U2 Combination Viewing Head and Signal Processors
Contents
1. Fig 5 U2 dimensions 5 3 32 130 4 19 32 118 3 4 19 NPT CONNECTION M34431 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS MANUAL SETUP Manual Configuration for Gas Firing Applications with Multiple Burners CAUTION ALL ADJUSTMENTS SHOULD BE CARRIED OUT BY A QUALIFIED PERSON BMS interlock s may require temporary bypass during configuration This operation should be carried out under supervised conditions and limited to minimum time Remove bypasses as soon as configuration and setup is completed Main gas control valve may include bypass PRV Make sure at least first burner is started up at minimum firing In some cases more than one burner may be started up at low fire depending upon bypass PRV Follow manufacturer s guidelines in controlling fuel flow as additional burners are brought into service 1 Goto menu for UVTron 2 Adjust gain settings to 50 3 If applicable go to UVSS menu and set UVSS gain to zero With zero gain flicker frequency filter need not be adjusted 4 If applicable go to IR menu and set IR gain GI to zero With zero gain flicker frequency filter need not be adjusted Go to Milliamp output gain GM and set at 50 Go to Flame OFF menu Set Flame OFF 600 as tial value 8 Go to Flame Failure Response Time FFRT Select 3 seconds 9 Go to Time Delay and select 0 seconds 10 Under supervised conditions light off gas igniter 112. 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS IRDA 0 OR 4 20 Enables or disables communications through the palm Sets the current output to either a 0 20mA output or a 4 20mA Enabled by default output scale The 4 20mA output scale is used by default RS485 Sets modbus to either READ ONLY or read and writable WRITE Ok Read and writable by default Table 4 Basic MODBUS Registers Map Register Name Description Minimum Maximum Size 40001 FLAMECOUNT Flame count of active channel read only 0 3425 16 bit 40002 PROCSTATUS mask only 4th bit 4 of 20 is writable other bits are read 0 255 8 bit only Not used 0000 0001 don tcare Relay 0000 0010 1 O off Not lockout 0000 0100 1 not lockout O lockout Not panel lock 0000 1000 1 unlocked O locked 4 to 20 output 0001 0000 1 default 4 20mA 0 0 20mA File 1110 0000 3 bits are the in use 0 7 40003 FLAMEON Flame On setting for current active file 51 3425 16 bit 40005 FLAMEOFF Flame Off setting for current active file 50 3424 16 bit 40007 OUTPUTGAIN Gain of the0 4 20mA output for the current active file 0 99 8 bit 40010 IRGAIN IR sensor gain setting for current active file 0 99 8 bit 40011 IRFILT High pass IR sensor filter setting for current active file O 8Hz 0 9 8 bit default 1 16 2 2 24Hz 3 33Hz 4 52Hz 5 75Hz 6 100 2 7 155Hz 8 215 2 9 300Hz 40012 UVTGAIN UV tube gain setting
3. Table 5 Extended Modbus Register Map Continued Register Name Description Minimum Maximum Size 40291 IRSAVEGAIN Saved gain of the IR sensor from the current file 0 99 8 bit determined by the auto gain function read only 40292 UVTUBESAVEGN __ Saved gain of the UV tube from the current file determined 0 99 8 bit by the auto gain function read only 40293 USSSSAVEGN Saved gain of the solid state UV sensor from the current 0 99 8 bit file determined by the auto gain function read only 40294 SAVEFILE Saves the active file at the time of auto gain Reads 255 if 0 255 8 bit the auto gain function has never been run read only 21 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS SAFETY MANUAL Uniscan 2 Product Declaration FIT FOR USE IN A Low Demand SAFETY APPLICATION Models 1010 1012 1016 1018 1010 PF 1012 PF 1016 PF 1018 PF Models SIL SFF PFD s pp Apu 1010 1010PF 3 0 gt 99 1 54 X104 1 08 105 7 22 X109 6 95 X10 1012 1012PF 3 0 gt 99 145 X104 8 19 107 7 22 109 6 62 109 1016 1016PF 3 0 gt 99 7 55 X105 1 08 X108 1 97 109 3 45 X10 1018 1018PF 3 0 gt 99 154 104 1 08 105 7 22 109 6 95 X109 System Architecture 1001 MTTR 8 hours Proof Test Interval 5 years Fit for use in SIL 3 environment Definitions Term Definition Dangerous Failure F
4. default 8 data bits parity default 1stop bit Baud parity and address are all changeable via the U2 interface in the Comms menu The address is set to 0 by default and must be changed in order to communicate with the unit When communicating with more than one unit ensure that no two units share the same address A graphical user interface is available for remote configuration and monitoring through Modbus called Flame Tools Refer to Table 4 and 5 for the Modbus registers map Comms Tapping COMMS on the U2 menu will access the communications sub menus including address baud parity IRDA RS485 and current output Address Address for modbus communication 0 247 When communicating with more than one unit ensure that no two units share the same address The default address is 0 so it must be changed before modbus communication can take place For applications where large quantities of U2 are used it is recommended to start with address 11 for burner 1 21 for burner 2 and so on Refer to Fig 3 Doing so will help alleviate potential communication issues when adding new or replacing existing U2 models which have zero 0 as the default address Two units with a 0 address could seize communications Baud Speed of modbus communications 2400 4800 9600 19200 38400 57600 or 115200 The default baud is 9600 Parity Modbus checking method NONE ODD or EVEN The default parity is NONE
5. and software elements in a system PFDayg Average Probability of Failure on Demand Average Probability of Failure on Demand In this case regarding the Uniscan 2 FIT Failures in Time A unit of measurement representing one failure per billion hours 1 000 000 000 hours is approximately 114 155 25 years 66 2071 02 22 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Safety Function of the Uniscan 2 The safety function of the Uniscan 2 signal processor consists of a Flame Relay which comprises its safety function and behaves as follows The Flame Relay Normally Open The Flame Relay will be energized when the product is powered and a flame on condition is detected for longer than the time delay value The Flame Relay will be de energized when the product is powered a flame off condition is detected and the FFRT Flame Failure Response Time has elapsed The Flame Relay will be de energized when the product is powered and detects a fault condition The Flame Relay will be de energized when power to the product is off All Uniscan 2 signal processor models contain a Self Check Relay designed to be energized during normal operation of the signal processor and de energized during detection of a fault or power down Due to the logic circuitry which energizes the coil of the Flame Relay it is physically impossible for the 3 50E 3 00E Flame Relay to be energized if the Self Check R
