IRIS P520, Applications Manual

Page 1: ...FLAME MONITORING SYSTEM MODEL P520 SIGNAL PROCESSOR APPLICATION MANUAL ...

Page 2: ...OF SIGHT PIPE 20 INSTALLING THE VIEWING HEAD 20 PURGE AIR 20 SET UP AND ADJUSTMENT PROCEDURES 20 SIGHTING ADJUSTMENT 21 INITIAL SET UP 21 ADJUSTING SET POINTS 22 TROUBLESHOOTING GUIDE 23 NOISE INTERFERENCE AND GROUNDING 23 S506 VIEWING HEAD 24 S506 SELF CHECKING VIEWING HEAD 25 S509 VIEWING HEAD 25 S511 VIEWING HEAD 26 S512 VIEWING HEAD 26 ORIFICING 28 FIGURE 14 ORIFICING SIGNAL REDUCING CHARACTER...

Page 3: ...ER ANALOG OUTPUT 17 FIGURE 12 VIEWING HEAD CROSS REFERENCE TABLE 18 FIGURE 13 CUTOFF FREQUENCIES 19 FIGURE 14 ORIFICING SIGNAL REDUCING CHARACTERISTICS OF DISCS 28 FIGURE 15 VIEWING HEAD ANGLE OF VIEW DISTANCE AND DIAMETER 30 FIGURE 16 VIEWING HEAD APPLICATION TABLES 32 33 FIGURE 17 BASIC BURNER START CIRCUIT 35 FIGURE 18 SPECIFICATIONS 39 FIGURE 19 MODEL P520 SIDE VIEW 40 FIGURE 20 S5XX VIEWING H...

Page 4: ...we recommend that you read the companion colour brochure describing the hardwareandthebasicoperationofthissignalprocessor CARD FRAMES The backplane card frame consists of a kit of parts that will make up a 19 inch card frame This kit does not include the card guides that the module slides into Four card guides are required for each P520 module therefore a total of sixteen card guides would be requ...

Page 5: ...ckup battery if used should be 24 volts to ensure that the 26 VDC power feeding the P520 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 bat tery The negative side of the battery goes to the GND terminal on the right Figure 1 shows how these terminals are connected inside the P520 Note the two...

Page 6: ...rent signal can be used with a volt meter by feeding the signal to a resistor connected to the ground The voltage developed across the resistor will follow Ohm s law V IR For example a 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 terminals called TX TX RX and RX at the bottom of the PCB are used for the serial ...

Page 7: ...HIELD 90 COVERAGE WITH 012 THK JACKET COLOR BLACK CABLED POLYPROPYLENE FILLERS FOR ROUNDNESS JACKET CROSSED LINKED POLYETHYLENE STRIP 3 8 TYPICAL GROMMET FLAT WASHER CABLE ENTRY NUT SHIELD CABLE PREPARATION 1 3 4 TYP CABLE CABLE CLAMP CONNECTOR WITH REAR COVER REMOVED INSULATE SHIELD WITH SHRINK TUBING LEAVING 3 8 STICKING OUT CONNECTOR JACKSCREW FINAL ASSEMBLY CABLE IS SHOWN WITH SHIELD ALREADY R...

Page 8: ...nnections 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...

Page 9: ...n affect the peak current such as whether or not there is flame being detected the remote meter output is connected and serial communication is occurring The viewing head is powered through the P520 via a 25A self resetting fuse In other words the 26 VDC power feeds into the P520 through a 75A self reset ting fuse and feeds back out through a 250 mA fuse to the viewing head resulting in a current ...

Page 10: ...ame 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 a low forward voltage drop for this applica tion 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 p...

Page 11: ...button or re motely through the serial communication REMOTE I O MODULE An input output I O module is available for imple menting the basic functions described in the previ ous section It will also help facilitate the field wir ing in applications where it is impractical to wire to the rear PCB of the P520 For example in a standard NEMA 12 wall mounted or free standing enclosure a card frame cannot...

Page 12: ...IRIS MODEL P520 APPLICATION MANUAL Page 12 FIGURE 7 IRIS P520 I O MODULE SCHEMATIC ...

