Honeywell U2 User Manual Download

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U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS

66-2071—02

SAFETY MANUAL

Uniscan 2 Product Declaration

FIT FOR USE IN A Low Demand SAFETY APPLICATION

Models: 1010, 1012, 1016, 1018, 1010-PF, 1012-PF, 1016-PF, 1018-PF

Definitions

Models

SIL HFT

SFF

PFD

1010/1010PF

>99%

1.54 X10

-4

1.08 X10

-5

7.22 X10

-9

6.95 X10

-9

1012/1012PF

>99%

1.45 X10

-4

8.19 X10

-7

7.22 X10

-9

6.62 X10

-9

1016/1016PF

>99%

7.55 X10

-5

1.08 X10

-5

1.97 X10

-9

3.45 X10

-9

1018/1018PF

>99%

1.54 X10

-4

1.08 X10

-5

7.22 X10

-9

6.95 X10

-9

System Architecture

1oo1

MTTR 8

hours

Proof Test Interval

5 years

Fit for use in

SIL 3 environment

Term

Definition

Dangerous Failure

Failure which has the potential to put the safety-related system in a hazardous or fail-to-function

state

Safety-Related System

A system that implements the required safety functions required to achieve or maintain a safe

state and is intended to achieve on its own or with other systems the necessary safety integrity for

the required safety functions.

Safety Function

Defined function, which is performed by a safety-related system with the aim of achieving or

maintaining a safe state for the plant, in respect of a specified hazardous event.

Proof Test

Periodic test performed to detect failures in a safety-related system so that, if necessary, the

system can be restored to an “as new” condition or as close as practical to this condition.

MTTR (Mean Time To

Restoration)

The average duration required for restoration of operations after a failure.

Rate of safe detectable failures per one billion hours.

For example, if

= 3000, then it is estimated that there will be about 3000 safe detectable

failures during every one billion hours of operation.

For

= 3000, this is about one safe detectable failure every 38 years.

Rate of safe undetectable failures per one billion hours.

Rate of dangerous detectable failures per one billion hours.

Rate of dangerous undetectable failures per one billion hours.

HFT

Hardware Fault Tolerance

System Architecture

Specific configuration of hardware and software elements in a system.

PFD

AVG

(Average Probability

of Failure on Demand)

Average Probability of Failure on Demand. In this case regarding the Uniscan 2.

FIT (Failures in Time)

A unit of measurement representing one failure per billion hours. 1,000,000,000 hours is

approximately 114,155.25 years.

Summary of Contents for U2

Page 1: ... technology does not provide satisfactory results The solid state UV photodiode has a peak response at 310 nm This sensor is suitable for gas oil and coal The principle of flame monitoring is flicker frequency based User selectable high pass filters are used to reject signals that are from background radiation The solid state IR photodiode has a peak response at 1400 nm This sensor is suitable for...

Page 2: ...ble for appli cations with higher ambient temperatures Please contact your distributor or Honeywell for assistance Weight 2 8 kg 6 1 lbs Physical Dimensions Diameter 11 7 cm 4 6 inches Length 15 5 cm 6 1 inches Paint Silicone free powder coat Mounting Process Connection 1 NPT female NOTE Refer to for Fig 9 and Fig 10 mounting examples Pipe Fit Conduit Connection PF 3 4 NPT FFRT 1 3 second nominal ...

Page 3: ...xample igniter equipment 3 Install a ground wire from the ignition transformer case to the igniter assembly 4 Ensure all igniter wires and cables show no signs of wear Replace any igniter cables or wires that are frayed or cracked 5 The U2 must be electrically isolated from the burner front a Electrical isolation can be accomplished by install ing an Ultem locking coupler adapter R 518 PT12 or R 5...

Page 4: ...een the sight pipe and the U2 allowing the U2 to be placed further away from the heat source Refer to the Fiber Optic Manual 69 2683 or contact your distributor or Honeywell for assistance with fiber optic selection and pricing The U2 models also have an internal sensor for measuring temperature To access the temperature reading at the U2 refer to Fig 2 Purge Air The U2 does not have a purge air c...