6. fire conditions of the application and that the same gain settings are used during each sensitivity check If it is determined that the sensitivity is below 5096 of the initial value terminated life of sensor the sensor should be replaced HIGH FREQUENCY FLICKER ZONE LOW FREQUENCY FLICKER ZONE DETECTOR IN GOOD SIGHTING POSITION PARALLEL SIGHTING BURNER NOZZLE CENTERLINE 8 DETECTOR IN POOR SIGHTING POSITION M33285 Fig 6 IR viewing head location 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS UV RADIATION ZONE UV VIEWING i HEAD SIGHTED ON UV ZONE Ro C X RI mo 7 Fig 7 UV viewing head location M33286 NO 1 FLAME NO 2 FLAME ENVELOPE ENVELOPE VIEWING HEAD VIEWING HEAD BURNER NOZZLE NO 1 BURNER NOZZLE NO 2 HIGH FREQUENCY LOW FREQUENCY HIGH FREQUENCY IR ZONE ZONE IR ZONE LESS THAN 36Hz M33287 Fig 8 Sighting opposed fired burners 66 2071 02 16 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS R 518 CL12 PG PURGE AIR COUPLER AND R 518 PT12 INSULATING LOCKING COUPLER ADAPTER BURNER FRONT PLATE SWIVEL MOUNT M33524 Fig 9 Viewing head mounting example BURNER FRONT PLATE OR WINDOWBOX R 518 CL12 PG 1 25 PURGE AIR COUPLER NPTF PIPE AND R 518 PT12 INSULATING LOCKING dz COUPLER ADAPTER FLANGE OPTIONAL M33628 Fig 10 Seco
7. for current active file 0 99 8 bit 40015 UVSSFILT High pass solid state UV sensor filter setting for current active 0 9 8 bit file File O 8Hz default 1 16Hz 2 24Hz 3 33Hz 4 52Hz 5 75Hz 6 100Hz 7 155Hz 8 215Hz 9 300Hz 40016 UVSSGAIN Solid state UV sensor gain setting for current active file 0 99 8 bit 40019 TEMPERATURE Current internal temperature of U2 read only 67 261 16 bit 40021 TIMEDELAY Time Delay setting in seconds for current active file 0 3 8 bit 40022 flame failure response time setting in seconds for 1 3 8 bit current active file 40023 VERSION Firmware version read only 32768 32767 16 bit 40085 BAUD Baud rate setting bits second Only affects RS 485 24 1152 16 bit communication not IRDA Default is 9600 The U2 and the master device must have the same baud settings 40086 Parity setting Only affects RS 485 communication not IRDA 0 2 8 bit 0 parity default 1 odd parity 2 even parity 40087 ADDRESS Modbus address of U2 used by RS 485 and IRDA Each flame 0 247 8 bit monitor must have a unique address 40092 NUMFILES User set limit on the number of files able to be used Default 8 1 8 8 bit 40093 FILE Current active file number Default 0 0 7 8 bit 40095 Flame count from the UV tube sensor only read only 32768 32767 16 bit 40096 Flame count from the sens
8. for file 3 40149 Current output gain for file 4 40159 Current output gain for file 5 40169 Current output gain for file 6 40179 Current output gain for file 7 40184 DISPLAYPAR Various parameters 0 4095 16 bit Dim setting 11 0000 000 between 0 dimmest and 24 brightest Default 24 Scroll type 00 0000 0011 O no pause 1 initial pause 2 end pause 3zinitial end pause Scroll wait 00 0001 1100 between 4 short and 32 long Default 16l Scroll time 00 1110 0000 between 0 faster and 14 slower Default 6 40185 IWSENS Touch wheel sensitivity default is 5 The higher the value 1 63 8 bit the more sensitive the touch wheel will be 40187 IWDATA Output from touch wheel When the wheel is touched the 0 255 8 bit output increases from 0 to 127 as you move your finger clockwise around the wheel The output is 232 when no touched Write a 1 to re calibrate the U2 Other numbers will give an error WARNING DO NOT TOUCH THE WHEEL WHILE RE CALIBRATING 19 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Table 5 Extended Modbus Register Map Continued Register Name Description Minimum Maximum Size 40189 PAGECNT Counts every fourth time power is reset to the U2 read 32768 32767 16 bit only 40190 IRFILTCOUNT IR filter selection for filter 0 read only 32768 32767 16 bit 40191 IR filter selection for filter 1 40192 IR filter selection for filter 2
9. 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 remove 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 5 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 install
10. supervised conditions light off oil igniter if appli cable 11 The viewing head will show in Red IR mode reading between 0 3425 12 Skip this step if the viewing head is already adjusted for gas igniter If necessary and when mounted on swivel mount or adjustable device adjust line of sight for the viewing head for maximum signal Lock up viewing head in this position 13 If selected setting is not correct to recognize oil igniter flame adjust IR gain and filter 14 Start the main oil firing per manufacturer s instructions 15 REPEAT THE ABOVE FOR ALL BURNERS ONE AT A TIME 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS After all burners are in service and boiler load is above 90 perform the following for discrimination tests and adjustments a Turn off the burner b Check if background signal is below Flame Off threshold If not increase Flame Off threshold so the background count is below set point If the back ground flame signals are too high increase IR filter setting to a higher value starting with 2 3 gt 4 gt 5 until background count is below Flame Off thresh old point NOTE gain adjustment c After 1 minute re start burner on pilot and main oil burner d Checkthat U2 recognizes the pilot and main flames If the flame signal is below Flame On threshold lower Flame On threshold below flame on signal e Repeat all tests if any changes are made to Gai
11. 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 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 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 each sensor green UVT Blue SSUV Red IR The upper r
