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p522 application manual.p65

1. 21 temperature 13 32 22 26 technical information 33 34 hydrogen e 27 time delay sssssseesssresssressrressseeen 12 16 26 29 32 I time delay OM u 16 32 incandescent 20 21 22 23 24 U information EN EE 31 ultraviolet UV tube 10 19 20 23 WALCO 16 26 V Su Q 18 19 tai visible 7 20 IRIS cable sannnnnnnunnunnnnnnnunnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnne 8 19 viewing heads multiple ad tote ME 14 29 L W lead sulfide PDS 20 wiring viewing head plug iieii 6 8 lens 13 15 20 22 23 24 25 wiring viewing head to P522 5 Rev April 2000 Page 39 IRIS MODEL 522 APPLICATION MANUAL NOTES Page 40 IRIS MODEL P522 APPLICATION MANUAL ADDENDUM 2 CHANGES FOR P522AC SIGNAL PROCESSOR The P522AC is an upgrade to the P522 Signal Processor It features universal AC input power higher current rating for the relay contacts a 24V OUT terminal to power the SEL inputs and compatibility with
2. 31 COMMUNICATING WITH MODICON PLC 32 COMMUNICATION WITH HUMAN INTERFACE HOST COMPUTER 32 RS 232 to RS 422 CONVERSION 32 SETTING ADDRESSES 32 TECHNICAL HELP gt gt gt 33 FIGURE 13 SPECIFICATIONS 34 FIGURE 14 MODEL P522 FRONT PANEL 35 FIGURE 15 MODEL P522 SIDE VIEW 36 FIGURE 16 S5XX VIEWING HEAD DIMENSIONS 36 FIGURE 17 IR VIEWING HEAD LOCATION 37 FIGURE 18 UV VIEWING HEAD LOCATION 37 FIGURE 19 OPPOSED FIRED VIEWING HEAD SIGHTING eee 38 FIGURE 20 VIEWING HEAD MOUNTING 38 NDE 39 IRIS MODEL P522 APPLICATION MANUAL Figure Index FIGURE 1 P522 REAR MOTHERBOARD 4 FIGURE 2 WIRING OF VIEWING HEAD 6 FIGURE 3 WIRING AND ASSEMBLY VIEWING HEAD 7 FIGURE 4 POWER SUPPLY TABLE TT T 9 FIGURE 5 SET POINTS enipe era ieee eE 11 FIGURE 6 REMOTE METER ANALOG OUTPUT 12 FIGURE 7 VEWING HEAD CROSS REFERENCE TABLE 13 FIGURE 8 CUTOFF FREQUENCIES 14 FIGURE 9 ORIFICING SIGNAL REDUCING CHARACTERISTICS OF DISCS 23 FIGURE 10 VIE
3. ee 215Hz FIGURE 8 CUTOFF FREQUENCIES Page 14 UV which doesn t have one be switched to a higher position This reduces the low frequency flicker reaching the detector so that the set points can be adjusted to affect flame discrimination The four cutoff frequencies are outlined in Figure 8 A higher filter position creates a narrower bandwidth causing an overall reduction in the flame signal how ever the ratio of flame ON to flame OFF may be im proved by properly setting this four position filter Note the readings on the four digit display when mak ing these adjustments The four digit number is an absolute indication of signal strength and is not af fected by changing the gain of the analog output MULTIPLE VIEWING HEADS This system can accommodate the parallel operation of two viewing heads with one signal processor The flame signals will be additive possibly requiring a lower sensitivity setting A word of caution about this type of operation the unwanted background with the burner flame out will also be additive possibly causing a discrimination problem in multiburner applications Note The S5xx series viewing heads cannot be wired in parallel Another variation is to switch the flame signal ON and OFF from each viewing head For example one viewing head can be used for the igniter and the other for the main burner While proving flame from the ig niter the main burner signal circ
4. RMT CHAN 262 9 5 56 9 5 METER SEL SEL VH B TIN A E AN LI DA ID L D 0 SIV GOSS QD 15 May 2008
5. FIGURE 4 POWER SUPPLY TABLE FACTORY STOCKED POWER SUPPLIES Power supplies are readily available from the fac tory for the P522 modules The 30 watt power sup ply will support up to six or seven P522 modules with one viewing head each The 50 watt power supply will power up to six or seven P522 modules IRIS MODEL P522 APPLICATION MANUAL with one viewing head each And the 100 watt power supply will support up to fifteen P522 modules with one viewing head per each 100 watt These switch ing type power supplies are efficient and very com pact To obtain the size and weight of the power supplies contact IRIS Systems Inc Each power supply can be either rail mounted or panel mounted and it is up to each end user to deter mine their installation preferences and requirements We recommend that not more than four P522 signal pro cessors be supported by one 26 VDC power supply For instance four P522 processors with one viewing head each equals a total of 26 watts a relatively small power supply particularly if an efficient switching type is used Other possible combinations can be used for in stance the battery backup terminal could be used for redundancy However care must be taken with these redundant schemes to make sure that failure of the primary power supply won t affect the backup power supply as well REDUNDANT POWER SUPPLIES It may be more economical to use larger capacity power supplies for
6. ing head Note that the flame signal wire going to terminal SIG is shielded and the shield is terminated at both ends of the cable SIG GND P522 24VDC SHUTTER DRIVE CONNECT SHIELD TO TERM 3 USE SHRINK TUBING FIGURE 2 WIRING OF VIEWING HEAD Page 6 SIGNAL IRIS MODEL P522 APPLICATION MANUAL IRIS CABLE 3 CONDUCTORS PLUS 1 COAX 3CONDUCTORS 16 AWG 19 STRAND INSULATED WITH CROSSED LINKED POLYETHYLENE 017 THK COLORS BLACK RED GREEN 1 16 AWG 19 STRAND INSULATED WITH CROSSED LINKED POLYETHYLENE 017 THK COLOR WHITE 36 AWG BRAIDED SHIELD 90 COVERAGE WITH 012 THK JACKET COLOR BLACK CABLED POLYPROPYLENE FILLERS FOR ROUNDNESS JACKET CROSSED LINKED POLYETHYLENE GROMMET FLAT WASHER STRIP 3 8 TYPICAL CABLE ENTRY NUT CABLE N x m ANNAN CABLE PREPARATION I 2 4 7 7 SHIELD CABLE CLAMP INSULATE SHIELD WITH SHRINK TUBING LEAVING 3 8 STICKING OUT CONNECTOR WITH REAR COVER REMOVED CONNECTOR JACKSCREW FINAL ASSEMBLY Optional LTA Adapter CABLE IS SHOWN WITH SHIELD ALREADY REMOVED FROM WHITE WIRE FIGURE 3 WIRING AND ASSEMBLY VIEWING HEAD Page 7 IRIS MODEL P522 APPLICATION MANUAL A source impedance resistor is required when using the P522 module with 5550 viewing head This resistor should be 330 ohm factory installed for viewing head cable runs up
7. CHANGES FOR P522DC SIGNAL PROCESSOR The P522DC is an upgrade of the P522 Signal Processor It features higher current rating for the relay contacts and is compatible with all SSXX viewing heads The front panel and the internal connections are shown on the right All the user features of the earlier P522 are maintained plus the self resetting fuses front panel lettering and the source impedance resistor requirement of Addendum 1 P522DC SPECIFICATIONS ELECTRICAL Main Power 22 26 VDC 130mA plus 100mA View Head Battery Power 22 26 VDC 130mA Battery lt Main V plus 100mA View Head ENVIRONMENTAL Ambient Temp 0 C to 52 C CSA Rating 0 Cto 60 C FM Rating OUTPUTS Flame Relay 2 Form C Contacts Self Checking Relay 1 Form C Contact Contact Ratings 5A 30VDC 125VAC and 277VAC Analog Signal 0 19 8mA or 4 19 8mA 360 ohms max resistance Power to View Heads fused with self resetting fuses at 0 25A INPUTS Isolated Chan Select Coil for V H Select SERIAL COMM RS 422 baud rate Cable 7 5 30 VDC Input 3900 ohms 17 48 VDC 24 VDC nom 4800 to 38400 user selected Two twisted pairs IRIS MODEL P522DC FLAME C gt D Cy NT ON 555 FLAME NO CAL YES 4 19 LOCKOUT mL SELF CHECK VIEWING HEAD CABLE When using 55 view heads in ordinary locations use IRIS C 328 cable o
8. There is 20 per cent probability that lock out will occur because of the duty cycle of the self check function 200 mSEC on and 800 mSEC off The other viewing heads the 5506 S511 do not in corporate the power monitoring shutdown function and will not cause lockout condition These design precautions ensure that there will never be an unsafe situation created by abnormal line power 115 VAC conditions The 26 VDC power is very unlikely to come on gradually but if this did occur the P522 would not get a proper reset So there is another function in the 87 52 processor used in the P522 implemented by circuitry and software that causes the P522 to appear dead i e the front panel will be dark and to stay this way until the power is recycled in an abrupt manner initiating the reset SET POINTS There 10 set points stored in memory in the P522 divided into two equal sets A and B 4 DIGIT NUMBER 0001 2999 4 DIGIT NUMBER 0000 2999 SET POINT FLAME ON FLAME OFF GAIN SET 2 DIGIT NUMBER 00 99 1 DIGIT NUMBER 1 2OR3 1 DIGIT NUMBER 0 1 20r3 FIGURE 5 SET POINTS F F R T TIME DELAY ON IRIS MODEL P522 APPLICATION MANUAL To see what the current set points are simply push the desired button For instance to determine the current FLAME ON set point press the FLAME ON button The set point will be displayed on the readout for about four seconds then return to normal The set points di
9. 4 n 1 1284 and dia 1 1284 X 2 2 2568mm or dia 0 0889 inches Using the same two inch focal length lens and mak ing this diameter equal to d we get 0 2 tan d 2F 6 2 tan 0 0889 2 X 2 0 2 2 545 The equation for angel of view of a camera lens is derived from where tan 0 2 R L and R L tan 0 2 The diameter d 2Ltan 6 2 which is the same equation as before with F L but now d will be the diameter instead of the diagonal If you use 2 545 then the above equation re solves to dia L 0444 s om _ FIGURE 10 VIEWING HEAD ANGLE OF VIEW DISTANCE AND DIAMETER 192 IRIS MODEL P522 APPLICATION MANUAL The table in Figure 10 shows the various distances L versus the diameter of the circle of view for the 5512 viewing head APPLICATION OF IRIS VIEWING HEADS It is impossible to provide steadfast rules for each type of viewing head and what application it should be used for The applications are becoming more difficult because of the wide range of fuels being used in addition to recent changes in burner design to comply with clean air standards The 5506 UV viewing head will always result in ex cellent discrimination between burners The key fac tor in using the UV type detector is obtaining con sistent and reliable signal under all conditions UV radiation is very susceptible to being absorbed and blocked by non hydrocarbon elements and unburned fuel as explain
10. 5509 has to do with linearity The non linearity of the Si channel due to the AGC circuit has already been explained This AGC is used upstream of the 25 turn potentiometer so you have no control over this action except for the viewing head sighting or for using orificing to change the amount of signal reaching the photodetector On the other hand the PbS channel upstream from its potentiometer is lin ear for low to medium brightness flames i e no distortion of the flame signal occurs with regard to amplifier saturation signal clipping or nonlinear amplification AGC as with the Si channel However saturation will occur with the PbS channel on high brightness flames You can detect this by observing the digital display reading for boiler load conditions as they vary from low to high If there is not much of signal increase between low load and high load then the PbS detector is saturating For example if the burner flame signal on oil reads 1950 under low load condi tions and reads 2000 on high load con ditions you can be sure that the PbS de tector is saturating To resolve this condition reduce the signal bright ness by orificing see next section ORIFICING The orifice disc installed in the flange is located immediately in front of the lens and will reduce the amount of signal radiation the same way camera aperture reduces the amount of light As mentioned in the previous section on the 5509 saturation c
11. all 55 viewing heads All the user features of the earlier P522 are maintained plus the self resetting fuses front panel lettering and the source impedance resistor requirement of Addendum 1 P522AC SPECIFICATIONS ELECTRICAL Main Power 85 264 VAC 47 440Hz 0 3A MAXIMIM IRIS MODEL P522AC FLAME Cy 7 ON 555 FLAME ON B CAL YES 4 19 LOCKOUT SELF CHECK Battery Power 22 24 VDC 130mA plus 100mA View Head ENVIRONMENTAL Ambient Temp 0 to 52 CSA Rating 0 Cto 60 C FM Rating OUTPUTS Flame Relay 2 Form Contacts Self Checking Relay 1 Form Contact Contact Ratings 30VDC 125VAC and 277VAC Analog Signal 0 19 8mA or 4 19 8mA 360 ohms max resistance Powerto View Heads fused with self resetting fuses at 0 25A 24VDC OUT 50mA MAXIMUM INPUTS Isolated Chan Select 7 5 30 VDC Input R 3900 ohms Coil for V H Select 17 48 VDC 24 VDC nom SERIAL COMM RS 422 baud rate 4800 to 38400 user selected Cable Two twisted pairs VIEWING HEAD CABLE When using 55 view heads in ordinary locations use IRIS C 328 cable or another cable running in a metal conduit to the control room or signal processor enclosure or use IRIS C 330 cable or a shielded cable with UL ITC and CSA CIC C22 2 No 239 ratings without conduit When using S55X viewing heads in hazardous locations
