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U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS

66-2071—02

6

Locking coupler (R-518-CL12-HTG)

 – Used with the R-518-

PT12 and R-518-PT12L insulating locking coupler adapters. 

Process connection end is 1 in. NPTF.

Connector (R-518-10)

 – Quick disconnect connector for all 

non-pipe fitting U2 models.

NOTE: Connector is not included with the non-pipe fit-

ting models. Order separately along with cable 

and required mounting accessories.

Cable (C12S)

 – 12 conductor cable with braided shield. Sold 

per foot.

NOTE: Cable is not included with the non-pipe fitting 

models. Order separately along with connector 

and required mounting accessories.

Cable+ Connector (ASY964)

 – Pre-assembled 15-foot 

(4.7m), 12-conductor cable (C12S) with quick disconnect (R-

518-10) for all U2 non-pipe fitting models.

Fiber Optic System Compatibility

 – The U2 models are 

compatible with the Honeywell FASA fiber optic extension 

products. The S550FOAD, S550FOADY-FT and S550FOADY-

FT-AL adapters are applicable. Contact your distributor or 

Honeywell for assistance with fiber optic selection and pricing.

USB to RS422/RS485 Converter (COMMOD)

 – Protocol 

converter for use with external communication to a remote 

computer.

OPERATION

IR and UV Detectors

See Table 1 on page 2 to determine which sensors are active 

in your U2 model.

The UVTron tube sensor responds to UV radiation from 

different fuel flames. The UVTron sensor generates pulses 

that are electronically conditioned to provide output indicated 

on the U2 display from 0000 to 3425 units.

The signals from the UVSS solid state sensor are processed 

based on flicker principle using FFT (Fast Fourier Transform). 

User selectable high pass filters are used to reject signals that 

are from background radiation. 

The signals from the IR solid state sensor are processed 

based on flicker principle using FFT (Fast Fourier Transform). 

User selectable high pass filters are used to reject signals that 

are from background radiation.

Each sensor allows independent adjustment for gain. For 

flicker-based sensors, there is also a high pass filter setpoint.

To further assist in flame discrimination setup, adjustable 

“Flame On” and adjustable “Flame Off” thresholds are also 

provided. The Flame On threshold and Flame Off threshold 

can then be set to monitor the target burner flame but to reject 

background radiation from other burners.

In order to energize the flame relay, the flame count must be 

higher than the programmed “Flame On” threshold for greater 

than the “Time Delay” value. Once the flame relay is 

energized, the flame signal can fall below the programmed 

Flame On threshold setting. As long as the flame signal 

remains above the programmed “Flame Off” setting, the 

system will continue to operate. When the flame signal falls 

below the programmed “Flame Off” threshold, it will not be de-

energized until after the “FFRT” (flame failure response time) 

expires, unless “Flame On” is detected.

The U2 includes a self check relay which should always be 

energized whenever the U2 has power. The self check relay is 

de-energized (failsafe) when an internal fault is detected. The 

self check relay is factory wired in series with the flame relay. 

One additional contact is provided for alarm purposes.

Self-Checking

There is a small processor in all viewing heads and it is 

possible that it could fail and produce erroneous viewing head 

pulses. The self-check circuitry guards against such an 

occurrence. There are several tasks that require intelligent 

interaction between the viewing heads and the signal 

processor. If all of the interactions do not occur properly, the 

flame relay will open.

User Interface

A touch wheel located on the back of the U2 is used for 

operator interface. The configuration menu is simple and easy 

to follow. Full character 4 digital scrolling LED displays are 

visible in the dark or sunlight. Individual sensor LEDs (3 total 

located below the display) flash to indicate the output of each 

sensor (green = UVT, Blue = SSUV, Red = IR). The upper 

right green self-check LED provides status of the hardware 

while the upper left red “Flame On” LED provides status of the 

flame relay (main safety device).

NOTE: The number of LEDs is model dependent.

The touch wheel is designed like an iPod

 to allow for slow or 

fast changes by moving a finger slower or faster around the 

back glass. Alternatively the user may tap 

 (-) or 

 (+) to 

make changes. Tap 

ENTER/STORE

 to enter a menu or store 

selected data. Tap 

BACK

 to return to the previous menu. Exiting 

all the menus will display the current flame count. The U2 

menus are detailed below.

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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