12. 0 used when 2 0 99 8 bit sensors are active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to FilterO through Filter9 read only 40250 to 40259 IRSAVEDGAIN1200 The gain at the IR filter to give a count of 1200 used when 0 99 8 bit 1 sensor is active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to FilterO through Filter9 read only 40260 to 40269 UVSAVEDGAINA4OO The gain at the UV filter to give a count of 400 used when 0 99 8 bit all 3 sensors are active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to FilterO through Filter9 read only 40270 to 40279 UVSAVEDGAIN6OO The gain at the UV filter to give a count of 600 used when 0 99 8 bit 2 sensors are active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to FilterO through Filter9 read only 40280 to 40289 UVSAVEDGAIN1200 The gain at the UV filter to give a count of 1200 used 0 99 8 bit when 1 sensor is active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to FilterO through Filter9 read only 40290 TUBSAVECNT Saved exponential count of the UV tube when the auto 32768 32767 16 bit filter routine was run read only 66 2071 02 20 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS
13. 000 1 O off Wheel 0001 0000 1 O off 40020 HIGHTEMP Stores the highest internal temperature C only the U2 0 261 8 bit has achieved read only 40060 SERIALNUM Factory set identification number read only 32768 32767 16 bit 40061 IDNUM User set identification number 32768 32767 16 bit 40062 OP2HOURS Total run time in 2 hour increments read only 32768 32767 16 bit 40089 KEYTIMEOUT Time in minutes before the touch wheel will disable itself 0 9999 16 bit Default of 60 Writing a 0 will disable this function 40094 MODEL Model number of the U2 unit read only 32768 32767 16 bit 40098 HIGHTIME Time in 2 hour increments when the highest temperature 32768 32767 16 bit occurred read only 40100 FLAMEON Flame On setting for file 0 51 3425 16 bit 40110 Flame On setting for file 1 40120 Flame On setting for file 2 40130 Flame On setting for file 3 40140 Flame On setting for file 4 40150 Flame On setting for file 5 40160 Flame On setting for file 6 40170 Flame On setting for file 7 40101 FLAMEOFF Flame Off setting for file 0 50 3424 16 bit 40111 Flame Off setting for file 1 40121 Flame Off setting for file 2 40131 Flame Off setting for file 3 40141 Flame Off setting for file 4 40151 Flame Off setting for file 5 40161 Flame Off setting for file 6 40171 Flame Off setting for file 7 40102 FFRT FFRT flame failure response time setting for file 0 1 3 8 bit 40112 FFRT flame failure response time setting for file 1 40122 FFR
14. 1 M 701 2 M 701 2 FLG M 701 2 SS M 701 3 M 701 3P M 701 4 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 bolts 3 in NPTF and 2 bolt flanged 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS 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 compatible with the Honeywell FASA fiber optic extension products The S550FOAD S550FOADY 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 CO
15. 40 C to 70 C FM U S CLASS I Il III DIV 1 GROUPS A B D E E amp G T6 Not for use in acidic or aliphatic hydrocarbon atmospheres DIP Il IIl 2 EFG T5 Ta 40 C to 70 C Connector series CLASS Il III DIV 2 GROUPS C D F amp G T5 NI 1 2 ABCD T5 Ta 40 C to 70 C 1 2 AEx nA nC IIC T5 40 C to 70 C IP66 21 AEx tb IIIC T85 C Ta 40 C to 70 C FM Canada XP 1 1 ABCD T6 Ta 40 C to 70 C DIP Il IIl 1 EFG T6 Ta 40 C to 70 C 1 1 Ex d IIC T6 Ta 40 C to 70 C DIP II 2 EFG T5 TA 40 C TO 70 C NE 1 2 ABCD T5 TA 40 C TO 70 C 1 2 EX NA NC IIC T5 TA 40 C TO 70 C IP66 IEC IECEx 13 0023X Ex d IIC T6 Gb IP66 Ex tb IIIC T85C Temperature range 40 to 185 F 40 to 70 C IECEx 13 0023X Ex nA nC IIC T5 Gc IP66 Ex tb T85C Temperature range 40 to 185 F 40 to 70 C Special conditions of use for IECEx as indicated below NOTES Special Conditions for Safe Use 1 Consult the manufacturer if dimensional information on the flameproof joints is necessary 2 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
16. 40193 IR filter selection for filter 3 40194 IR filter selection for filter 4 40195 IR filter selection for filter 5 40196 IR filter selection for filter 6 40197 IR filter selection for filter 7 40198 IR filter selection for filter 8 40199 IR filter selection for filter 9 40200 UVFILTCOUNT SSUV filter selection for filter O read only 32768 32767 16 bit 40201 SSUV filter selection for filter 1 40202 SSUV filter selection for filter 2 40203 SSUV filter selection for filter 3 40204 SSUV filter selection for filter 4 40205 SSUV filter selection for filter 5 40206 SSUV filter selection for filter 6 40207 SSUV filter selection for filter 7 40208 SSUV filter selection for filter 8 40209 SSUV filter selection for filter 9 40210 to 40219 IRSAVEDCNT Saved exponential count of the IR filter when the auto filter 32768 32767 16 bit routine was run Registers correspond FilterO through Filter9 read only 40220 to 40229 UVSAVEDCNT Saved exponential count of the UV filter when the auto 32768 32767 16 bit filter routine was run Registers correspond to FilterO through Filter9 read only 40230 to 40239 IRSAVEGAIN400 The gain at the IR filter to give a count of 400 used when 0 99 8 bit all 3 sensors are active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to FilterO through Filter9 read only 40240 to 40249 IRSAVEDGAING60O The gain at the IR filter to give a count of 60
17. Honeywell U2 Combination Viewing Head and Signal Processors 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 filters are used to re
18. MMOD 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 provide 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 Each sensor allows independent adjustment for gain For flicker based sensors there is also a high pass filter setpoint 66 2071 02 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