Page 13: ...m A S TP S TO P S W FLA M E O N FLA M E O F F O P E N B N R V FR O M PLC B N R VA LVE O P E N P ILO T V FR O M PLC P ILO T VA LVE N O TE S ER IA L TR A N S M ISS IO N TE R M IN A LS TX R X N O T SH O W N IN TH IS D W G IS O LATE D C O N TA C T C LO S E O N N O FU E L TR IP S TR S TA R T S W FIGURE 8 FIELD WIRING TO I O MODULE ...

Page 14: ... ribbon cable receptacle The I O module is illustrated in Figures 6 9 and the wiring schematic of this module is provided in Figures 7 8 9 The I O module provides a mas ter relay load relay with two sets of form A con tacts rated to 15 Amps and is designated as M2 in the schematic SC V VH SEL CH GND V SIG GND SIG GND SC SIG GND SIG SEL TX TX TX TX RX RX RX RX FLAM E R ELAY SELF C HEC KING RELAY V ...

Page 15: ... 26 VDC The P520 will be resetwhenthepoweristurnedon however thepower must be a step function i e the power must be ap plied abruptly for this reset to work properly The P520 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 i...

Page 16: ...e 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 indicates which channel is functionally active and is selected at the rear PCB marked CHAN SEL At any time you can press the reset button causing ...

Page 17: ...hetable below while holding down both the Ý and ß 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 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 be displayed toggl...

Page 18: ... room to remove the housing for servicing see Figure 20 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...

Page 19: ...ected 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 flamesignalswillbeadditive possiblyrequiringalower sensitivity setting A word of caution about this type ofoperation theunwantedbackgroundwiththeburner flame out will also be additive possibly causing a dis crimination problem ...

Page 20: ...rovide reliable flame sensing The viewing head is tapped for a one inch national pipe thread NPT threaded pipe Any diametersighting pipelargerthanoneinchwillrequire a reducer coupling or swivel mount see Figure 25 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 ...

Page 21: ...of the S506 viewing head is more likely to be line of sight than the S512 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...

Page 22: ... 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 SET POINT 75A 25B OFF SET POINT 25A 75B where A is the lowest burner ON reading and B is the highest burner OFF reading Actually a smaller ratio will work as long as the lowest BNR ON reading and the highest BNR OFF reading never...

Page 23: ...meter check at viewing head terminals on rear PCB for 26 VDC across V and PWR GND If the voltage is low check the power supply If the voltage is zero check fuse F2 on the main PCB this is a 25 Amp 20 mm fuse 3 If the voltage measures 26 VDC at viewing head terminals check the voltage at pins four 26 VDC and five PWR GND of the viewing head con nector If the voltage is zero check the wiring and or ...

Page 24: ...ually supplied by a step up autotransformer and not being isolated from the power line it can cause interference particularly if there are grounding prob lems The usual problem occurs when the trans former is energized resulting in a 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 It is the secondary wir...

Page 25: ...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 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...

Page 26: ...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 displaymustbeusedforthisadjustmenttodetectwhen the signal pulls out of a limiting or compressing mode i e when the signal goes below 2700 S511 VIEWING HEAD This viewing head uses a germanium photodiode that has a nar...

Page 27: ...his type of saturation can be de tected on the digital display by observing the signal count The S509 will be completely saturated at a 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 200 Hz the count of 2100 can be taken as the thresh ol...

Page 28: ... solid state flicker types The UV tube in the S506 is not likely to saturate however if the count is over 1500 orificing will definitely improve the discrimi nation ratio An orifice disc 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 ins...

Page 29: ... 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 amplific...

Page 30: ...changes in burner design to comply with clean air standards The S506 UV viewing head will always result in excellent discrimination between burners The key factor in using the UV type detector is obtaining a consistent and reliable signal under all conditions UV radiation is very susceptible to being absorbed and blocked by non hydrocarbon elements and un burned fuel as explained before UV type de...

Page 31: ...s designed it functions as a safety device that will provide protection from boiler or furnace explosions However the output of the flame relay in most instal lations is not used directly to control the fuel valves Thecircuitryusedbetweentheflamerelayandthesafety shutoff valve solenoid should be carefully examined Forexample aconditionwheretheflamere layoftheP520feedsonlytoaprogrammable logic cont...