12. by devices such as valves so lenoids and relays that use springs to return them to a safe state when energized Burner control systems designed for power to open and power to close type systems are different because of the storage battery backup upon loss of AC power However the philosophy of fail safe concepts and safety with regard to critical loops is the same The external protective circuitry required for the boiler common MFT function can be as simple as using a single relay energized by a string of contacts in series that would include the usual permissives proper air flow fuel pressure fuel temperature etc More elaborate designs involving the PLC for alarm ing or prompts in addition to diagnostic functions will complicate the MFT circuitry but the underly ing philosophy must be to maintain an external di rect fail safe function Also consideration should be given to the air purge timing function The dangerous condition occurs when the purge timer times out short of the required time delay One way to overcome this type of mal IRIS MODEL P522 APPLICATION MANUAL TABLE OF IRIS VIEWING HEADS AND PERFORMANCE WITH VARIOUS FUELS DISC discrimination between burners and flaming background SIG signal strength GAS HYDROGEN PROPANE AND NATURAL GAS GAS LOW NO BURNERS MODEL TYPE COMMENTS 5506 DISC good SIG good 5509 PbS Only DISC none SIG fair 5550 UV amp PbS DISC excellent SIG very
13. characteristics of the different viewing head models available before applying them to par ticular application Detailed descriptions of the viewing heads are provided in this manual and the VIEWING HEAD AP PLICATION TABLES Figure 11 are a useful summary of the viewing heads and their response to different fuels B The initial settings for the flicker type viewing heads 5509 5511 5512 should be as follows 1 Set filter switch to LL position 2 Gain potentiometers POTS full clockwise these are 25 turn potenti ometers slight clicking sound will be heard when the POT is maximum clockwise There are two POTS on the 5509 one for the Si channel and one for the PbS channel If the fuel is natural gas turn the Si channel off POT full counter clockwise Refer to section S509 VIEW HEAD There are no initial settings for the 5506 UV viewing head It is important that this viewing head be properly aimed to pick up the maximum signal as described in the previous section ADJUSTING SET POINTS Before adjusting the set points take readings with the P522 on the two worst case conditions described see section SETUP AND ADJUSTMENT PRO CEDURES Write down the readings for the burner ON and OFF with other burners on under low load conditions and then the readings for the burner ON and OFF under high load conditions IRIS MODEL P522 APPLICATION MANUAL There must be a definitive ratio between the read
14. checking function indicates that both the P522 and the viewing head are func tioning properly The software in the P522 activates the self checking relay only if there are less than 10 pulses coming in from the viewing head during each dark period To energize this relay the software must generate pulses at a particular rate and with a spe cific duty cycle to a self checking circuit If this regular pattern is not maintained or if any of the circuitry fails the relay will drop out The blinking LED on the front panel labelled SELF CHECK is evidence that voltage is applied to the coil of this self checking relay because both are energized by the same voltage The difference is that the voltage to the coil is applied steadily while the voltage from the relay to the LED is gated on and off by the soft ware in conjunction with the pulses counted during the dark period Note that with regard to the viewing head the self checking function still works the same way as with the M502 A513 and D504 signal processors For instance a runaway UV tube will cause a lockout condition more than 10 pulses counted during the dark period Refer to section EXPLANATION OF 1 9 gt 10 PULSES COUNTED DURING THE DARK PERIOD in the Model 500 Signal Proces sor Application Manual A runaway UV tube or any component failure in cluding the shutter will cause a lockout condition that will de energize the flame relay The LOCKOUT light on
15. does not offset the fact that the UV radiation present is very narrow This is not true however for low NOx gas burners the UV is usually much less in intensity with this type of burner and spreads out in front of the burner getting readings from all over the furnace when many burners are on This is particularly true when fuel gas recirculation is used Another factor to consider when aiming the viewing heads is the load condition of the boiler The flames from a burner can be radically varied at different loads one of the reasons for trying to select a sight ing that will minimize the changing flame at differ ent loads If the flame front moves farther away at higher loads then a sighting parallel to the burner axis will be best A large diameter sight pipe with a swivel mount is recommended for all installations on large multiburner boilers Refer to Figure 20 INITIAL SETUP A The initial settings for the P522 signal processor should be as follows 1 F F R T Time Delay Off to 3 SEC 2 GAIN SET to 25 3 TIME DELAY ON to 0 4 FLAME ON to 200 5 FLAME OFF to 100 The above settings will be satisfactory for most applications but are used only as starting point So many variables can affect the readings that it is impossible to catalogue all the settings and each viewing head has its own characteristics for the different types of fuels and burn ers We recommend that you become knowledgeable about the
16. some other type of fuel disruption This is also a dangerous condition particularly for two to four burner installations The flame monitor must detect this flamed out burner so the fuel valve safety shutoff valve supply ing this burner will close This means that the flame OFF threshold for this flame monitor must be set above the signal level produced by the other burners that are in a high fire condition SIGHTING ADJUSTMENT Before making definitive settings i e establishing the set points for flame ON OFF you must opti mize the sighting of the viewing head This can be done if a swivel joint is used at the end of the sight Page 16 pipe and the diameter of the sight pipe is large enough to allow a range of angles to be viewed see section ANGLE OF VIEW OF VIEWING HEAD As a general rule the sighting of the 5506 viewing head is more likely to be line of sight than the 5512 infrared flicker viewing head which will read flame signals bouncing off the side of the sight pipe and other reflectors Sometimes the reading with the IR detectors can be greater with a reflective signal than the direct line of sight The UV viewing head on the other hand will have to be aimed at the part of flame having the highest concentration of UV which is usually at the root of the flame at the throat of the burner and in a very narrow range The angle of view of the S506 is somewhat wider than the 512 or S509 but this
17. the Si channel off by turning the Si POT at least 30 turns counter clockwise The signal level will now be lower because only the PbS de tector is being used so the set points must be re evaluated If you are using an S511 viewing head and not achieving success Page 17 IRIS MODEL P522 APPLICATION MANUAL C ful discrimination it is likely due to the automatic gain control action see sections on the viewing heads for de tailed explanation of this problem When using the PbS only or the 5506 same for the 5512 make sure the sig nal is not saturating particularly at high load conditions Refer to section ORIFICING For the 5550 the 5552 and the 5556 see corresponding manual s TROUBLESHOOTING GUIDE NO FLAME SIGNAL and NO DISPLAY 1 Check wiring refer to section WIR ING AND INSTALLATION 2 Check the voltage at PWR IN termi nals with volt meter It should mea sure approximately 26 VDC If not check the power supply and wiring or replace the power supply 3 If 26 VDC is measured remove the power for 10 seconds If the self re setting fuse has tripped removing then reapplying power will reset the fuse DIGITAL DISPLAY IS SHOWING 0000 AND NO FLAME SIGNAL 1 Using volt meter check at viewing head A terminals on the bottom of the mother board for 26 VDC across V and GND If the voltage is low check the power supply If the supply is okay removing and reapplyin
18. to 500 feet and it should be 150 ohm for cable runs 500 feet to 1000 feet The resistor should be installed across the SC and SIG GND terminals 1 4 watt resistor is suitable Originally specifications of the IRIS Model 500 in structed that five conductor cable be used with one wire shielded However the standard is now four conductor cable with one wire shielded In this case the shield is used as the signal ground wire that goes to terminal SIG GND on the P522 and to pin 3 on the viewing head plug The shield should be braided type for this application do not use foil type shield so that a solid signal ground is main tained This signal ground shield is also the self checking circuit return path Refer to Figures 2 and 3 for wiring details Connections of the IRIS cable to the viewing head plug should be performed as follows After removing the plug from its packaging take the cable entry nut out of its housing Remove rubber grommet and flat sealing washer With a pair of long nosed pliers remove the center ring only of the rub ber grommet 1 Strip two inches of the cable s outer cover from the cable removing any cellophane wrap or filler material and strip the in sulation from the shielded wire if insu lated over shield a full two inches to expose shield Slide the shield back until bulge devel ops close to where the wire exits the cable s outer covering Carefully spread a f
19. 400019 Temperature Channel read only 400020 Temperature Channel B read only 400021 Time Delay on Upper nibble B lower 400022 FFRT Upper nibble lower A 400023 Firmware Version read only 0X OR DISCRETE REGISTERS All read only 000001 View head Channel Selected 0 Channel 000002 Flame On Relay Status 000003 Processor Lockout Status 0 lockout 000004 Panel Access Disabled 0 disabled 000005 4 20 output Status 0 0 40 Communicating with Modicon PLC Each Modicon PLC comes with Modbus port The control program can read write the settings from to the P520 P522 scanner via this port XMIT loadable module is needed to send Modicon func tions XMIT loadable module is available from Modicon Inc Page 32 Note Not all models of Modicon PLC s will accept the XMIT loadable module Please consult you local Modicon dealer for more information Communication with Human Interface Host Computer A number of Modbus drivers for Microsoft Window 95 and NT are available from the third party devel oper such as Rockwell Software s WinTelligent Linx Modicon A Modicon driver allows applica tion programs such as Microsoft Excel Wonderware and RSView to communicate with the P520 P522 scanners directly RS 232 to RS 422 CONVERSION It is necessary to use a RS 232 to RS 422 converter at the host computer The IRIS COMM converter module can be used and is recommended because of its photocoupler isolation Th
20. ANUAL MODEL P522 FLAME FLAME ON FLAME OFF TN SELF CHECK Wo 2 m OK GAIN SET TIME DELAY ON RESET e SISISISISISISIS gt I I IV ID S SS SS amp gt amp gt amp gt SJ DV S SS I FIGURE 14 MODEL P522 FRONT PANEL Page 35 IRIS MODEL P522 APPLICATION MANUAL MOUNTING BRACKET TERMINALS DQ g 522 N TERMINALS 6 4 163mm FIGURE 15 MODEL P522 SIDE VIEW 8 05 204 47 4 23 107 44 1 NPT FEMALE PIPETHREAD VIEWING HEAD ls FRONT VIEW IC Pp ou RC TA __ 4 2 NPT FEMALE PIPE THREAD VIEWING HEAD SIDE VIEW x QUICK DISCONNECT PART NUMBER R 518 08 GN 9 9 Si PbS VIEWING HEAD FLANGE REMOVED FIGURE 16 SSXX VIEWING HEAD DIMENSIONS Page 36 IRIS MODEL P522 APPLICATION MANUAL HIGH FREQUENCY FLICKER ZONE DETECTOR IN GOOD SIGHTING POSITION PARALLEL SIGHTING BURNER NOZZLE CENTERLINE DETECTOR IN POOR SIGHTING POSITION LOW FREQUENCY FLICKER ZONE FIGURE 17 IR VIEWING HEAD LOCATION UV RADIATION ZONE UV VIEWING HEAD SIGHTED ON UV ZONE