19. T flame failure response time setting for file 2 40132 FFRT flame failure response time setting for file 3 40142 FFRT flame failure response time setting for file 4 40152 FFRT flame failure response time setting for file 5 40162 FFRT flame failure response time setting for file 6 40172 FFRT flame failure response time setting for file 7 401038 TIMEDELAY Time Delay setting for file O 0 3 8 bit 40113 Time Delay setting for file 1 40123 Time Delay setting for file 2 40133 Time Delay setting for file 3 40143 Time Delay setting for file 4 40153 Time Delay setting for file 5 40163 Time Delay setting for file 6 40173 Time Delay setting for file 7 40104 UVTGAIN UV tube gain setting for 0 0 7 8 bit 40114 UV tube gain setting for file 1 40124 UV tube gain setting for file 2 40134 UV tube gain setting for file 3 40144 UV tube gain setting for file 4 40154 UV tube gain setting for file 5 40164 UV tube gain setting for file 6 40174 UV tube gain setting for file 7 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Table 5 Extended Modbus Register Map Continued Register Name Description Minimum Maximum Size 40105 UVSSGAIN Solid state UV sensor gain setting for file 0 0 7 8 bit 40115 Solid state UV sensor gain setting for file 1 40125 Solid state UV sensor gain setting for file 2 40135 Solid state UV sensor gain setting for file 3 40145 Solid state UV sensor gain sett
20. The viewing head will show in Green UV mode reading between 0 3425 12 If necessary and when mounted on swivel mount or adjustable device adjust line of sight for the viewing head for maximum signal Lock up viewing head in this position 13 If selected setting is not correct to recognize igniter flame adjust UV gain 14 Start the main gas firing per manufacturer s instructions 15 REPEAT THE ABOVE FOR ALL BURNERS ONE A TIME After all burners are in service and boiler load is above 90 perform the following for discrimination tests and adjustments a Turn off the burner b Check if background signal is below Flame Off threshold If not increase Flame Off threshold so the background count is below set point c After 1 minute re start burner on pilot and then main gas fuel d Check that the U2 recognizes the pilot and main flames If the flame signal is below Flame On threshold lower Flame On threshold below flame on signal e Repeat all tests if any changes are made to Gain Flicker set point Flame On and Flame Off Threshold Go to Flame ON menu Set this to 800 as an initial value NOTE Above is a simplified version of discrimination adjustments Vessels equipped with a large number of burn ers T fired units and cross fired boilers will require several adjustments including use of multiple files for obtaining the required discrimi nation Manual Configuration for Oil Firing App
21. 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 example 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 125 cable colors are referenced for the Connector CAB22 wires 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS NOTE Ifthe 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 Fu
22. V view ing head sensors 23 Setup 1 Ensure the Uniscan 2 signal processor is fully opera tional 2 While performing the proof test disconnect or disregard the signal processor outputs so that any outputs due to testing do not affect the overall safety system and potentially cause a hazardous situation 3 Record all previously entered user programmable set tings so that you can restore them to their desired val ues after the proof test 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Tests 1 Remove power to the signal processor and using a multimeter ensure there is no continuity between the relay common and self check wires see chart below for color codes 2 Reapply power to the signal processor and using a multimeter ensure continuity between the relay com mon and self check wires 3 Use a light source to generate a flame on condition and using a multimeter ensure continuity between the relay common and flame relay wires 4 Remove any light source to generate a flame off condi tion and using a multimeter ensure there is no continu ity between the relay common and flame relay wires after the FFRT Flame Failure Response Time has Change one of the settings of the signal processor and store the changed setting Remove power to the signal processor for 10 seconds Restore power to the signal processor and ensure the stored value has remained unchanged Use your light source to gen
23. a GAIN SS UV FILTER SS UV GAIN IR GI32 2400 4800 9600 19200 38400 57600 115200 GAIN FLAME i TIME DELAY LAST MENU FFRT Paner Look 9 LOCK 0000 MEL 7 i FLAME OFF TIME OUT MIN 0000 1 oe 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 Temperature Gain SSUV Displays the processor temperature Tapping enter will bring NOTE If sensor is not available in your model then no the user into the submenu which will allow changes between menu item will exist for sensor setting See displaying Celsius or Fahrenheit display the software version Table 1 on page 2 to determine which sensors or display the number of hours the unit has been in operation are active in your U2 model Displays the solid state UV gain adjustable 0 99 The default Gain UVTron value is 75 NOTE If sensor is not available in your model then menu item will exist for sensor setting See Gain IR nl d 22 which sensors NOTE If sensor is not available in your model then no y j menu item will exist for sensor setting See Displays the Uvtron gain adjustable 0 99 The default value Table 1 on page 2 to determine which sensors is 32 are active in your U2 mod
24. actory for assistance with unlocking the panel At that point the user can reset or deactivate the password Once the appropriate code is entered and the Panel Lock sub menu accessed it is automatically disabled The default setting for the Panel Lock feature is disabled OFF The Time Out sub menu allows the user to enter a time allotment from 0 9999 minutes in which to allow adjustments of settings before the panel returns to monitoring mode and the touch wheel disables itself if there is no menu activity Panel Time Out helps prevent accidental changes to parameter settings Once the panel has timed out to modify settings simply enter 1234 as prompted by the display The Panel Time Out is by default 9999 minutes NOTE If the display shows 9999 it can also indicate saturation of the UVSS and or IR sensor If the problem persists after checking the panel lockout feature and resetting as described above refer to the Troubleshooting section of this document for instruction Auto Gain NOTE Auto Gain and Auto Filter cannot be used with U2 1016 PF model Routine that automatically determines the gain for the IR and SSUV sensors that are on necessary to generate a total flame count of approximately 1200 Be sure that all desired sensors are turned on gain of at least 1 before the routine is run U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Auto Filter Routine that automatically determines the optimum filte
