposed to pressures over 500 psi contact your distributor or Honeywell for guidance Temperature The U2 can withstand an ambient temperature of 158 F 70 C The case temperature of the housing must not exceed 158 F 70 C Purge air will help reduce conducted heat through the sight pipe and flange A heat insulating Ultem locking coupler adapter R 518 PT12 R 518 PT12L is required and will reduce the conducted heat however direct radiation can cause the housing case temperature to exceed limits If the ambient heat direct radiation is excessive then a fiber optic extension should be considered The extension uses a fiber optic cabl
8. e assembly between the sight pipe and the U2 allowing the U2 to be placed further away from the heat source Refer to the Fiber Optic Manual 69 2683 or contact your distributor or Honeywell for assistance with fiber optic selection and pricing The U2 models also have an internal sensor for measuring temperature To access the temperature reading at the U2 refer to Fig 2 Purge Air The U2 does not have a purge air connection directly on it so purge air must be provided via the mounting method Refer to the ACCESSORIES section and Fig 7 for suggested U2 mounting Purge air is used to prevent very hot gases from reaching the U2 by continuously blowing cooler air through the sight pipe Air required is about 0 13 Nm3 min 5 SCFM delivered at 25 mm 1 in above the maximum back pressure as measured at the Y or T section of the purge air connection Use a flexible air supply line to allow for repositioning of the U2 and sight pipe until a final and permanent position has been decided A continuous flow of air must be maintained in order to reduce conducted heat and to keep the sight pipe and U2 lens free of dirt and debris The air supply must be clean free of oils and water and preferably cool In order to electrically isolate the U2 the purge air line should be installed using an insulating material such as a rubber hose in between the purge air line and the U2 Clearance Make sure there will be sufficient room to rem
9. each sensor green UVT Blue SSUV Red IR The upper right green self check LED provides status of the hardware while the upper left red Flame On LED provides status of the flame relay main safety device NOTE The number of LEDs is model dependent The touch wheel is designed like an iPod to allow for slow or fast changes by moving a finger slower or faster around the back glass Alternatively the user may tap lt or gt to make changes Tap ENTER STORE to enter a menu or store selected data Tap BACK to return to the previous menu Exiting all the menus will display the current flame count The U2 menus are detailed below TWO BUTTON INTERFACE BACK AND ENTER EVERYTHING ELSE CAN BE DONE BY SCROLLING INTERFACE MODES FLAME DISPLAY TAP BACK MAY REQUIRE MORE THAN ONE TAP TAP OR FROM DISPLAY TAP ENTER MOVE THROUGH MENU WITH TAPS OR SCROLLS ADJUST MODE TAP ENTER FROM ADJUSTABLE MENU ITEM CHANGE VALUE USING ANY TECHNIQUE NO YES MODE CHANGE TO YES AND TAP STORE LAST MENU GAIN TUBE UV GT32 GAIN SS UV FILTER SS UV GAIN IR Gis2 FILTER IR Fio4 GAIN MA OUT GM32 M33314 Fig 2 User interface menu overview NOTE If sensor is not available in your model then no menu item will exist for sensor setting See Table 1 on page 2 to determine which sensors are active in your U2 model 66 2071EP 01
10. g challenges detecting flame in a sulfur recovery unit can present a challenge for IR flame monitors The IR detector will detect natural gas used for the warm up of the reactor Usually the combustion air is turbulent enough to cause a good flicker signal When sour gas is introduced and the natural gas is shut down the flame signal could potentially drop off or drop out entirely due to a complete change in the flicker content for the existing U2 sighting In this case optimizing the flame signal for the sour gas by zeroing in on this flame and not the warm up burner may be beneficial Once optimizing the sighting for the sour gas has been completed the signal level could potentially be too low on the natural gas In this case using the UV detector for this application may be beneficial It may be beneficial to use two sets of set points for Flame On and Flame Off one set for proving and detecting the natural gas flame and the other for proving and detecting the sour gas flame The switch over from the two different files should be done when removing the natural gas burner This can be implemented from the burner management system The switch over and the use of different files with independent settings is explained in the sections File on page 8 and Manual Setup on page 13 Another factor that needs to be considered when aiming the viewing head is the load condition of the boiler The flames from a burner can be radic