Page 5: ...larly true when flue gas recirculation is used There will however be a relatively stronger signal near the root of the flame and the more intense spot should be located during the aiming or sighting process The root or intense spot may be further out than with the standard gas burner so it is imperative that a swivel mount be used when making sighting adjustments As an example of proper sighting c...

Page 6: ...e also provided The Flame On threshold and Flame Off threshold can then be set to monitor the target burner flame but to reject background radiation from other burners In order to energize the flame relay the flame count must be higher than the programmed Flame On threshold for greater than the Time Delay value Once the flame relay is energized the flame signal can fall below the programmed Flame ...

Page 7: ... The default value is 75 Filter SSUV NOTE If sensor is not available in your model then no menu item will exist for sensor setting See Table 1 on page 2 to determine which sensors are active in your U2 model Displays the current solid state UV high pass filter adjustable 0 9 The default filter is 3 See the filter cutoff frequencies in Hertz in the table below M33314 GT32 G 32 F 09 GI32 FI04 GM32 0...

Page 8: ... unknown state If not being used or if using the default file 0 connect the file input wire to ground When connected to 24 Vdc the file selection 1 The other means of selecting and activating a file is via the Modbus RTU interface using register address 40093 Modbus interface can be accomplished via FlameTools software or another Modbus RTU interface Panel Tapping the ENTER STORE button when PANEL...

Page 9: ...d modification which is available from the factory If the password is forgotten or lost the user must contact the factory for assistance with unlocking the panel Refer to the Panel section of this manual and or contact the factory for assistance Bad Message If the display shows Bad upon entering the access code for the PANEL Lock feature it means the access code that was just entered is incorrect ...

Page 10: ...Hz 9 300Hz 0 9 8 bit 40012 UVTGAIN UV tube gain setting for current active file 0 99 8 bit 40015 UVSSFILT High pass solid state UV sensor filter setting for current active file File 0 8Hz default 1 16Hz 2 24Hz 3 33Hz 4 52Hz 5 75Hz 6 100Hz 7 155Hz 8 215Hz 9 300Hz 0 9 8 bit 40016 UVSSGAIN Solid state UV sensor gain setting for current active file 0 99 8 bit 40019 TEMPERATURE Current internal tempera...

Page 11: ...ER CONTROL BNR 1 31 BNR 2 12 BNR 2 32 BNR 3 13 BNR 3 33 BNR 4 14 BNR 4 34 BNR 5 15 BNR 6 16 ADDRESS BOILER 3 COMMOD USB TO RS422 485 CONVERTER M33862 WIRE SIDE PRODUCT SIDE A TDA B TDB C RDA D RDB E GND TDA TDB RDA RDB GND NOTES SELECT THE APPROPRIATE DIP SWITCH SETTINGS FOR RS 485 COMMUNICATION PER THE VENDOR S INSTRUCTION SHEET SOFTWARE DRIVERS MAY BE DOWNLOADED FROM B B ELECTRONICS WEBSITE CONV...

Page 12: ...U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS 66 2071 02 12 Fig 5 U2 dimensions 3 4 19 NPT CONNECTION 2 29 32 73 1 25 1 25 NPT CONNECTION 5 3 32 130 4 19 32 118 M34431 ...

Page 13: ...threshold lower Flame On threshold below flame on signal e Repeat all tests if any changes are made to Gain Flicker set point Flame On and Flame Off Threshold NOTE Above is a simplified version of discrimination adjustments Vessels equipped with a large number of burn ers T fired units and cross fired boilers will require several adjustments including use of multiple files for obtaining the requir...

Page 14: ...carried out under supervised conditions and limited to minimum time Remove bypasses as soon as configuration and setup is completed For vessels equipped with gas igniters follow setup procedure described above For best discrimination two to three files may be required to accommodate three different fuel firings 1 Establish igniter flame as described above 2 Start warm up oil burner 3 Go to IR menu...