25. ailure which has the potential to put the safety related system in a hazardous or fail to function state Safety Related System A system that implements the required safety functions required to achieve or maintain a safe state and is intended to achieve on its own or with other systems the necessary safety integrity for the required safety functions Safety Function Defined function which is performed by a safety related system with the aim of achieving or maintaining a safe state for the plant in respect of a specified hazardous event Proof Test Periodic test performed to detect failures in a safety related system so that if necessary the System can be restored to an as new condition or as close as practical to this condition MTTR Mean Time To The average duration required for restoration of operations after a failure Restoration Asa Rate of safe detectable failures per one billion hours For example if Asa 3000 then it is estimated that there will be about 3000 safe detectable failures during every one billion hours of operation For 3000 this is about one safe detectable failure every 38 years Rate of safe undetectable failures per one billion hours Add Rate of dangerous detectable failures per one billion hours Adu Rate of dangerous undetectable failures per one billion hours HFT Hardware Fault Tolerance System Architecture Specific configuration of hardware
26. ation 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 flame emits As well sour gas H5S 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 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 s
27. djustment to obtain the required discrimination In general flicker filter adjustment works better for discrimination than Above is simplified version of adjustment Ves sels equipped with a large number of burners fired units and cross fired boilers will require For vessels equipped with gas igniters follow setup procedure described above For best discrimination two to three files may be required to accommodate three different fuel firings k oh eh N 99 14 25 26 Establish igniter flame as described above Start warm up oil burner Go to IR menu and adjust gain setting to 50 If equipped with UVSS sensor adjust gain to 0 Adjust IR filter to 1 and UVSS filter to 9 Go to milliamp output gain and adjust to 50 Go to Flame ON and adjust to 1200 Go to Flame off and adjust to 800 Go To FFRT and adjust to 3 seconds Go to Time Delay and adjust to zero 0 seconds With oil firing at the minimum on the first burner adjust gain up or down to be just above 1200 One by one light off the remaining burners and adjust gain as necessary When all mill burners are firing oil start pulverizer sys tem Adjust mill output to minimum coal flow as recommend by the manufacturer If the signal is still above Flame On for all burners asso ciated with the mill no further adjustment will be neces sary Repeat for at least one more mill by establishing gas igniters a
28. e voltage input to the File Select wire purple or black 9 Refer to Table 3 When the file select line is grounded the file selection O 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 ground 66 2071 02 When connected to 24 Vac the file selection 1 The other means of selecting and activating a file is via the Modbus RTU interface using register address 40093 Modbus interface can be accomplished via FlameTools software or another Modbus RTU interface Panel Tapping the ENTER STORE button when PANEL appears on the menu screen will provide access to two sub menus Panel Lock and Time Out The Panel Lock sub menu enables or disables a security feature that locks the U2 interface preventing any parameter modifications To enable this feature a special 4 digit access code is required which is available from the factory It requires that same code to unlock allowing parameter changes after it has been enabled Once the Panel Lock feature is enabled by entering the code the panel is locked out immediately from further adjustment If a user attempts to modify any U2 parameters while the Panel Lock feature is enabled a lockout message will appear on the display The display will show Bad upon entry of an incorrect access code If the password is forgotten or lost the user must contact the f
29. el Displays the IR gain adjustable 0 99 The default value is 75 Filter SSUV 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 Displays the current solid state UV high pass filter adjustable 0 9 The default filter is 3 See the filter cutoff frequencies in Hertz in the table below FILTER 1 2 3 4 5 6 7 8 9 o HERTZ 16 24 33 52 75 100 155 215 300 7 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Filter IR 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 Displays the current IR high pass filter adjustable 0 9 The default filter is 3 See the filter cutoff frequencies in Hertz in the table below FILTER 0 1 2 3 4 5 6 7 8 9 HERTZ 9 16 24 33 52 75 100 155 215 300 mA Out Displays the current output gain adjustable 0 99 or OPEN if the current output is open The default value is 32 Flame On Displays the flame on value adjustable 51 3425 The flame on value can not be adjusted below the flame off value When the flame count is greater than the flame on value for greater than the time delay value the flame relay will energize The default val
30. elay is not energized To reduce the chance of a false flame on condition due to welded Flame Relay contacts it is recommended that the user wire the Flame and Self Check Relays in series Also as another added safety feature neither relay can be driven by a simple continuously high or continuously low signal which could potentially be caused by a fault Each relay must be driven by an alternating signal of the proper frequency and duty cycle from the processor Proof Test Interval The Proof test must be conducted every 1 to 5 years This range is given to allow for the test to be performed during the normally scheduled burner shutdown period It is the responsibility of the user to perform the proof test in the specified time frame The following diagram for the U2 1010 shown for example presents the dependence of the PFDayg on the proof test interval The PFDayg increases as the proof test interval increases 2 50E 2 00E PFD AVG 1 50 94 1 00 5 00 5 0 00 9 0 1 2 3 4 TIME YEARS 5 6 7 8 9 10 M34953 Fig 11 1010 PFDayg over time Proof Test Procedure EQUIPMENT Powered Uniscan 2 signal processor Multimeter able to take voltage and resistance measurements 22V DC to 26V DC power supply Light source capable of generating a flame on condition Generally an incandescent bulb will work for IR viewing head sensors and a deep UV light or flame will work for U