21. BURNER NOZZLE CENTERLINE FIGURE 18 UV VIEWING HEAD LOCATION Page 37 IRIS MODEL 522 APPLICATION MANUAL NO 1 FLAME 2 FLAME ENVELOPE ENVELOPE VIEWING HEAD VIEWING HEAD BURNER NOZZLE NO 1 HIGH FREQUENCY LOW FREQUENCY HIGH FREQUENCY IR ZONE IR ZONE ZONE LESS THAN 36Hz FIGURE 19 OPPOSED FIRED VIEWING HEAD SIGHTING 2 BURNER FRONT PLATE 2 NPT NIPPLE j IRIS R 518 12 IRIS VIEWING HEAD BURNER NOZZLE CENTERLINE 1 2 PURGE CONNECTION X IRIS 701 2 QUICK DISCONNECT SWIVEL MOUNT CABLE CONNECTION SUPPLIED FIGURE 20 VIEWING HEAD MOUNTING Page 38 IRIS MODEL P522 APPLICATION MANUAL INDEX 4 20 6 12 lockout PI 10 11 15 18 20 32 lockout condition nent 10 11 Lt 18 21 22 23 24 25 s Le dc 16 25 26 angle of view 24 15 M apertul6 eco diese 22 fen 10 11 B modbus communication 31 background flame 16 21 N battery eee eee eee eee eee reer eee errr 5 9 10 19 26 natural gas NR 14 17 20 21 23 25 baud rate siiis dE 31 32 noise 12 18 brightness ard eee 21 22 Olt 14 15 16 20 22 23 25 aei d
22. IRIS lt gt FLAME MONITORING SYSTEM MODEL P522 SIGNAL PROCESSOR APPLICATION MANUAL IRIS MODEL P522 APPLICATION MANUAL Table of Contents IRIS MODEL P529 anne WIRING AND INSTALLATION FIGURE 1 P522 REAR MOTHERBOARD 4 WIRING TO THE PLUG IN TERMINALS 5 WIRING OF VIEWING HEAD 6 FIGURE 2 WIRING OF VIEWING HEAD 6 FIGURE 3 WIRING AND ASSEMBLY VIEWING HEAD gt 7 OPTIONAL LTA ADAPTER 7 POWER SUPPLY cete eue s 8 FIGURE 4 POWER SUPPLY TABLE 9 FACTORY STOCKED POWER SUPPLIES 9 REDUNDANT POWER SUPPLIES 9 SELF CHECKING FUNCTION 10 APPROVALS 10 POWERING UP THE P522 10 SET POINT ae 11 FIGURE 5 SET POINTS 11 CHANGING SET POINTS 11 FLAME FAILURE RESPONSE TIME F F R T 12 4 20mA REMOTE OUTPUT 12 FIGURE 6 REMOTE METER ANALOG OUTPUT 12 INSTALLATION OF VIEWING HEAD 13 FIGURE 7 VEWING HEAD CROSS REFERENCE TABLE tn 13 SIGHTING OF THE VIEWING HEAD 13 MULTIBURNER REQUIREMENTS 14 FIGURE 8 CUTOFF FREQUENCIES 14 MULTIPLE VIEWING HEADS 14 DETERMINING SIGHT PIPE SIZE 15 SELECTING THE PIPE 15 MOUNTING H
23. OLE gt 15 MOUNTING OF SIGHT PIPE 15 INSTALLING THE VIEWING HEAD 15 PURGE AIH ue aus 15 SETUP AND ADJUSTMENT PROCEDURES 16 SIGHTING ADJUSTMENT 16 INITIAL SETUP sn 16 ADJUSTING SET POINTS 17 TROUBLESHOOTING GUIDE 18 NOISE INTERFERENCE AND GROUNDING 18 Page 2 6506 VIEWING HEAD 19 5506 SELF CHECKING VIEWING HEAD 20 5509 VIEWING HEAD 20 S511 VIEWING HEAD 21 5512 VIEWING HEAD 21 ORIEIGING En 23 FIGURE 9 ORIFICING SIGNAL REDUCING CHARACTERISTICS OF DISCS 23 SIGNAL SOURCES ae 23 VIEWING HEAD ANGLE OF VIEW 24 FIGURE 10 VIEWING HEAD ANGLE OF VIEW DISTANCE AND DIAMETER 25 APPLICATION OF IRIS VIEWING HEADS 25 LOW NOx APPLICATIONS 26 APPLICATION OF P522 26 USING A PLC WITH IRIS FLAME MONITOR 26 FIGURE 11 VIEWING HEAD APPLICATION TABLES 27 FIGURE 11 VIEWING HEAD APPLICATION TABLES Cont d 28 BASIC BURNER START CIRCUIT 29 FIGURE 12 BASIC BURNER START CIRCUIT 30 MODULE COMMUNICATIONS 31 MODBUS COMMUNICATION
24. V H ENVIRONMENTAL Ambient Temperature Case Temperature OPTICAL Angle of View UV Tube SPECIFICATIONS 26Vdc 5 20 300mA 100mA for each additional V H Viewing Head NEMA TYPE 4 P522 Signal Processor 0 to 50 5506 5509 5511 5512 5513 0 C to 60 5580 54 C to 177 5506 5509 5511 5512 S513 0 C to 60 5580 54 C to 177 5506 4 degrees 5509 3 9 degrees 5511 1 6 degrees 5512 3 2 degrees 5580 3 6 degrees 5550 5552 5556 IR 1 0 degrees UV 3 0 degrees Cable Between Viewing Head and Signal Processor OUTPUTS Flame Relay Self Checking Relay Analog Flame Signal Power to Viewing Head INPUTS Channel Select Isolated Input Flame Signal from V H Isolated Input SERIAL COMMUNICATION RS 422 Differential Page 34 4 conductor 16 AWG or 18 AWG one wire shielded with braided shield for flame signal 2 Form C Contacts 1 Form C Contact Contact Ratings Max switching power 60W 125VA Max switching voltage 220Vdc 250Vac Max switching current 2A dc ac 0 to 20mA current output for remote meters and 4 to 20mA output for DCS etc 360 ohm max resistance 26Vdc fused 0 25A 14 3Vdc Pulsing 0 2 Sec ON 0 8 Sec OFF VIN 7 5 30Vdc range Input R 3900 ohms 26Vdc 6 4mA 10Vdc 2 3mA VIN 7 5 30 range Input 3900 ohms 13 6Vdc 3 2mA 4800 or 9600 Baud user selected Cable requirement 2 twisted pairs FIGURE 13 SPECIFICATIONS IRIS MODEL P522 APPLICATION M
25. WING HEAD ANGLE OF VIEW DISTANCE AND DIAMETER 25 FIGURE 11 VIEWING HEAD APPLICATION TABLES 27 FIGURE 11 VIEWING HEAD APPLICATION TABLES Cont d 28 FIGURE 12 BASIC BURNER START CIRCUIT 30 FIGURE 13 SPECIFICATIONS u IS nnns 34 FIGURE 14 MODEL P522 FRONT PANEL 35 FIGURE 15 MODEL P522 SIDE VIEW 36 FIGURE 16 S5XX VIEWING HEAD DIMENSIONS 36 FIGURE 17 IR VIEWING HEAD LOCA ION 37 FIGURE 18 UV VIEWING HEAD LOCATION 37 FIGURE 19 OPPOSED FIRED VIEWING HEAD SIGHTING 38 FIGURE 20 VIEWING HEAD MOUNTING 38 Page 3 IRIS MODEL P522 APPLICATION MANUAL IRIS MODEL P522 The P520 and P522 Signal Processors are used with the IRIS Model 500 Viewing Heads The P522 Signal Processor is relay panel mount ver sion of the P520 plug in module and replaces the M502 motherboard and its two plug in daughter boards the A513 and the D504 WIRING AND INSTALLATION Before wiring or installing the P522 we recommend that you read the companion colour brochure desc
26. We recommend that at least three CFM at approximately eight inches of water column above windbox pressure be provided for each viewing head The air supply must be clean free from oil and water and preferably cool Page 15 IRIS MODEL P522 APPLICATION MANUAL SETUP AND ADJUSTMENT PROCEDURES Multiburner applications require the most care in adjustments to ensure proper flame out operation under worst case conditions refer to previous sec tion MULTIBURNER REQUIREMENTS These same procedures can be followed for single burner applications even though the adjustment re finements described here may not be necessary There are two basic worst case conditions in multiburner installation One is the initial light off of other burners after the first burner has been established particularly if the established burner or burners has a flame envelope that over laps the trial burner sighting If there is a flame out or ignition failure of this burner or its igniter during this startup sequence the flame monitor must detect this condi tion meaning that it must discriminate between the lack of flame and the back ground flame of the established burner This would represent discrimina tion under low fire conditions Second would be when the fired unit is in a high fire condition all burners are firing at maximum rate when suddenly one burner flames out possibly because of a clogged oil gun or
27. action causing worse discrimination ratio the ra tio of flame ON to flame OFF The PbS detector 5512 is linear up to the point satu ration begins Saturation will occur on bright flame signals reading of 1800 or more is an indication that the PbS cell is saturating Only orificing can correct this Remember The 5512 will read all fuels propane and natural gas pulverized coal light and heavy oil and all waste fuels The 5509 performs in similar manner to the 5512 by turning the Si channel off ORIFICING Orificing the viewing head sight path will greatly improve performance in many applications particu with regard to discrimination between flames The flame signal or radiation intensity can be suffi ciently great that the IR type photodetectors PbS will be completely saturated This will be true with large power utility boilers where the burners are very large and relatively close to each other If you can not look at the flame with the naked eye without it hurting then orificing should be used This test works for incandescent type flames such as oil and coal but will not be valid for natural gas flames Orificing will help improve the discrimination char acteristics for UV type viewing heads as well as the solid state flicker types The UV tube the 5506 is not likely to saturate however if the count is over 1500 orificing will definitely improve the discrimi nation ratio An orifice d
28. ad is used you must wire to the V H A termi nals To the left of the viewing head terminals are two terminals marked V H SEL viewing head se lector relay Energizing this connection with 19 to 38 VDC will cause the relay on this PC board to switch to viewing head B The nominal voltage of this relay is 24V but the 26 VDC power circuit can be used to switch this relay if desired Only the viewing head signal wire SIG and the sig nal ground wire SIG GND are switched with this changeover relay the 26 VDC and power ground circuit is not disturbed Make sure that the viewing head signal wire and signal ground braided shield in the four conductor cable are both connected be cause this ground connection is the only return path for the signal and self checking circuit Also the 26 VDC used to switch this relay must be connected with the proper polarity because the relay used is a single side stable type Relays that are polarized magnetically offer increased contact force resulting in higher current carrying capability The two ter minals marked V H SEL go directly to the relay coil The pair of terminals designated CHAN SEL to the left of the V H SEL terminals is used for selecting channel A or channel B on the P522 Energizing this pair of terminals causes the B channel to be se lected Polarity must be observed when wiring this connection the positive terminal is on the right This is an isolated input so two wires a
29. ad with signal sources other than flame can result in erroneous readings Flame is composed of a basic brightness radiation with superimposed flicker of usually not more than five per cent These flicker components vary in a ran dom fashion from zero frequency DC to relatively high frequencies Hz and up As explained pre viously the viewing head has been designed to re spond to actual flame signals so that discrimination can be achieved between the flame being monitored and unwanted background Page 23 IRIS MODEL P522 APPLICATION MANUAL Signal sources other than flame such as incandes cent or fluorescent light can cause false readings that should be understood For example fluorescent light is nonsinusoidal in character meaning that there is sharp peak when the fluores cent tube fires on the positive AC power cycle with less amplitude excursion on the negative cycle resulting in a radical voltage swing in the amplifiers employed in the viewing head This sharp peak causes the first stage amplifiers AGC circuit for photovoltaic photodetectors to react violently resulting in down stream signal perturbations that are not normal This can be even worse if strobe light is used as signal source An incandescent light source is sinusoidal in char acter resulting in a less disturbing signal for the viewing head but still does not resemble a true flame source because of the large AC DC comp
30. an occur downstream from the gain ad justment potentiometers because of the signal ampli fication process This type of saturation can be de tected on the digital display by observing the signal count The 5509 will be completely saturated at count of 2800 3000 Saturation begins waveform just starts to clip at a count of 2100 This threshold is somewhat dependent upon the flicker frequencies and their distribution but for the lower frequencies up to Page 22 200 Hz the count of 2100 can be taken as the thresh old This amplifier type saturation usually will not occur with the S512 viewing head when reading ac tual flames It can occur when reading artificial sig nal sources such as incandescent and fluorescent lamps because of the large AC DC component It should be noted that amplifier type saturation is not harmful per se but saturation of the photodetector caused by high brightness flames can be You cannot control the nonlinearity caused by the action of the Si channel on the 5509 but with the Si channel turned off you can control the linear ity of the PbS channel by observing the count on the digital display and reducing the gain when neces sary by orificing Saturation of the PbS detector can only be corrected by orificing turning down the gain adjustment potentiometer will not help because it is the PbS cell upstream that is the cause Another nonlinearity of the PbS detector that should be noted ha
31. ange for making this measurement This measurement should be made under various conditions i e during the sequencing of the igniter and burner In addition to using the isolated nipple for the view ing head flange you must use nonconductive rub ber or plastic hose for the purge air there is 1 2 inch NPT pipe thread on the flange This will pre vent the current from flowing through the IRIS cable power ground back to the P522 Another source of interference is from high voltage spark igniters high voltage of 6 KV or more is usually supplied by step up autotransformer and not being isolated from the power line it can cause IRIS MODEL P522 APPLICATION MANUAL interference particularly if there are grounding prob lems The usual problem occurs when the trans former is energized resulting in bogus flame sig nal The problem is not caused by the spark across the gap but by radiation from the high voltage wir ing feeding the spark gap Itis the secondary wiring of the transformer high voltage AC that causes this interference both the insulated wire to the spark gap as well as the ground return This circuit loop acts like giant antenna Also this type of trans former can cause ground problem because it is an autotransformer and because it 5 not isolated from the power line The high voltage current to the ig niter must return to the transformer through the plant ground which is the condu