11. ilters are used to reject signals that are from background radiation Contents INtrOGUCUON 24 22 2k de eee ea bah a eae ede 1 Application indivi aie en bee nd 1 Specifications eeoa ethan eed tenet edt 2 Approval S 5 sh dees es sanae netara Sarain iea aioe Tainaa N 3 Installation i2253 estes ses T 4 AGCCOSSONIGS 1 505 cheeseatenchataedect testa tee tebe tienen cetee ek dees de 6 Operation ck sede eld Ae 6 Troubleshooting vesicic aece hota i 9 Communicating Through Modbus ceeeeceeeeeeeeeeeeees 10 Manual Setup AA T 13 Automatic Setup siinsete tonii aeeiiaii 14 Maintenance e EEE EE ETT 15 Safety Manual ceccesceesceseeeeseeeeeeseeeeeeeeeaeeseeeeaeeeaeees 22 Safety Function of the Uniscan 2 ceeee 23 Proof Test Procedure cseeesseeesseeeeeneeeeeneeereaes 23 Proof Test Interval eeeeeeesseeeesseeeeeneeeeeneeereaes 23 Product Decommissioning secere 24 66 2071EP 01 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Table 1 Available models and associated features Connector Pipe Fit Connection UVTron Model Connection 3 4 in NPT Sensor SSUV Sensor IR Sensor U2 1010 X X X X U2 1010 PF X X X xX U2 1010 PF 050 xX X X xX U2 1010 PF 100 X X X X U2 1012 X X U2 1012 PF xX X U2 1016 X X U2 1016 PF xX X U2 1018 x x x U2 1018 PF X X X The U2 1010 PF 050 has a 50 ft 15m pigtail and the U2 1010 PF 100 has a 100 f
12. le a rubber hose in between the purge air line and the U2 U2 models with a pipe fitting have slightly different wiring than models with a removable connector Refer to the table and diagram below for wire function connection and comments Honeywell C12S cable colors are referenced for the Connector CAB22 wires NOTE If the fault and flame contacts are wired to 220 VAC voltage and cable runs are long it may be necessary to use isolating interposing relays to reduce induced noise Table 3 U2 Wires and their function Pipe Fitting Connector Connection CAB19 CAB22 Function Comments Drain wire Shield Cable shielding Tie to ground black Black Yellow Green Ground Power ground Red Black 10 Power Connect to 22 26 VDC Green Yellow 3 Relay common Common for both flame and self check relays Yellow Yellow 4 Self check relay Normally open contact Grey Yellow 2 Flame relay Normally open contact Brown Yellow RS 485 communication Modbus Connection White White RS 485 communication Modbus Connection Blue Black 7 Future use Future use Orange Black 8 Current output 0 20 or 4 20 mA output corresponding to flame count Use ground as return line Purple Black 9 File select Grounded parameter file 0 24V parameter file 1 NOTE The file input wire should not be left uncon nected or in an unknown state If not being used or if using the default file 0 connect the file input wire to groun
13. liphatic hydrocarbons hexane and acids atmospheres in Class I Division 1 locations To reduce the risk of ignition of hazardous atmospheres an approved sealing fitting is required at the enclosure in Class I Division 1 locations 66 2071EP 01 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS INSTALLATION Grounding and Shielding IMPORTANT Installer must be a trained experienced flame safe guard service technician and should be familiar with the equipment operation and limitations and be aware of any applicable local codes and regulations 1 Connect a safety ground to the U2 housing if applicable 2 The U2 and all associated cable conduit must be at least 12 inches 31 cm from any source of high energy or voltage for example igniter equipment 3 Install a ground wire from the ignition transformer case to the igniter assembly Wiring Ensure all igniter wires and cables show no signs of wear Replace any igniter cables or wires that are frayed or cracked The U2 must be electrically isolated from the burner front a Electrical isolation can be accomplished by install ing an Ultem locking coupler adapter R 518 PT12 or R 518 PT12L in conjunction with a locking cou pler R 518 CL12 HTG or R 518 CL12 PG between the viewing head flange and the burner mount b The purge air line should also be isolated from the viewing head This can be accomplished by install ing any insulating material for examp
14. ove the U2 for servicing Mounting Honeywell offers a range of swivel mounts both pipe thread or flange mounting for use with sight pipes or direct windbox mounting Refer to the section Accessories on page 6 Viewing Head Sighting The sighting of the U2 should be parallel to the center line of the burner in the direction of the flame If used the sight pipe should be mounted as close to the center line as possible so as to sight along the flame rather than across the flame Doing so will ensure continuing flame detection under changing load conditions Refer to Fig 4 5 and 6 Utilizing a sighting or the sight pipe aimed at the root of the flame where the turbulent combustion air mixes with the flame is a good starting point for optimizing the sighting Where practical using a swivel mount to zero in on the highest signal will assure the maximum performance The optimum scanner location is parallel to the burner center line The use of a swivel mount allows for line of sight adjustment where practical to use Examples of U2 installation with and without a swivel mount are shown in Fig 9 and Fig 10 If using a sight pipe the diameter should be large enough to allow a reasonable field of view and to allow for adjustment of the swivel mount angle Pulverized coal unburned fuel smoke oil mist dirt dust and other impurities in the fuel can act as masking agents that attenuate the ultraviolet radiation that the fl