31. erate flamecounts of between 1200 and 2600 in the signal processor Note the flamecount a Increase the gain and store the setting Ensure the flamecount increased b Decrease the gain and store the setting Ensure the flamecount decreased Restore all original settings as recorded in Setup and reconnect the signal processor to the safety system elapsed Product Decommissioning 5 Measure the current draw of the U2 and ensure it is less than 120 mA When required decommissioning of the Uniscan 2 flamescanner should be performed in accordance with requirements of the overall safety system Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Honeywell U S Registered Trademark Golden Valley MN 55422 2013 Honeywell International Inc 66 2071 02 M S Rev 07 13 customer honeywell com Printed in United States
32. figuration This operation should be carried out under supervised conditions and limited to minimum time Remove bypasses as soon as configuration and setup is completed Adjust all sensor gain settings to 50 Go to Flame ON menu Set this to 800 Go to Flame OFF menu Set this to 600 Go to the AUTO GAIN menu tap enter scroll to yes then tap enter again 5 Wait as instructed by the display Bom After the burner is in service and boiler load is above 9096 perform the following for discrimination tests and adjustments 6 Gotothe AUTO FILTER menu tap enter 7 Turn off the burner being monitored as instructed by the display 8 Tap enter scroll to yes then tap enter again 9 Ensure the current flame count is less than the FLAME OFF value 10 Restart the burner being monitored 11 Ensure the current flame count is greater than the FLAME ON value MAINTENANCE The UV tube sensor has a limited lifespan Under extreme conditions the lifespan can be as low as 10 000 hours However in the most favorable conditions the lifespan is 50 000 hours or more The service life of the UV tube sensor is considered terminated when the sensitivity becomes lower then 50 of the initial value A monthly sensitivity check is suggested to determine if the UV tube sensor s life is terminated The reading of the U2 digital display should be compared to the initial reading of the unit when it was installed Ensure similar burner
33. ight 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 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 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS TWO BUTTON INTERFACE BACK AND ENTER HONEYWELL U2 PROGRAMMING EVERYTHING ELSE CAN BE DONE BY SCROLLING INTERFACE TECHNIQUES INTERFACE MODES TAP PRESS FINGER ON BUTTON AND REMOVE FLAME DISPLAY TAP BACK MAY REQUIRE MORE THAN ONE TAP SCROLL PRESS FINGER GLASS AND MOVE FINGER IN CIRCLES TWIRL HELP TAP OR FROM DISPLAY RAMP HOLD FINGER ON THE OR BUTTON LAST MENU ENTER MOVE THROUGH MENU WITH TAPS OR SCROLLS ASUBMENUS A s ADJUST MODE TAP ENTER FROM ADJUSTABLE MENU ITEM 7 FACTORY DEFAULT E ee CHANGE VALUE USING ANY TECHNIQUE L NOYES MODE CHANGE TO YES AND TAP STORE HOURS FILE DEFAULT lt eFoR c READONLY r 7 7ST RS485 MI WRITE ONLY DEFAULT 0 gt 20 OR 4 gt 20 ADDRESS GAIN TUBE UV GT32 3425 C
34. ignal 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 sighting 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 sy
35. ing for file 4 40155 Solid state UV sensor gain setting for file 5 40165 Solid state UV sensor gain setting for file 6 40175 Solid state UV sensor gain setting for file 7 40105 UVSSFILT Solid state UV sensor filter setting for file 0 0 7 8 bit 40116 Solid state UV sensor filter setting for file 1 40126 Solid state UV sensor filter setting for file 2 40136 Solid state UV sensor filter setting for file 3 40146 Solid state UV sensor filter setting for file 4 40156 Solid state UV sensor filter setting for file 5 40166 Solid state UV sensor filter setting for file 6 40176 Solid state UV sensor filter setting for file 7 40107 IRFILT IR sensor filter setting for file 0 0 7 8 bit 40117 IR sensor filter setting for file 1 40127 IR sensor filter setting for file 2 40137 IR sensor filter setting for file 3 40147 IR sensor filter setting for file 4 40157 IR sensor filter setting for file 5 40167 IR sensor filter setting for file 6 40177 IR sensor filter setting for file 7 40108 IRGAIN IR sensor gain setting for file 0 0 7 8 bit 40118 IR sensor gain setting for file 1 40128 IR sensor gain setting for file 2 40138 IR sensor gain setting for file 3 40148 IR sensor gain setting for file 4 40158 IR sensor gain setting for file 5 40168 IR sensor gain setting for file 6 40178 IR sensor gain setting for file 7 40109 OUTPUTGAIN Current output gain for file 0 0 7 8 bit 40119 Current output gain for file 1 40129 Current output gain for file 2 40139 Current output gain
36. ject signals that are from background radiation Contents rei o PPM 1 Application rec 1 Specifications 2 Approvals qq aas 3 Installation sin a 3 iraire saraa 5 Operation rm 6 Troubleshooting 2 9 Communicating Through Modbus 9 Manual Setup 13 Automatic Setup 14 Maintenance 15 Safety 22 Safety Function of the Uniscan 2 23 Proof Test Procedure 23 Proof Test Interval eseese 23 Product Decommissioning 24 66 2071 02 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 X U2 1010 PF 050 X X X X U2 1010 PF 100 X X X X U2 1012 X X U2 1012 PF X X U2 1016 X X U2 1016 PF X 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 ft 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 rela
37. lating 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 cable 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 3 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 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS 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