32. applications using 12 or more P522 signal processors For example the 100 watt power supply available from the factory can handle twelve P522 modules each with one view ing head Should the power supply fail a redundant scheme utilizing two power supplies with steering rectifiers to pre vent current from flowing into a failed power supply output would prevent the 12 flame monitors from being de energized The positive output from each power supply is wired to the anodes of the MBR 1545CT This dual Schottky type rectifier rated for 15 Amps will present low forward voltage drop for this application Both power supplies can be adjusted for 26V output and a low voltage indicator light can be used on the output of each power supply to monitor their outputs Larger power supplies can be used with this redun dant wiring scheme if there are more than twelve P522 Page 9 IRIS MODEL P522 APPLICATION MANUAL modules in system Care should be taken when wir ing multiple P522s to ensure the selected bus wires will carry the current The plug in terminals on the P522 will accommodate a wire size up to 14AWG allowing for relatively high currents Note that if the power wiring 26 VDC is daisy chained by using the terminal pairs provided the pairs are jumpered by copper traces on the mother board so if the plug is pulled out the jumpered connection is broken SELF CHECKING FUNCTION When energized the self
33. are station number from 0 to 63 Press up down button to change the station number Press Store button to save station number Protocol Detect P522 with firmware version 5 0 still supports the existing IRIS protocol After power up processor will listen for both protocols Once the protocol has been detected communication must remain in this protocol until the unit is powered off MODBUS RTU Function Supported Four Modbus functions are supported 01 Output Coil Read 03 Holding Register Read 06 Preset Single Holding Register 16 Preset Multiple Holding Register Page 31 IRIS MODEL P522 APPLICATION MANUAL Registers Map 4X OR NUMERICAL REGISTERS 400001 Count Of Active Channel read only 400002 Processor Status read only 400002 0 View head Channel Selected 0 Channel 400002 1 Flame On Relay Status 400002 2 Processor Lockout Status O lockout 400002 3 Panel Access Disabled 0 disabled 400002 4 4 20 output Status 0 0 40 400003 Flame On Channel A 400004 Flame On Channel 400005 Flame Off Channel A 400006 Flame Off Channel 400007 Gain Channel 400008 Gain Channel 400009 IR Analog Channel 400010 IR Digital Gain Channel 400011 IR Filter Channel 400012 UV Gain Channel 400013 IR Analog Gain Channel B 400014 IR Digital Gain Channel B 400015 IR Filter Channel 400016 Gain Channel 400017 View Head Type Channel read only 400018 View Head Type Channel B read only
34. are two reasons for this the primary reason being the inherent nonlinearity caused by the AGC in the Si channel The wide dynamic range of the Si photodetector re quires control of the gain of the first amplifier stage If this were not done amplifier saturation of the sig nal would occur on bright flame signals resulting in the loss of the flicker signal The problem occurs because the AGC responds to the brightness of the flame For example when a burner is on the flame monitor is picking up a strong bright signal from the root of the flame when the burner goes out the flame monitor is reading background flame from other burners This background flame is less bright causing the AGC cir cuit to increase the gain of the amplifier with a consequential reduction in the dis crimination ratio the ratio between the count displayed with flame ON and the count displayed with flame OFF The AGC nonlinearity is self defeating so to speak and is the principle reason this Si element is usually turned off The other reason is that the Si photodetector will not see propane or natural gas If this is the main fuel then Page 21 IRIS MODEL P522 APPLICATION MANUAL you should definitely turn off the Si channel which cannot contribute to the flame signal from the burner when it is gas but can only read background glow which will certainly cause discrimination problem An important aspect of using the 5512 instead of the
35. ause problems with fuels that either block or absorb the UV signal For example in pulverized coal burner there can be unburned fuel at the burner nozzle creating skirt that blocks the UV radiation coming from the flame Heavy oil burners can also cause prob lems with UV type flame detection par ticularly if the fuel has high sulfur con tent which will absorb the UV radiation MULTIBURNER REQUIREMENTS Multiburner installations require discrimination This means that in spite of the brightness of other flames in the furnace the flame relay must respond only to the presence or absence of the flame pro duced by the burner that it is monitoring Not every viewing head can be positioned so that its line of sight does not intercept flames from other burners a situation that occurs in multi level opposed fired furnaces where the burners face each other In such cases the sighting angle is setup as described above with the viewing head sighting along the flame directly into the flame root If an opposing or adjacent burner flame falls within the line of sight of the viewing head it may be effectively tuned out by setting the FLAME OFF set point high enough to ignore this background If discrimination cannot be achieved by doing this it is recommended that the filter switch in the viewing head except the 5506 5511 amp 5512 105Hz 5550 amp 5552 16 2 24 2 33Hz 52Hz 75Hz 100Hz 155Hz PPs PP
36. be displayed toggling back to the 0 20mA range will again cause four dashes to appear on power up of the unit Tha factory default setting are 4 20 One thing to consider when feeding the 4 20mA sig nal to a remote computer or DCS is that there is no isolation between the P522 ground and the remote system ground If there is a ground potential differ ence between the two systems then there could be serious noise and performance problems You will not encounter this problem when using a remote meter by itself because it will not be tied into an other electrical system will not be sharing grounds The bargraph reading on the front panel will not be affected by this change to 4 20mA output It will re main the same as before go to zero on no signal detected The 4 20mA output will still perform the same way on the high end 1 a strong signal it will saturate at the same level slightly above 22mA Specifications for the analog current output signal are provided in SPECIFICATIONS Figure 13 INSTALLATION OF VIEWING HEAD Before beginning the actual installation determine the best location for mounting the viewing head based upon the following factors VIEWING HEAD CROSS REFERENCE OLD NUMBER 5506 5506 IRX2S S509 NEW NUMBER FIGURE 7 VEWING HEAD CROSS REFERENCE TABLE PRESSURE The viewing head lens will withstand 5 psi If the lens assembly is exposed to greater than 5 psi through sight pip
37. ctive metal of the plant The solution to these problems is to locate the igni tion transformer as close as possible to the igniter and away from the P522 and power supply The shorter the secondary wire run the better Also the ground return path should be examined Is the ig niter properly grounded and is this good plant ground Plus you should examine the grounding of the transformer case we recommend that there be good plant ground on the transformer case and that the transformer be enclosed metal enclosure that is also grounded Usually there are no straightforward solutions to electrical interference problems each will have its own unique causes However there are certain pre cautions or guidelines that you should be aware of The first thing to check is the grounding of the in stallation Make sure the AC power feeding the sys is grounded and that the ground is bona fide plant ground And make sure the proper cable is being used for the viewing head Note Do not use cables that employ foil type shields aluminum polyester We recommend you use the standard IRIS cable that has a braided shield 5506 VIEWING HEAD The 5506 viewing head employs UV tube that has spectral response of 185 260nm It is an inherent pulsing device i e the power supply has been de signed so that the tube emits pulses when UV radia Page 19 IRIS MODEL P522 APPLICATION MANUAL tion is present Its ou
38. e then an isolation unit must be used An IRIS isolation unit with purge air entrance is avail able as an accessory TEMPERATURE The viewing head will withstand an ambient tem perature to 80 C 176 F However the case tem perature of the housing must not exceed 60 C 140 F Purge air will help reduce conducted heat through sight pipe to flange a plastic nipple will also help but direct radiation can cause housing case temperature to exceed limits If the ambient heat direct radiation is excessive then a fiber optic ex tension should be used please refer to the IRIS Model 500 Fiber Optic System manual This sys tem is composed of a viewing head a fiber optic assembly and an amplifier module IRIS MODEL P522 APPLICATION MANUAL The model S5xx series of viewing heads have in place a sensor for sensing the internal temperature of the head To access the reading of the viewing head temperature press the Reset and the Down arrow key at the same time The temperature read ing will be displayed in the four digit readout The reading indicated in C will disappear and the nor mal reading will continue after several seconds VIBRATION Do not install the viewing head where it could be subject to vibration A vibrating viewing head flicker type can simulate flame when viewing a glowing background Provide an antivibration mount if excessive vibrations are present CLEARANCE Make sure there will b
39. e 5 6 8 channel selet uet tret bera 10 32 P COM POL MD EE 6 PbS channel d nues 17 21 22 communication port 2 PLO 26 29 31 32 current output issu 13 power fallure 2 L n 10 D pressure uu Gdansk ne EG 13 15 26 a fajor a E 20 21 23 disable Im 32 pulverized coal HECTORE ORE 14 20 23 25 E pulses counted 10 15 la Ghi 10 eee 19 relay contacts n 5 29 F remote meter 6 9 12 eee 12 16 rTesel __r 10 11 13 18 29 31 32 Bre AP RE 26 31 registers map 32 FEET 232 2 ETE E semen 32 RS 232t0 RS 422 ns 6 32 dcin P 25 26 6 fiber ie 13 safe start cheCk 29 filter 14 17 20 24 32 saturation of the photodetector 22 VE ME NTE rr Dao MN 6 10 11 flame relay 5 10 14 20 26 29 self check relay PE Re Fo 11 flicker 13 14 16 17 21 22 23 24 25 serial communication 6 9 10 12 fuses ssssasassassaasanausassansussuuanasuaasasuauesusuassanassaseussasuass 5 9 Si channel Yes DIT RD OD 17 20 21 22 23 25 G Mek Skee 20 grounding tiec 18 19 germanium photodiode
40. e converter must have galvanic ground isolation SETTING ADDRESSES Each P522 must have its own unique address The address is easy to change Press the RESET push button for 22 seconds causing the P522 to immedi ately display its address on the four digit display 0000 to 0063 and change using the UP or DOWN arrow buttons When the desired address is dis played push the STORE button and the P522 will immediately respond to this new address In current software revisions of the processor ver sions 3 0 and higher the baud rate can also be changed when the module address is changed The baud rate is displayed in the highest two digits of the numeric display i e 4802 is 4800 baud and address 2 To change to 9600 baud increase the display past 4863 The next display will be 9600 which is 9600 baud address 0 Then increase the display further to the desired address To return to 4800 baud reduce the display below 9600 and set the desired address TECHNICAL HELP For technical assistance in installing this product please contact IRIS Systems Inc 7583 Vantage Place Delta B C V4G 1A5 Canada Phone 604 584 LR LS Fax 604 581 9790 Factory and Repairs IRIS Systems Inc J B Systems Inc 4944 113th Avenue North Clearwater Fl 33760 Phone 727 545 3900 Fax 727 547 9589 IRIS MODEL P522 APPLICATION MANUAL Page 33 IRIS MODEL P522 APPLICATION MANUAL ELECTRICAL Input Power with one