15. s 3 in NPTF and 2 bolt flanged Locking coupler R 518 CL12 HTG Used with the R 518 PT12 and R 518 PT12L insulating locking coupler adapters Process connection end is 1 in NPTF Connector R 518 10 Quick disconnect connector for all non pipe fitting U2 models NOTE Connector is not included with the non pipe fit ting models Order separately along with cable and required mounting accessories Cable C12S 12 conductor cable with braided shield Sold per foot NOTE Cable is not included with the non pipe fitting models Order separately along with connector and required mounting accessories Cable Connector ASY964 Pre assembled 15 foot 4 7m 12 conductor cable C12S with quick disconnect R 518 10 for all U2 non pipe fitting models Fiber Optic System Compatibility The U2 models are compatible with the Honeywell FASA fiber optic extension products The SS50FOAD SS550FOADY FT and S550FOADY FT AL adapters are applicable Contact your distributor or Honeywell for assistance with fiber optic selection and pricing USB to RS422 RS485 Converter COMMOD Protocol converter for use with external communication to a remote computer OPERATION IR and UV Detectors See Table 1 on page 2 to determine which sensors are active in your U2 model The UVTron tube sensor responds to UV radiation from different fuel flames The UVTron sensor generates pulses that are electronically conditioned to pro
16. t 30m pigtail All models include the following 1 Electronic check no mechanical shutter for self check of the system 2 24 VDC input SPECIFICATIONS Power 22 26 VDC 120 mA max Output relay contacts SPST 2 A 30 VDC or 250 VAC Ambient temperature 40 to 70 C 40 to 158 F Enclosure IP66 NOTE Optional air cooling for housing is available for appli cations with higher ambient temperatures Please contact your distributor or Honeywell for assistance Weight 2 8 kg 6 1 Ibs Physical Dimensions Diameter 11 7 cm 4 6 inches Length 15 5 cm 6 1 inches 66 2071EP 01 Ten 10 flicker frequency filters for solid state UV and IR sensor model dependent Gain selection Eight 8 different file configurations Resettable fuses Pap Paint Silicone free powder coat Mounting Process Connection 1 NPT female NOTE Refer to for Fig 9 and Fig 10 mounting examples Pipe Fit Conduit Connection PF 3 4 NPT FFRT 1 3 second nominal 2 4 second maximum Time Delay On 0 3 seconds Fuses Automatically resettable NOTE If one of the devices is triggered due to high power draw disconnect power from the system for a mini mum of 30 seconds then reconnect power U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS APPROVALS The U2 is a FM approved combustion safeguard and flame sensing system The U2 also carries the following approvals Table 2 Approvals
17. vide output indicated on the U2 display from 0000 to 3425 units The signals from the UVSS solid state sensor are processed based on flicker principle using FFT Fast Fourier Transform User selectable high pass filters are used to reject signals that are from background radiation The signals from the IR solid state sensor are processed based on flicker principle using FFT Fast Fourier Transform User selectable high pass filters are used to reject signals that are from background radiation U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Each sensor allows independent adjustment for gain For flicker based sensors there is also a high pass filter setpoint To further assist in flame discrimination setup adjustable Flame On and adjustable Flame Off thresholds are also provided The Flame On threshold and Flame Off threshold can then be set to monitor the target burner flame but to reject background radiation from other burners In order to energize the flame relay the flame count must be higher than the programmed Flame On threshold for greater than the Time Delay value Once the flame relay is energized the flame signal can fall below the programmed Flame On threshold setting As long as the flame signal remains above the programmed Flame Off setting the system will continue to operate When the flame signal falls below the programmed Flame Off threshold it will not be de energized until
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