38. lications with Multiple Burners CAUTION ALL ADJUSTMENTS SHOULD BE CARRIED OUT BY A QUALIFIED PERSON BMS interlock s may require temporary bypass during configuration This operation should be carried out under supervised conditions and limited to minimum time Remove bypasses as soon as configuration and setup is completed Main oil control valve may include bypass PRV Make sure at least first burner is started up at minimum firing In some cases more than one burner may be started up at low fire depending upon bypass PRV Follow manufacturer s guidelines in controlling fuel flow as additional burners are brought into service For vessels equipped with gas igniters follow setup procedure described above For best discrimination two channels may be required to accommodate two different fuels firing As an example after the gas igniter is established introduce oil to the burner and change the file number selection 1 Goto menu for IR sensor 2 Adjust gain settings to 50 3 Adjust Filter set point to 1 4 If applicable go to UVSS menu and set UVSS gain to zero With zero gain flicker frequency filter need not be adjusted 5 Goto Milliamp output gain GM and set at 50 6 Goto Flame ON menu Set this to 800 as an initial value 7 Goto Flame OFF menu Set Flame OFF 600 tial value 8 Goto Flame Failure Response Time FFRT Select 3 seconds 9 Goto Time delay and select 0 seconds Under
39. n Flicker set point Flame On and Flame Off Thresh old NOTE several adjustments including use of multiple files for obtaining the required discrimination Manual Configuration for Coal Firing Applications with Multiple Burners In general coal firing units are equipped with several coal mills Each coal mill may supply pulverized coal to several burners For units equipped with a gas igniter and gas warm up burners two dedicated files for each U2 are highly recommended One file should be dedicated to the gas igniter and warm up gas burners and the other to main coal For units equipped with a gas igniter and oil warm up burners two files are recommended one file for the gas igniter and the other for the oil warm up burners and main coal firing NOTE Alternately 3 files may be used however only two files may be selected via the File Select 0 24 Vdc input on the U2 The third file must be selected via a Modbus RTU interface Refer to Table 3 and the FILE section of this document N CAUTION ALL ADJUSTMENTS SHOULD BE CARRIED OUT BY A QUALIFIED PERSON BMS interlock s may require temporary bypass during configuration This operation should be carried out under supervised conditions and limited to minimum time Remove bypasses as soon as configuration and setup is completed 66 2071 02 With IR sensor two adjustments are available gain and flicker set point Both may require a
40. nd oil burners for the mill When first Mill is established turn off the warm up burn ers one by one If the signal falls below the Flame Off point adjust gain to higher value so that signal remains above Flame Off point After all oil burners and igniters are off adjust mill coal flow as per manufacturer recommendations Repeat for all mills Go back to first mill reduce coal flow to minimum Establish igniter and oil burners Stop the mill as per manufacturer s recommendations Sweep the mill of coal and then shutdown oil burners if igniters are in service turn off igniters If the flame signal from the back ground is above the Flame Off point increase Flame Off set point and or increase filter frequency set point Make adjustment to all units associated with this mill RE ESTABLISH THE MIL AND REPEAT THE ABOVE FOR THE REMAINING MILLS ONE AT A TIME Above is simplified version of adjustment Ves sels equipped with a large number of burners T fired units and cross fired boilers will require several adjustments including use of multiple files for obtaining the required discrimination AUTOMATIC SETUP NOTE For single burner systems only Multiple burners require several manual adjustments to obtain the proper discrimination U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS N CAUTION ALL ADJUSTMENTS SHOULD BE CARRIED OUT BY A QUALIFIED PERSON BMS interlock s may require temporary bypass during con
41. nd vertical head mounting example Mounting Examples applicable to both Fig 7 and Fig 8 Due to the heat and electrical insulation requirements of the U2 it is highly recommended to use the Honeywell locking coupler adapter and locking coupler accessories for mounting attached directly to the U2 In order to maintain the specified U2 temperature the minimum distance to mount the U2 from the sight pipe is 2 3 inches 5 8 cm using the R 518 PT12 L and the R 518 CL12 HTG locking coupler Cooling air should be provided via a Y or in between the locking coupler and the sight pipe to reduce conducted heat and to keep the sight pipe and U2 lens clean of debris and dirt Refer to the Mounting and Sighting section on purge air requirements For electrical isolation reasons the purge air line should be installed using an insulating material such as a rubber hose in between the purge air line and the viewing head Note that an extension pipe may be required to locate the U2 further from the burner front plate to avoid high temperatures 17 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Table 5 Extended Modbus Register Map Register Name Description Minimum Maximum Size 40017 SENSORS Bit mask shows populated sensors model dependent 0 255 8 bit read only UV tube 0000 0001 1 O off IR sensor 0000 0010 1 O off SSUV 0000 0100 1 O off 0000 1
42. or only read only 32768 32767 16 bit 40097 SSUVFLAME Flame count from the solid state UV sensor only read only 32768 32767 16 bit 66 2071 02 10 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS BOILER 1 ADDRESS ADDRESS BOILER 3 MODBUS MASTER CONTROL FOR PF VERSION CAB 19 WHITE BROWN FOR QD VERSION CAB 22 WHITE YELLOW NOTES A CONVERTER MAY BE NECESSARY FOR COMMUNICATION WITH THE MODBUS MASTER CONTROL USE SHIELDED CABLE FOR COMMUNICATION WIRING M33521 Fig 3 Typical Communication Wiring and Recommended Addressing Of Of toa Df RoB PRODUCT SIDE A TDA COMMOD USB TO RS422 485 CONVERTER B TDB CONVERTER U2 CONNECTOR U2 PIPE FITTING iae CONNECTOR DESCRIPTION CAB22 CAB19 TDA INPUT OUTPUT YELLOW BROWN TDB DATA B INPUT OUTPUT WHITE WHITE E GND RDA DATAA INPUT OUTPUT RDB DATAB INPUT OUTPUT GND GROUND SHIELD DRAIN WIRE SELECT THE APPROPRIATE DIP SWITCH SETTINGS FOR RS 485 COMMUNICATION PER THE VENDOR S INSTRUCTION SHEET SOFTWARE DRIVERS MAY BE DOWNLOADED FROM B amp B ELECTRONICS WEBSITE Fig 4 Wiring of RS422 485 to USB Converter to U2 66 2071 02 U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS 66 2071 02 1 25 NPT 1 95 CONNECTION 2 29 32 73