Page 32: ...d o o g G I S 2 1 5 S S b P d o o g C S I D 1 d o o g G I S 0 5 5 S S b P V U t n e l l e c x e C S I D d o o g y r e v G I S 2 5 5 S y l n O S b P d o o g C S I D d o o g G I S 6 5 5 S y l n O V U t n e l l e c x e C S I D d o o g y r e v G I S L E D O M E P Y T S T N E M M O C 6 0 5 S V U d o o g C S I D d o o g G I S 9 0 5 S 2 1 5 S y l n O S b P e n o n C S I D r i a f G I S 0 5 5 S S b P V U ...

Page 33: ... 3 PULVERIZED COAL L E D O M E P Y T S T N E M M O C 6 0 5 S V U t n e l l e c x e C S I D r o o p y r e v G I S 2 9 0 5 S y l n O S b P d o o g C S I D d o o g G I S 9 0 5 S i S r i a f C S I D d o o g G I S 1 1 5 S e G r o o p C S I D d o o g y r e v G I S 2 1 5 S S b P d o o g C S I D d o o g G I S 0 5 5 S S b P V U t n e l l e c x e C S I D d o o g y r e v G I S 2 5 5 S y l n O S b P d o o g y...

Page 34: ...ded 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 P520 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...

Page 35: ...IRIS MODEL P520 APPLICATION MANUAL Page 35 FIGURE 17 BASIC BURNER START CIRCUIT ...

Page 36: ...ived according to the RS 422 standard The differential mode allows long wire runs in harsh electrical environments MODBUS COMMUNICATION Modbus Communication for IRIS P520 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 P520 processor st...

Page 37: ... module is available from Modicon Inc 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 dri...

Page 38: ...stance in installing this product please contact IRIS Systems Inc 7583 Vantage Place Delta B C V4G 1A5 Canada Phone 604 584 4747 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 ...

Page 39: ...or 16 AWG or 18 AWG one wire shielded with braided shield for flame signal OUTPUTS Flame Relay 2 Form C Contacts Self Checking Relay 1 Form C Contact Contact Ratings Max switching power 60W 125VA Max switching voltage 220Vdc 250Vac Max switching current 2A dc ac Analog Flame Signal 0 to 20mA current output for remote meters and 4 to 20mA output for DCS etc 360 ohm max resistance Power to Viewing H...

Page 40: ...IRIS MODEL P520 APPLICATION MANUAL Page 40 FIGURE 19 MODEL P520 SIDE VIEW FIGURE 20 S5XX VIEWING HEAD DIMENSIONS ...

Page 41: ...IRIS MODEL P520 APPLICATION MANUAL Page 41 FIGURE 21 4 MODEL P520s FRONT AND REAR VIEW MOUNTED IN FACF ...

Page 42: ...FIGURE 23 UV VIEWING HEAD LOCATION DETECTOR IN GOOD SIGHTING POSITION PARALLEL SIGHTING BURNER NOZZLE CENTERLINE DETECTOR IN POOR SIGHTING POSITION LOW FREQUENCY FLICKER ZONE HIGH FREQUENCY FLICKER ZONE UV VIEWING HEAD SIGHTED ON UV ZONE BURNER NOZZLE CENTERLINE UV RADIATION ZONE ...

Page 43: ...O 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 2 NPT NIPPLE TOE IRIS M 701 2 SWIVEL MOUNT IRIS R 518 12 1 NIPPLE IRIS VIEWING HEAD 1 2 NPT PURGE CONNECTION BURNER FRONT PLATE BURNER NOZZLE CENTERLINE QUICK DISCONNECT CABLE CONNECTION SUPPLIED ...

Page 44: ...27 28 29 information 36 37 infrared 21 31 Interference 23 24 IRIS cable 8 24 L lead sulfide 25 26 lens 18 20 25 27 28 29 30 lockout condition 10 15 16 19 low NOx 21 30 31 32 M memory 15 16 modbus communication 36 N natural gas 18 22 25 26 28 30 NEMA 11 noise 17 23 O oil 19 21 25 27 28 31 33 P PbS channel 22 26 27 PLC 31 34 36 37 power failure 15 pressure 18 20 34 propane 25 26 28 pulses 10 20 24 2...

Page 45: ...IRIS MODEL P520 APPLICATION MANUAL Page 45 NOTES ...