41. e plug end particularly the shield from the WHT wire Make sure the shield doesn t touch the other terminals POWER SUPPLY Careful consideration should be given to the power supply used for the P522 26 VDC is used to back bias the steering rectifier as shown in Figure 1 to prevent the power from feeding into the 24 VDC supply Each P522 module draws approximately 150 mA and each viewing head draws about 100 mA of power 26 VDC Actually the 5506 and 5511 view ing heads use less current but it is a good idea to figure 100 mA for each viewing head used Also the amount of current drawn by the P522 will de pend upon other factors that can affect the peak cur rent such as whether or not there is flame being de tected the remote meter output is connected and se rial communication is occurring The viewing head is powered through the P522 viaa 0 25 A self resetting fuse In other words the 26 VDC power feeds into the P522 through a 0 75 A self resetting fuse and feeds back out through a 250 mA fuse to the viewing head resulting in a current drain of about 0 25 A for each P522 with one view ing head This small amount of current means that one power supply could support a number of P522 modules The self resetting fuses change to high re sistance when their current ratings are exceeded but recover to their normal low resistance when power is removed IRIS MODEL P522 POWER SUPPLY CAPACITY IN WATTS x
42. e section WIRING OF VIEWING HEAD Pin 5 of the view ing head male receptacle has an internal tab that grounds this connection to the viewing head housing The terminal marked GND connects to the chassis ground of the P522 This ground is made through the etch on the rear side of the PC board to the metal base It is important that the AC power be grounded source i e GND going to plant ground refer to section POWER SUPPLY Interference problems can occur if the power supply chassis and the P522 chassis are at different ground potential than the viewing head housing which will be at ground potential associated with the burner front In these situations the IRIS flame monitor effectively sup plies plant ground between the burner front and the panel enclosure If there is large potential dif ference between these points considerable current can flow through the viewing head cable which can in turn damage the P522 signal processor or the as sociated power supply If there is voltage difference between the viewing head and the sight pipe then you should use non conductive one inch plastic nipple between the sight pipe and the viewing head mounting flange This voltage difference can be easily measured by dis connecting the viewing head from the mounting flange so that there is no continuity between the view ing head and the boiler front Note Use a battery operated multimeter on high voltage AC r
43. e sufficient room to remove the housing for servicing see Figure 16 SIGHTING OF THE VIEWING HEAD In general the sighting of the viewing head should be parallel to the center line of the burner in the di rection of the burner flame This applies to both the UV type as well as the flicker type Flicker type detectors respond to the high frequency flicker of the flame so in order to achieve maximum dis crimination between burners the near portion of the primary combustion zone should be favoured meaning the sight pipe should be mounted as close as possible to the burner center line The sight pipe should be aimed at the root of the flame which radi ates the most intense high frequency flicker energy Sighting along the flame rather than across it per mits the detector to view a greater depth of the flame root obtaining better response see Figure 17 When sighting for a UV viewing head you must aim for the UV zone which is usually at the very first part of the flame root UV radiation from most flames is restricted to a narrow region it starts very close to the burner nozzle and does not extend out very far from the burner nozzle You may have to angle the sighting inward toward the flame root as shown in Figure 18 Page 13 IRIS MODEL P522 APPLICATION MANUAL The effectiveness of the sighting will depend upon both the type of viewing head as well as the fuel UV flame detection works fine on natural gas but will c
44. ed before UV type detectors usually work very well on natural gas However low NOx type burners utilizing fuel gas recirculation FGR can cause problems with UV flame detection The 5509 two colour photodetector viewing head has been very successful in sulfur recovery applications Claus reactors in the gas processing and petrochemi cal industries The basic drawback is the nonlinearity of the Si channel caused by the AGC action as previ ously explained see section 5509 VIEWING HEAD and section 5512 VIEWING HEAD Also the Si channel will not see natural gas The S511 Ge viewing head will detect all types of flames fuels and has been very successful in de tecting flame in lime kilns and sulfur recovery reac tors The only drawback is the poor discrimination between burners The 5512 PbS only viewing head will detect all types of flames fuels The basic drawback which can be corrected by orificing is the photodetector saturation on bright flames In general flicker type detectors work very well when the combustion air at the root of the burner is turbulent They work better on heavy oil and pul verized coal flames than on natural gas flames Natu ral gas burners usually exhibit lower flicker frequen Page 25 IRIS MODEL 522 APPLICATION MANUAL cies than oil burners particularly the low NOx type burners UV type detectors work very well on natu ral gas but they are not so good on oil flames and work poo
45. evisions of the processor chip at 4800 or 9600 baud The baud rate is displayed with the module address in the current versions see SETTING AD DRESSES section The data transmitted to and from the P522 is over two twisted pairs that are dif ferentially driven and received according to the RS 422 standard The differential mode allows long wire runs in harsh electrical environments MODBUS COMMUNICATION Modbus Communication for IRIS P522 Flame Moni toring System Signal Processor Introduction Modbus Communication protocol allows the P522 to communicate with any process controllers or hu man interface host computers that support this pro tocol The P522 processor status and settings are organized as 23 4X holding registers and five 0X IRIS MODEL P522 APPLICATION MANUAL discrete registers For more information on Modbus protocol please refer to Modicon s Modbus Proto col Reference Guide PI MBUS 300 Rev E Communication Setting P522 can communicate only in Modbus RTU mode with the following configuration 9600 baud 8 data bits no parity 1 stop bit The factory default of a P520 P522 station number is 0 It is important to change the station number so that there is no duplicate stations To change or check the station number Press and hold Reset button for 4 seconds The 4 LED digits will show the baud rate and the station number The 2 leftmost digits are the baud rate 96 or 48 the 2 rightmost digits
46. ew strands of the shield at the bulge making sure not to break any strands to create an opening and slip wire out of shield through opening Carefully return shield to original shape and length by pulling gently then cover with plastic shrink tubing to prevent shorts Page 8 Slide nut with threads toward the cable end the washer and the grommet onto the cable approximately six inches Slip the cable through the bottom open ing of the connector making sure that the cable s outer jacket is secure under the cable clamp and tighten the two screws on the cable clamp Reassemble the grommet flat washer and cable entry nut and tighten Before wiring to connector strip each wire 3 8 inch as shown in assembly dia gram Figure 3 Proceed to wire the connector Refer to Figure 2 for terminal locations Connect the viewing head signal wire WHT the shielded wire to terminal No 1 by inserting it into the opening then tightening the retaining screw Connect the shutter drive signal wire BLK to terminal No 2 Connect the signal ground shield from the WHT wire to terminal No 3 with shrink tubing Connect the 24 VDC power wire RED to terminal No 4 Connect the power ground wire GRN to terminal No 5 Assemble the back of the plug and insert jackscrew through the plug assembly The cable wiring at the other end going to the signal processor is easier The cable should be prepared in a similar way to th
47. follows refer to Figure 12 1 Pressing the start button START will start the ignition sequence provid ing there is no MFT present purge is complete and all the limits for firing are satisfactory and no flame is being de tected This latter function is the safe start check jargon common in the flame safeguard industry Note that the PLC is started at the same time as time delay 1 TD1 is pulsed ON The push button switch must be actuated for at least 50 milliseconds to ensure the Delay After De Energized DADE timer is started The master relay RM Contact pulls in sealing the loop around the flame relay RF contact normally closed The RM contact provides the current path to the ignition transformer and igniter valve Note that the igniter valve contact from the PLC must be commanded closed at this time A master relay is used so that there is adequate current carrying capac ity which may not be the case for using the flame relay contacts by themselves The P522 flame relay contacts are rated to 2 Amps at 220 VAC Alternatively additional normally open RM contacts can be used either in series or parallel to accommodate the load requirement sometimes two contacts in series are used to minimize contact wear caused by inductive arcing when contacts are open interrupted igniter operation The only necessary requirement is that the burner valve s be powered by RM contact s as shown A sub
48. g place readings on the digital display of 27700 3000 and if this is interfering with the ON OFF ratio causing a discrimination problem it can be easily resolved by turning both the Si and PbS 25 turn POTs down No effect will be noticed until about 10 turns counter clockwise and we recommend 15 counter clockwise turns on the first try The digital display must be used for this adjustment to detect when the signal pulls out of a limiting or compressing mode i e when the signal goes below 2700 511 VIEWING HEAD This viewing head uses a germanium photodiode that has a narrower spectral range 750 nm to 1900 nm IRIS MODEL P522 APPLICATION MANUAL than the lead sulfide cell used in the 5509 and 5512 viewing heads It will detect all types of flames including natural gas and propane Being a photodiode it is operated in the photovol taic mode the same as the Si element in the 5509 The same type AGC circuit is used which is inher ently nonlinear If it appears that a limiting action needs correction the same remedy can be used here as on the 5509 512 VIEWING HEAD The 5512 viewing head employs a PbS only photode tector and performs in a similar manner as the 509 two colour model with the Si channel turned off Sichannel potentiometer turned full counter clockwise It has been our experience that for many applica tions using the 5509 the Si channel is not used usually it is turned off There
49. g the power af ter 10 seconds will reset the 0 25A self resetting fuse if it has tripped 2 If the voltage measures 26 VDC at P522 terminals remove the connector from the viewing head and open the red connector refer to viewing head wiring diagram of this plug Figure 2 Page 18 3 Check the voltage at pins 4 26 VDC and 5 PWR GND of the viewing head connector If the voltage is zero check the wiring of the connector for shorts and or replace the viewing head cable If 26 VDC is measured then the viewing head may be defective and should be replaced C FLAME SIGNAL SHOWS ON DIS PLAY FLAME ON RELAY AND LIGHT ARE OFF 1 The viewing head is incorrectly wired or defective see B above 2 The set point values for flame ON are incorrect D FLAME SIGNAL SHOWS ON ANA LOG BARGRAPH DISPLAY FLAME ON LIGHT IS OFF LOCKOUT LIGHT IS ON 1 The viewing head may be defective 2 There may be noise or ground ing problem see NOISE INTER FERENCE AND GROUNDING following section 3 Press RESET button on front panel E 1 9 LED STAYS ON 1 There may be noise or grounding problem see D2 above 2 The viewing head may be defective F FRONT PANEL BUTTONS DO NOT RESPOND 1 The P522 front panel may be locked out NOISE INTERFERENCE AND GROUNDING On the plug in terminals going to the viewing heads at the bottom of the P522 the terminals marked GND go to pin 5 on the viewing head plug se