Page 15: ... value 10 Restart the burner being monitored 11 Ensure the current flame count is greater than the FLAME ON value MAINTENANCE The UV tube sensor has a limited lifespan Under extreme conditions the lifespan can be as low as 10 000 hours However in the most favorable conditions the lifespan is 50 000 hours or more The service life of the UV tube sensor is considered terminated when the sensitivity b...

Page 16: ...ghting opposed fired burners UV VIEWING HEAD SIGHTED ON UV ZONE BURNER NOZZLE CENTERLINE UV RADIATION ZONE M33286 VIEWING HEAD BURNER NOZZLE NO 1 NO 1 FLAME ENVELOPE NO 2 FLAME ENVELOPE VIEWING HEAD BURNER NOZZLE NO 2 HIGH FREQUENCY IR ZONE LOW FREQUENCY ZONE LESS THAN 36Hz HIGH FREQUENCY IR ZONE M33287 ...

Page 17: ...ided via a Y or T in between the locking coupler and the sight pipe to reduce conducted heat and to keep the sight pipe and U2 lens clean of debris and dirt Refer to the Mounting and Sighting section on purge air requirements For electrical isolation reasons the purge air line should be installed using an insulating material such as a rubber hose in between the purge air line and the viewing head ...

Page 18: ...or file 6 Flame On setting for file 7 51 3425 16 bit 40101 40111 40121 40131 40141 40151 40161 40171 FLAMEOFF Flame Off setting for file 0 Flame Off setting for file 1 Flame Off setting for file 2 Flame Off setting for file 3 Flame Off setting for file 4 Flame Off setting for file 5 Flame Off setting for file 6 Flame Off setting for file 7 50 3424 16 bit 40102 40112 40122 40132 40142 40152 40162 4...

Page 19: ...118 40128 40138 40148 40158 40168 40178 IRGAIN IR sensor gain setting for file 0 IR sensor gain setting for file 1 IR sensor gain setting for file 2 IR sensor gain setting for file 3 IR sensor gain setting for file 4 IR sensor gain setting for file 5 IR sensor gain setting for file 6 IR sensor gain setting for file 7 0 7 8 bit 40109 40119 40129 40139 40149 40159 40169 40179 OUTPUTGAIN Current outp...

Page 20: ...f 400 used when all 3 sensors are active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to Filter0 through Filter9 read only 0 99 8 bit 40240 to 40249 IRSAVEDGAIN600 The gain at the IR filter to give a count of 600 used when 2 sensors are active to total a count of 1200 Saved at the time the auto filter routine was run Registers correspond to Filter...

Page 21: ...e current file determined by the auto gain function read only 0 99 8 bit 40293 USSSSAVEGN Saved gain of the solid state UV sensor from the current file determined by the auto gain function read only 0 99 8 bit 40294 SAVEFILE Saves the active file at the time of auto gain Reads 255 if the auto gain function has never been run read only 0 255 8 bit Table 5 Extended Modbus Register Map Continued Regi...

Page 22: ...ed system with the aim of achieving or maintaining a safe state for the plant in respect of a specified hazardous event Proof Test Periodic test performed to detect failures in a safety related system so that if necessary the system can be restored to an as new condition or as close as practical to this condition MTTR Mean Time To Restoration The average duration required for restoration of operat...

Page 23: ...y high or continuously low signal which could potentially be caused by a fault Each relay must be driven by an alternating signal of the proper frequency and duty cycle from the processor Proof Test Interval The Proof test must be conducted every 1 to 5 years This range is given to allow for the test to be performed during the normally scheduled burner shutdown period It is the responsibility of t...

Page 24: ...tion and using a multimeter ensure there is no continu ity between the relay common and flame relay wires after the FFRT Flame Failure Response Time has elapsed 5 Measure the current draw of the U2 and ensure it is less than 120 mA 6 Change one of the settings of the signal processor and store the changed setting Remove power to the signal processor for 10 seconds Restore power to the signal proce...

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