43. r SSUV sensor persists for greater than 1 second the flame Relay will open and the U2 will lock out with an error code code 1 for SSUV saturation and code 8 for IR saturation When a lockout occurs the U2 must be reset to continue normal operation This is accomplished by pressing the enter key twice at the front panel Lockout Message If a lockout message appears on the screen the user has attempted to access the U2 menus while the PANEL Lock feature is enabled The Lock feature requires a special 4 digit code for access and modification which is available from the factory If the password is forgotten or lost the user must contact the factory for assistance with unlocking the panel Refer to the Panel section of this manual and or contact the factory for assistance Bad Message If the display shows Bad upon entering the access code for the PANEL Lock feature it means the access code that was just entered is incorrect Refer to the Panel section of this manual for further details NOTE Refer to Grounding and Shielding on page 3 for further troubleshooting help in regards to proper grounding and shielding techniques COMMUNICATING THROUGH MODBUS Modbus RTU communication protocol allows the U2 to communicate with any process controllers or human Interface host computers that support this protocol When communicating through Modbus use the following register map to access and control the U2 9600 baud
44. r for the SSUV and IR sensors This routine should only be done after the AUTO GAIN routine NOTE While using the Auto Gain and Auto Filter modes the system will be adjusting to the firing condi tions at the time of implementation This condi tion should be carefully selected to ensure discrimination through complete load changes from minimum to maximum and from cold burner boiler startup to hot burner boiler startup Default Tapping will access the file default and factory default sub menus File Default Changes the settings of the current file being adjusted see FILE menu Factory Default Changes all settings to factory default settings Communications security and all file settings will have to be reset so only initiate factory defaults when absolutely necessary TROUBLESHOOTING 9999 on Display 9999 on the U2 display can indicate saturation of the UVSS and or IR sensor in addition to the PANEL Time Out sub menu being accessed First check to see if the PANEL Time Out sub menu has been accessed and exit the menu as described in the Panel section of this document If the problem still persists then sensor saturation is likely Decrease the gain for UVSS and or IR sensor to 0 then gradually increase the gain level s to a suitable level to prevent saturation In rare cases an orifice disk may be required Refer to the ACCESSORIES section of this document for part numbers If saturation of the IR o
45. stem 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 radically 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 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
46. surface should only be done with a damp cloth 3 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 aliphatic 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 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 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
47. ture 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 ground M33313 Fig 1 Connector Pinout NOTES J tis 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 66 2071 02 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 insu
48. ue level is 800 Flame Off Displays the flame off value adjustable 50 3424 The flame off value can not be adjusted above the flame on value When the flame count is less than the flame off value for greater than the FFRT value the flame relay will de energize The default value level is 600 Flame off is usually set to approximately 2 3 the value of flame on however this value should never be less than 100 FFRT The flame failure response time is the time it takes for the flame relay to de energize after the flame count falls below the flame off value FFRT flame failure response time can be set to 1 2 or 3 which will not exceed 2 3 or 4 seconds respectively The factory default value is 1 second Time Delay The time it takes for the flame relay to energize after the flame count rises above the flame on value Time delay can be set to 0 1 2 or 3 The factory default value is 3 seconds File The U2 is able to store up to 8 different file configurations fileO file7 Settings that are stored include UVT gain SSUV gain IR gain SSUV filter IR filter mA output gain flame on flame off File 0 is default NOTE The U2 touch wheel interface allows access to all eight files for changing parameters however the file selection cannot be changed via the U2 interface it can only be changed via the File Select wire input or modbus Only two files 0 and 1 may be automatically activated by changing th
49. y contacts SPST 2 A 30 VDC or 250 VAC Ambient temperature 40 to 70 C 40 to 158 F Enclosure 66 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 2071 02 Ten 10 flicker frequency filters for solid state UV and IR sensor model dependent Gain selection Eight 8 different file configurations Resettable fuses De 9 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 f 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 APPROVALS The U2 is a FM approved combustion safeguard and flame sensing system The U2 also carries the following approvals U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS Table 2 Approvals Market Pipe fit series PF Must be sealed at the enclosure XP 1 1 ABCD T6 Ta 40 C to 70 DIP Il Ill 1 EFG T6 Ta 40 C to 70 C 1 1 AEx d IIC T6 Ta 40 C to 70 C 21 tb IIIC T85 C Ta
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