50. ge the filter performance when using this type of signal source In general it is appropriate to use signal sources pow ered by the 60 Hz line for viewing head cursory check ing but obviously not for definitive performance No detrimental effects will result from using signals that saturate the viewing head amplifiers VIEWING HEAD ANGLE OF VIEW The angle of view of the IRIS 5509 viewing head has been specified at 2 8 degrees A description of what this means is given in this manual see 274 paragraph section DETERMINING SIGHT PIPE SIZE The angle of view is a function of the focal length of the lens and the size of the photodetector element The equation for angle of view of a camera lens is 2F tan 0 2 d where F effective focal length of lens angle of view d diagonal of negative so that the angle is 0 2 tan d 2F The diagonal of the negative is used for photographic reasons related to the size of the negative but a bet ter measure for the purposes of this explanation would be the diameter of a circle The photodetec tor element used for the 5509 is 2 0 x 2 5 mm which is nearly square and the longer side is used for the angle of view calculation 2 8 degrees The PbS element used in the 512 is 2 0 x 2 0 mm square If you take the area of this element 4 mm and find a circle of the same area the diameter will be 2 2568 mm This was derived as follows Area circle nR TR 4mm SO R
51. good 5552 PbS Only DISC none SIG fair 5556 UV Only DISC excellent SIG very good FIGURE 11 VIEWING HEAD APPLICATION TABLES Page 27 IRIS MODEL P522 APPLICATION MANUAL OIL HEAVY OIL air amp steam atom PULVERIZED COAL Flaming backgrounds such as wood waste black liquor etc Not so good if background fuel is wood waste grate fired Usually inconsistent not reliable 3 Can be very good depends on the amount of Atom steam or air FIGURE 11 VIEWING HEAD APPLICATION TABLES Cont d Page 28 function is to use an auxiliary timer so that time out of both the PLC and the auxiliary timer is re quired before light off AND relationship The wiring diagram in Figure 10 shows basic ig niter burner circuit that can be used with PLC to accomplish the safe operation of burner or burners in a multiburner installation Note that the burner shut down BURNER STOP SW is included this circuit IRIS MODEL P522 APPLICATION MANUAL 3 The DADE timer will time out opening the contact around the RF contact If there is no flame detected the RM will drop out shutting down the sequence Once flame is detected the PLC logic se quence can continue by opening the burner valve and then after a time delay closing the igniter valve this is called is equally as critical as flame monitor protection BASIC BURNER START CIRCUIT The sequence of operations for the basic burner start circuit is as
52. hure this view ing head employs a two colour photodetector using a see through silicon Si front element and a lead sulfide PbS back element It is important to un derstand how this viewing head operates with respect to different fuels and flame conditions The electromagnetic spectrum or spectral range for the Si element is 350 nm to 1100 nm for the PbS element it is 1100 nm to 3000 nm The Si element will detect all incandescent type flames such as oil pulver ized coal and most waste fuels It will not see natural gas or propane fuels at all The PbS element will detect all flames including natural gas and propane For this reason the 5509 viewing head will exhibit stronger signals for oil and pulverized coal than for natural gas providing both the Si and PbS 25 turn POTS are full clockwise full on Typical bright signals for oil can read as high as 2900 on the digital display while natural gas may read as high as 2100 For instance a propane torch two inches away from the viewing head will read 1900 The above typi cal readings are made with the filter switch in the LL position An important characteristic that must be explained is the nonlinearity of the Si channel on bright sig nals The Si element is photodiode that is oper ated in the photovoltaic mode the diode generates current when exposed to light or radiation The sen sitivity range of this device in this mode is quite large fro
53. ictable 5506 SELF CHECKING VIEWING HEAD The self checking characteristics of the 506 are implemented by using a shutter that blocks the flame light path every second for 200 milliseconds The reason for doing this presumably is to detect a run away UV tube The McGraw Edison type tube tra ditionally used for UV flame detection is known to have an avalanche mode runaway condition that creates pulses when there is no flame present The UV tube used in the S506 is a different type of tube having an anode and cathode instead of the dual anode type used by others This tube also uses a relatively low voltage for operation and we have Page 20 experienced a runaway condition with this tube only once with a tube that had been subjected to such a significant shock that the electrodes inside were clearly bent Why use self checking if the tube does not runaway Because any runaway failure for any reason is unacceptable and self checking monitors all electronic components from the UV tube to the flame relay Each time the shutter closes the flame signal is blocked resulting in a cessation of pulses This is interpreted by the P522 as a normal condition no pulses during the dark period and the flame relay is kept energized If this does not occur the P522 will go into a lockout state causing the flame relay to de energize see sec tion SELF CHECKING FUNCTION 5509 VIEWING HEAD As explained in the 5509 product broc
54. ings for burner ON and burner OFF This ratio can be defined by using the lowest reading for burner ON from both of the load conditions and the high est reading for burner OFF from both of the load conditions If the readings are 2 1 or more BNR ON to BNR OFF then there should be no problem discriminating between burners A good balance for the set points would be ON 5er point 75 25B OFF ser pomr 25 75B where is the lowest burner ON reading and B is the highest burner OFF reading Actually smaller ratio will work as long as the lowest BNR ON reading and the highest BNR OFF reading never deteriorates to the point the former is equal to or less than the latter In other words must always be greater than B Using a safety factor of 2 1 will allow for flame signal changes that prob ably will occur over period of time A FOR FLICKER TYPE VIEWING HEADS If unable to achieve discrimi nation from background signals for mod els 5509 5511 and S512 viewing heads remove the viewing head housing from the flange and place the filter switch to the next highest position L Reinstall the viewing head and take another set of read ings Note the filter switch should be moved only one position at time for each set of readings Refer to section MULTIBURNER REQUIREMENTS FOR THE 5509 VIEWING HEAD If you are still unable to achieve satisfac tory flame OFF operation remove the viewing head and turn
55. isc is simply a metal disc with a circular hole in the center which is placed directly in front of the lens Four orifice discs are available with cen ter hole diameters of 3 8 1 4 3 16 and 1 8 inch These discs are installed with retaining rings in the flange at the edge of the 1 2 inch NPT female pipe thread for the purge air An internal type retaining ring 15 first installed by positioning the ring in the IRIS MODEL P522 APPLICATION MANUAL machined groove inside the flange opening from the housing side The orifice disc is then fixed in place tightly between the two retaining rings Install the retaining ring or snap ring in the machined groove inside the flange from the housing side Usually an orifice disc with a larger diameter hole is tried first There will be a reduction in signal so readjustments will be required following the steps outlined in the section INITIAL SETUP If the dis crimination is still not satisfactory then try an orifice disc with a smaller diameter hole Generally speaking orificing should always be con sidered when the burner s are large SOK 165 of steam and up particularly when the 5509 and S512 viewing heads are used The table in Figure 9 shows the signal reducing characteristics of the different orifice discs Aperture Fn Hole f Stop Relative light passing power FIGURE 9 ORIFICING SIGNAL REDUCING CHARACTERISTICS OF DISCS SIGNAL SOURCES Testing the viewing he
56. ition The main power feeds in through the terminals situ ated on the upper left side see GND 26 V and BAT Each designated terminal is a double terminal or pair so that the wiring from the power supply can be daisy chained from one P522 to the next without having to twist wires together into one termination The pair designated BAT is for battery backup if used Note the rectifier used internally to prevent the 26 VDC main power supply from feeding into the battery The backup battery if used should be 24 volts to ensure that the 26 VDC power feeding the P522 will not feed back into the battery In other words no current will flow from the battery as long as voltage of the main power supply is above that of the battery The negative side of the battery goes to the GND terminal on the left Figure 1 shows how these terminals are connected inside the P522 Note the two fuses marked F1 and F2 Fl is the main power fuse for the signal proces sor as well as the viewing head s and is rated at 75 Amp Fuse F2 feeds only to the viewing head s IRIS MODEL P522 APPLICATION MANUAL and is rated at 25 Amp On newer units those with NO CAL and YES in red letters on the front panel these fuses are self resetting types and will recover from an overload automatically after power 1s re moved from the P522 for 10 seconds The viewing head terminals bottom right are iden tified as V H A and V H B If only one viewing he
57. lame sensing The viewing head is tapped for a one inch national pipe thread NPT threaded pipe Any diameter sighting pipe larger than one inch will require a reducer coupling or swivel mount see Figure 20 MOUNTING HOLE Cut a hole for the sight pipe in the burner front windbox at the selected location The hole should be large enough in diameter to allow adjustment of the sighting angle If register vanes interfere with the desired line of sight trim the interfering vanes to ensure an unobstructed view of the flame MOUNTING OF SIGHT PIPE After cutting the pipe to the desired length thread one end of the pipe to fit the viewing head flange or required coupling see Figure 20 Insert the other end of the pipe into the mounting hole align the pipe to the desired sighting angle and tack weld it in place to allow further sighting adjustments Make sure the tack weld will support the weight of the detector when it is installed Once the final position has been determined weld the sight pipe in place INSTALLING THE VIEWING HEAD The viewing head flange screws directly onto a one inch NPT threaded pipe see Figure 20 Use cres cent wrench to tighten the flange onto the sight pipe PURGE AIR Use a flexible air supply line allowing reposition ing of the sight pipe until the permanent detector position has been verified A continuous flow of air must be maintained in order to keep the head cool and the sight pipe clean
58. m nanoamperes to milliamperes 50 some means to prevent saturation in the first stage of amplifica tion is required The PbS element on the other hand has a rather limited dynamic range exhibiting not more than a 15 1 ratio from dark to a bright signal In order to prevent saturation an AGC type circuit is used so that the DC component or brightness signal doesn t saturate causing a loss of the AC com ponent or flicker signal On a bright signal this Si channel is limited or compressed so that there is a maximum signal reached that will not be exceeded no matter how much brighter the signal is Another non linear characteristic can be attributed to both the Si and PbS channels on bright signals exhibiting a large AC DC component such as an in candescent light source In this case the amplifi ers downstream of the first stage are in a clipping mode i e approaching 120Hz squarewave which even though the signal is AC has a limiting charac teristic This is indicated on the digital display with a count or signal strength of about 2900 This is with the filter switch in the LL position the display will read about 2100 with the filter switch in the H position Fortunately flame signals do not exhibit this large AC DC component so the amplifiers downstream play a lesser role with this type of non linearity see section SIGNAL SOURCES However if it is determined that there is a limiting action takin
59. num ber is displayed press the STORE button When the set point is stored four dashes are displayed momentarily indicating that the selected number was stored into the EEPROM Illogical settings cannot be made so if four E s are displayed when push ing STORE P B then an error was made when se Page 11 IRIS MODEL P522 APPLICATION MANUAL lecting the set points For instance selecting a flame out set point that is equal to or greater than the flame on set point will result in this error indication s well the set points can be selected remotely through the serial communication port using host computer explained in greater detail later in this manual FLAME FAILURE RESPONSE TIME F F R T The flame failure response time or F F R T is de fined as the time it takes for the flame relay to de energize after the flame signal from the viewing head drops out This time delay is programmable from both the front panel of the P522 and remote host computer Only three settings are possible one two and three seconds The maximum time delay is limited to three seconds in compliance with the FM Factory Mutual limit of the F F R T to not more than four seconds The P522 decision making process on pe riodic basis and the decision to start a F F R T time delay before de energizing the flame relay is initi ated every second in step with the sampling rate of the flame signal This means that
60. of the flame relay in most instal lations is not used directly to control the fuel valves The circuitry used between the flame relay and the safety shutoff valve solenoid should be carefully examined For example a condition where the flame relay of the P522 feeds only to a pro grammable logic controller PLC and the PLC controls the fuel valve repre sents a dangerous installation with the po tential for a serious explosion Page 26 USING A PLC WITH IRIS FLAME MONITOR PLCs are inherently unsafe when used by them selves 2 3 Schemes have been devised to make them safe such as feeding outputs back to the in puts to check the outputs using multiple outputs in series for redundancy and using watchdog timers that presumably detect malfunctions None of these methods will make a PLC critical control loop 100 per cent safe PLCs cannot and should not be used by themselves for burner control or burner management systems without external protective circuitry to make them 100 per cent safe The critical loops that must be pro tected are the main fuel trip MFT functions initial burner igniter light off subsequent continued burner firing with flame monitoring and burner shutdown Most burner control systems are designed for over all fail safe operation safe means that in the event of a failure of any component s or power the burner or boiler will be shutdown safely This usu ally is accomplished
61. onent present The element in an incandescent light pro duces radiation in step with the AC power cycle ef fectively turning on and off 120 times per second There is a certain amount of thermal inertia so that the element doesn t turn off completely but the large ratio of ON to OFF AC DC still prevails A more realistic simulated signal source can be created by employing an AC to DC power supply with super imposed ripple feeding an incandescent lamp If the 120 Hz AC ripple is about 10 per cent then this sig nal source can be used to more closely resemble a flame source keeping in mind that the simulated flicker is a single frequency of 120 Hz Consideration should be given to the effects of pre senting a single frequency simulated flame source to the downstream four position filter For example if an incandescent light source is used powered by the 60 Hz line switching from LL to L position will not affect the 120 Hz signal at all because of the cutoff frequency of 36 Hz and 71 Hz respectively providing the downstream stages of amplification are not saturated sinusoidal 120 Hz signal amplified to re Page 24 semble a squarewave caused by waveform clipping of the operational amplifiers If this signal is saturated then switching from LL to L may indeed cause a higher reading in the signal processor caused by the squarewave type waveform presented to the filter For this reason it is impor tant not to jud
62. r increases the unwanted background that results in poor discrimination Page 29 IRIS MODEL P522 APPLICATION MANUAL 4 NO IWY 440 3WV13 30v3H31NI 39V3U31NI 91d OL 91d OL Old 084 JAIVA NHST 3A1VA NOIT N3d0 N3d0 NO 99 uvau NO 8d dOLS SLOVLNOO HINYNE p 0254 SLOVINOO WO SLIT 1303 3131dW09 39ufld 134N ON FIGURE 12 BASIC BURNER START CIRCUIT Page 30 The BASIC BURNER START CIRCUIT shown in Figure 12 is a basic circuit requiring only two pieces of external hardware for each burner 1 Master Relay with at least two nor mally open contacts rated for load 2 DADE Timer with two instant close timeout open contacts 1 Bryant Design of Fail Safe Control Systems Power January 1976 2 Bryant Is Your Plant s Control Sys tem Safe Power August 1979 3 Fischer Are PLCs Suitable for Emer gency Shut Down Systems Presented at 43 symposium for the process in dustries Texas A amp M University 1988 MODULE COMMUNICATIONS The P522 communicates with any host computer that has an RS 232 serial I O port and supports ASCII character code transmission at 4800 baud or in cur rent r
63. r another cable running in metal conduit to the control room or signal processor enclosure or use IRIS C 330 cable or shielded cable with UL ITC and CSA 22 2 No 239 ratings without conduit When using S55X viewing heads in hazardous locations the above cabling specifications also apply except that if conduit is used it must be sealed at both ends Contact information Sales and Applications IRIS Systems Inc 7583 Vantage Place Delta B C Canada V4G LAS Ph 800 667 IRIS Ph 604 584 4747 Fax 604 581 9790 Factory and Repairs JB Systems Inc 4944 113 Ave Largo FL 33760 Ph 727 545 3900 Fax 727 547 9589 GAIN SET FFRT TIME DELAY ON RESET AN VERN C a J SE O lt Ge Approved US TA GN TN AN 1 NN 2 qp ub Y 2 CD er u SUD o 5 6 olli 6 5 9 2 9 tjt t t amp m de Lu ot 19 A n N 2 186 2 RELAY 1 gt Poe L lt FA E L 201779 gt 75 gt 2 RELAY 2 3 24V SIG 4 F2 le gt SIG GND 4 o ST VH 57 SEL RELAY ANALOG CURRENT DRIVE 0 20mA OR 4 20mA d SHUTTER DRIVE RS 422 CHAN SELECT i 9 o gt 01090 o sa
64. r terminals called TX TX RX and RX to the left of RMT METER terminals are used for the serial communication link The serial commu nication is achieved by using ASCII character code transmission at 4800 or 9600 baud through the RS 232 com ports on the host computer The P522 uses RS 422 data transmission which is over two twisted pairs that are differentially transmitted and received allowing long wire runs to be used through noisy environments An RS 232 to RS 422 converter must WIRING SIDE VIEW COVER REMOVED 2057 2 GREEN be used to communicate with the P522 and the con nections are made to the terminals marked TX TX RX and RX The transmitting twisted pair goes to the TX terminals and the receiving twisted pair goes to the RX terminals Note the terms transmit and receive used here with respect to the P522 will be reversed with re spect to the RS 232 connection on the host computer Refer to later sections in this manual for detailed description of the software and how it is to be used with the P522 WIRING OF VIEWING HEAD Wiring of the viewing head is made to the terminals on the lower right side of the P522 These terminals are described as follows TERM DESCRIPTION V 24 VDC power to viewing head GND Power Ground SC Self check shutter drive signal to viewing head SIG Flame signal from viewing head SIG GND Signal ground Figure 2 shows four conductor cable to the view
65. re required Any DC voltage from 7 5 to 30 may be used The current required will depend upon the voltage be cause this is a photocoupler interface circuit with a 3900 ohm resistor feeding the LED light source For example a 26 VDC voltage will result in a current flow of 25 3900 0064 Amp If flame is being detected and the channels are switched the flame relay will remain energized for Page 5 IRIS MODEL P522 APPLICATION MANUAL one cycle regardless of the new set points allowing channel changes on the fly so to speak If the new flame OFF set point is equal to or greater than the current signal count then the flame relay will de energize on the subsequent cycle The pair of terminals designated RMT METER to the left of the CHAN SEL terminals is for the remote meter connection This output is current driven sig nal that ranges from 0 to 20 mA for remote meters and can be switched to a range of 4 to 20 mA for DCS distributed control system applications refer to sec 4 20mA REMOTE OUTPUT Connect the terminal marked positive to the positive meter ter minal This current signal can be used with a volt meter by feeding the signal to a resistor connected to the ground The voltage developed across the resis tor will follow Ohm s law IR For example 3 volt meter can be used with a resistor of 3 02 150 ohms which will result in a full scale reading of 3 volts for a 20mA output The fou
66. re shutting down in an or derly manner This prevents bogus num bers from being stored and protects ex isting data in the EEPROM Electrically Erasable Programmable Read Only Memory from corruption and is facili tated by a special internal power supply that holds a charge like a battery just long enough to allow the processor to do its job before going dead This internal circuit monitors the 26 VDC power feeding the P522 and when the voltage drops to about 19 volts the processor shuts down the pro gram stops running and the self checking function ceases the self checking relay de energizes The blinking SELF CHECK light on the front panel will go out and the flame relay will de energize Please note that the 5509 and 5512 viewing heads will shut down at about 17 0 volts these heads have their own power monitoring capability and will shut down on their own independent of the signal processor When the power feeding the P522 exceeds 19 volts the processor starts the program again The SELF CHECK O K light will start blinking and the self check relay will energize If flame is present and 5509 or 5512 viewing head is being used the flame signal will not come back on until the power reaches 21 5 volts This can cause lockout condition if the viewing head turns on during the dark period defined by the periodic self check signal going to the viewing head each second requiring manual reset of the P522
67. rib ing the functions and attributes of this series of sig nal processors 7A 2 S 9 SG SS 426V VM ee SC OFF 0 20mA or 4 20mA ANALOG CURRENT DRIVE SHUTTER DRIVE CHAN V H SEL SEL FIGURE 1 P522 REAR MOTHERBOARD Page 4 WIRING TO THE PLUG IN TERMINALS Figure illustrates the plug in terminals on the rear mother board and how they are connected internally The flame relay and self checking relay contacts are situated together in the upper right portion of the diagram RF C refers to the common terminal of the flame relay with ON being flame on and OFF being flame off You will note that there are two sets of contacts used for the flame relay SC C refers to the common terminal of the self check ing relay There is only one pair of contacts used for the self checking function Here the designa tion ON refers to the self checking taking place in normal manner OFF indicates a failure in the view ing head or processor resulting from the hardware i e the shutter mechanism in the viewing head or the output relay itself electronic components anywhere or internal software in the P522 or the power to the unit is OFF the most likely cond
68. rly on pulverized coal flames LOW NOx APPLICATIONS Since the advent of low NOx burners and combustion techniques to reduce emissions the application of flame monitors has been radically changed i e an infrared flicker flame monitor will not discriminate between burners in boilers utilizing low NOx gas burners This is particularly true if FGR is being used Only a UV flame monitor with wide linear range 5506 can be used In this type of application UV radiation is spread out all over the furnace but the more intense radiation is concentrated at the root of the flame envelope so the flame monitor must be aimed at this zone On the other hand a UV flame monitor will not work on low NOx oil flame because there is little UV radiation detectable from this type of staged com bustion Only an infrared flicker type flame moni tor 5509 5512 will discriminate between burners The viewing head application tables see Figure 11 show most of the common applications and the view ing heads recommended for them If you have enqui ries regarding applications that are not listed please contact Bob Langthorne at IRIS Systems Inc for rec ommendations APPLICATION OF P522 Great effort has gone into designing the P522 signal processor to make it fail safe When properly in stalled and functioning as designed it functions as a safety device that will provide protection from boiler or furnace explosions However the output
69. s to do with the signal sensitivity and temperature The PbS type detector becomes less sensitive with increasing temperature For example the sensitivity or signal will drop to one half with an increase in tem perature from 25 to 50 further increase in sensitivity will occur above 50 C This is the reason for the 60 operating temperature limitation on the viewing head This characteristic is in herent in all PbS detectors but should not cause problem with respect to flame monitoring and discrimination The sig nal level will be stable once tempera ture equilibrium has been reached This sensitivity versus temperature characteristic is another reason why the PbS cell should not be ex posed to high brightness flames The radiation of the flame is focused on the PbS element causing its tem perature to rise reducing the displayed count This reduction in output with increased flame intensity is another form of saturation Also the exposure to el evated temperatures over period of time causes an aging process resulting in change of the dark resis tance of the PbS element and a loss of sensitivity To reiterate The nonlinearity of the Si channel caused by the action has been major con tributor to discrimination problems The background will always be less intense because it is further away less by the square of the distance Being less in tense means it receives more amplification AGC
70. sequent flame failure will cause the RM to drop out de ener gizing the main fuel valve s regardless of the state of the PLC This wiring diagram is not intended to illustrate all the logic that would normally be used in a multiburner system but to show only the bare es sentials required to make the PLC safe Such func tions as low fire permissive on first burner started flameout alarm and reset main burner time trial for ignition and igniter shutdown would be part of the PLC logic Occasionally it is necessary to use two viewing heads one for the igniter and one for the burner with one signal processor In this case you can switch between them using one head at a time the igniter viewing head when proving igniter flame and the burner viewing head for proving main flame re fer to section MULTIPLE VIEWING HEADS A safe start check would have to be made on both viewing heads you do not want to start up a burner if itis already reading other flames You can do this by looking at both flame monitors in parallel switch both inputs together by connecting together the SIG terminals of each viewing head and the SIG GND terminals of each viewing head before starting the ignition sequence This will result in the normally closed RF contact on the P522 having to be closed in order to start the burner This parallel viewing head operation should only be used for the start up sequence because adding the flame signals togethe
71. splayed will be for the channel that is active which is indicated by a steady illumination of push button A or B To see the other channel set points first select the chan nel A or B then press the desired set point button For example if channel A is already ON indicating it is functional and B is pressed A will go out and B will pro ceed to blink slowly indicating that fur ther action is required If A is already ON and A is pressed it will stay steady ON and start to blink rapidly after a set point button is pressed In all cases A or B will rapidly blink after the set point is selected This action alerts the user that the current display is no longer that of the flame signal and further action is required The fact that A or B is already on has nothing to do with the process of viewing the current set points except that you do not have to select the channel if it is already on The steady illumination of A or B indi cates which channel is functionally active and is se lected at the plug in terminals marked CHAN SEL At any time you can press the reset button causing the P522 to go back to its normal operating condi tion The reset button is also used for resetting the lockout condition as explained in the section SELF CHECKING FUNCTION CHANGING SET POINTS Changing any of the five set points is easy Simply bring up the desired set point and change it using the UP or DOWN arrow buttons When the desired
72. the P522 will indicate this condition requiring a reset to return to normal flame monitoring mode A reset can be achieved only if the lockout condition Page 10 has been corrected and can be performed from the front panel by pressing the RESET button or re motely through the serial communication APPROVALS The P522 and viewing heads have Factory Mutual FM Approval for Combustion Safety Canadian Standards Association CSA Certification and National Recog nized Testing Laboratories NRTL Listing POWERING UP THE P522 Once the power is connected 26 VDC to the plug in connector the P522 will be operational There is no ON OFF switch on the P522 the moment it is pow ered on it will reset and start up The self checking light will start blinking and one of the channel LEDs A or B will light A will be ON if the channel select input at the plug in connector is de energized Make sure the voltage is 24 to 26 VDC The P522 will be reset when the power is turned on however the power must be a step function i e the power must be ap plied abruptly for this reset to work properly The P522 has been designed to deal with any fore seeable power failure or anomaly For example if the power goes off while you are in the process of storing a set point either from the front panel or from the remote host computer the internal power monitor circuit will signal the P522 processor to complete the store function befo
73. the above cabling specifications also apply except that if conduit is used it must be sealed at both ends Contact information Factory and Repairs JB Systems Inc 4944 113 Ave Largo FL 33760 Ph 727 545 3900 Fax 727 547 9589 Sales and Applications IRIS Systems Inc 7583 Vantage Place Delta B C Canada V4G 1A5 Ph 800 667 IRIS Ph 604 584 4747 OK GAIN SET FFRT TIME DELAY ON RESET N VEN O 2 ER J NT O lt GB Approved TI 077 A EA i lt D 2 Q M e M C e Q u gt u 2 s 8 9 x 35 o 5 6 o 5 6 5 622685390 9 9 9 Elle b b UN E L Ld o 2 KZ 9 SE L F1 2 SC I 75A 4 RELAY gt 2 P 24V 10W RF 2 DC RELAY a POWER SUPPLY 24V SIG 5 72 F2 lt 25A SIG GND 0 VH SEL RELAY ANALOG 4 CURRENT DRIVE pr 0 20mA OR 4 20mA 3 SHUTTER DRIVE RS 422 CHAN SELECT 9 o gt o sa RMT CHAN 262 9 3 050 9 5 METER SEL SEL VH A V H B T D DA IND h AM ES CAL f NG D G SID GOSS OD OS ID IVS r 15 May 2008 IRIS MODEL P522 APPLICATION MANUAL ADDENDUM 2B
74. the actual flame out condition 1 drop out of the flame signal from the viewing head will in all probability occur dur ing the sampling period that causes the actual F F R T to be greater than the set time For example suppose the signal from the viewing head drops out immedi ately after a sampling from the P522 and the sampling perceives flame to be present If the F F R T set point is set for three seconds there will be an actual time delay of nearly four sec onds In other words the actual F F R T will be the current set point time plus an additional amount of time not exceeding one second de pending upon when the flame signal from the viewing head drops out Page 12 4 20mA REMOTE OUTPUT The standard remote meter output has a 0 20mA range and is designed to drive remote meters as ex plained earlier in this manual You can convert this output to a 4 20mA range as follows Press the front panel push buttons indicated in the table below while holding down both the and buttons Press all in each row together i e three in the first row two in the second row and three in the last row FLAME FLAME TIME DEL FIGURE 6 REMOTE METER ANALOG OUTPUT Doing this toggles the function back and forth be tween the 0 20mA and 4 20mA ranges The change will be verified by four dashes and 4 20 momentarily displayed If the module is programmed for the 4 20mA range 4 20 will
75. the angle of view For the S509 viewing head this angle of view is about 2 8 degrees For the 5512 the angle is slightly less To understand what this means imagine a circular target of flame radiation one inch in diameter 24 inches away from the lens this is the maximum field of view the detector sees In other words a one inch diameter sight pipe two feet long will allow maxi mum signal to be detected A two inch diameter sight pipe four feet long presents the same target Actually a one inch target three feet away causes an immeasurable signal attenuation so you can use a two inch diameter pipe up to six feet long with no signal attenuation The angle of view for the 5511 viewing head is 1 1 degrees This translates into a one inch circular tar get 52 inches away from the lens In other words a one inch diameter sight pipe four feet long or a two inch diameter sight pipe eight feet long will allow maximum signal to be detected For a detailed explanation of how the angle of view is derived refer to section ANGLE OF VIEW OF VIEWING HEAD If a long sight pipe is required then we recommend that a swivel mount be used to overcome any optical misalignment that might be present see Figure 20 IRIS MODEL P522 APPLICATION MANUAL In this way the flame signal can be optimized by adjusting the viewing head to the target at the end of the pipe SELECTING THE PIPE We recommend a black iron pipe to provide reliable f
76. tput is randomly spaced pulses with an average pulse rate proportional to the UV radiation present The digital count when reading natural gas will be about the same as the S512 and probably will be less when reading heavy oil flame The very narrow spectral response of the UV tube makes this type of detector ideal for discriminating between flame glowing refractory and other burn ers However because of its response to only the very short wavelengths problems can occur because this radiation is easily absorbed and masked by un burned fuel or other impurities in the coal 1 with pulverized coal Sour gas HS will readily absorb these short 200 nm wavelengths as well as other waste fuels resulting in a dropout of the flame sig nal Even standard glass will absorb this wavelength therefore it is necessary to use a quartz lens with this viewing head In general the 5506 viewing head will work well on natural gas flames It will respond to oil flames but with a lower signal level The sighting should be parallel to the axis of the burner and aimed at the foot of the flame Photographs of gas and oil flames using visual and UV sensitive film clearly show that the UV zone is much smaller than the visible zone and the highest UV intensity occurs near the flame root In addition the zone of higher UV intensity does not overlap the same zones of adjacent or op posing burners so with proper sighting discrimi nation is pred
77. uit can be opened leaving only the igniter viewing head signal to be read And when proving flame from the main burner the igniter sig nal circuit can be broken We recommend that only the flame signal from each viewing head be switched leaving the other connec tions to the viewing head intact the one exception would be the 5506 UV head Both the flame signal and shutter drive circuits should be switched so that when the head is not being used the shutter is not switched on and off This was done in the design of the rear mother board see section WIRING AND INSTALLATION Note that both the SIG and SIG GND circuits are switched However this can cause a lockout condi tion if the transfer of the viewing heads is done dur ing the dark period This problem can be avoided by changing channels when switching heads by wiring the two terminal blocks V H SEL and CHAN SEL together in parallel This will inform the P522 that the viewing heads are being transferred and the pulses counted during the dark period will be ignored DETERMINING SIGHT PIPE SIZE In order to determine the proper sight pipe it is im portant to understand how the viewing head views the flame The viewing head employs a plano con vex lens in front of the photodetector that focuses the flame radiation on the surface of the detector The active photodetector element is quite small and its diameter and the focal length of the lens deter mines

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