Honeywell
Infrared
Flame Detector
The
Flame Detector includes a lead
sulfide photocell that is sensitive to the infrared
radiation emitted by the combustion
as natural gas, oil, and coal.
such
n
suitable for combination or dual-fuel
radiation is compatible with a wide range of flame
supervisory applications.
applications.
q
When installed properly, can supervise the pilot
flame and/or the main burner flame.
Models are available with
48 and 96 inches
lengths of 30,
m].
Mounts easily on a standard
inch sight pipe.
Flexible metal cable protects and electrically
shields the detector leadwires.
n
n
The lead sulfide photocell plugs into an electrical
socket in the
placeable.
assembly and is field re-
q
Accessories available include a heat block, seal-off
adapter, reducer bushing, swivel mount and orifice
plate.
The lead sulfide photocell’s sensitivity to infrared
CONTENTS
F.P. Rev.
l
Inc. 1991 Printed in U.S.A. Form Number
Download from Www.Somanuals.com. All Manuals Search And Download.
SPECIFICATIONS
l
ORDERING INFORMATION
Specifications
Reducer bushing for mounting the detector on a in.
l
SUPER
MODELS
sight pipe; specifically, for replacing
flame detectors.
lead
SUPER TRADELINE models offer features not
TRADELINE or standard models, and are designed to
replace a wide range of Honeywell and competitive
controls. SUPER TRADELINE models are selected and
packaged to provide ease of stocking, ease of handling,
and maximum replacement value. Specifications of
PER TRADELINE models are the same as those of
standard models except as noted below.
SUPER TRADELINE pack with cross reference label
and special Instruction sheet.
l
STANDARD MODELS
MODELS: See Table 6 for flame safeguard controls and
associated amplifiers.
RESPONSE: Responds to infrared radiation
with wavelengths between 0.75 and 1 .O micron.
LEAD SULFIDE PHOTOCELL: Photoconductor
decreases as incident radiant energy increases.
SUPER TRADELINE MODEL AVAILABLE:
48 in.
leadwires; includes
Bushing with
105061
and
Reducer Bushing.
AMBIENT TEMPERATURE RATING:
maximum at the lead sulfide photocell.
MOUNTING:
F
C]
SUPER TRADELINE FEATURES:
l
plate (with
in.
mm] diameter
agonal orifice) for reducing the detector field-of-view.
Heat block for insulating the detector
Mount-knurled collar with
threads for mounting on a standard
(see fig. 1).
NPSM in-
in. pipe
=
sight pipe
and up to
temperatures higher than
F 121” C].
F
into socket in
TABLE l-MODELS AVAILABLE.
(see Fig. 8).
0.125 in.
insulate the detector from sight
mount the detector on a in. sight pipe, specifically to replace
mm] diameter hexagonal orifice to
the detector field of view.
temperatures higher than
F
and up to
F
lead sulfide infrared flame detectors.
Order Information
products from your Authorized Flame Safeguard Distributor or Wholesaler, refer to the
When purchasing replacement and
Catalog or price sheets for complete ordering number, or
SUPER TRADELINE. if desired.
2. Length of leadwires or 96 in.
3. Lead sulfide cell order
4. Replacement parts, if desired.
5. Accessories, if desired.
or 2.44 m].
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Residential and Building Controls Division Sales Office (check white pages of phone directory).
2. Residential and Building Controls Division Customer Satisfaction
Honeywell Inc., 1885 Douglas Drive North
Minneapolis. Minnesota 554224386 (612) 542-7500
(In Canada-Honeywell
740 Ellesmere Road, Scarborough, Ontario
International sales and
service offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan Mexico,
Netherlands, Spain Taiwan, United Kingdom, U.S.A.
Download from Www.Somanuals.com.2All Manuals Search And Download.
SPECIFICATIONS
ACCESSORIES:
WIRING CONNECTIONS:
Nominal 30, 48, or 96 in.
18
Bushing with Focusing Lens
1.22, or 2.44 ml
105134
Plate, to reduce the detector
of view.
for 194°F
and one white.
C];
Diameter of
Hexagonal Orifice
(in.)
0.125
Leadwires enclosed in flexible metal
mm] maximum outer diameter.
DIMENSIONS: See Fig. 1.
in.
Part No.
105134
3.175
APPROVALS:
Underwriters Laboratories Inc. listed: File No.
Canadian Standards Association certified: Master file
LR-95329-1.
temperatures higher than 125” F
250” F
and up to
Factory Mutual approved.
Industrial Risk Insurers acceptable.
hot gases
reaching the lead sulfide photocell.
Reducer Bushing, to mount the detector on a
IMPORTANT: Caution, stickers, form 96-610, are in-
in. sight pipe;
to
lead
cluded with
Underwriters Laboratories
detectors.
Inc. requires that this sticker
on any junction
Hookup
box in which
leadwires are connected. The
heat and moisture-resistant, No. 20
stickerprohibits routing any other wiring through the
junction box.
C] for continuous duty; tested for operation up to 600
volts and breakdown up to 7500 volts.
Swivel Mount; provides adjustable positioning
of the
PARTS:
Lead Sulfide Photocells
Fig. l-Mounting dimensions of
infrared Flame Detector and accessories, in in. [mm].
106061
HEAT BLOCK
SEAL-OFF ADAPTER
105134
PLATE IN
INCH
INCH
COUPLING
SIGHTING
INCH PIPE NIPPLE
PIPE
14 NPSM
INTERNAL THREAD
THREADS
‘COLLAR.
14 NPSM
INTERNAL THREADS
EXTERNAL THREADS
EXTERNAL THREADS
INSTALLING OR REPLACING A
AND ACCESSORIES
105061
HEAT BLOCK
396427
REDUCER
BUSHING
SIGHTING PIPE
14 NPSM
INTERNAL THREADS
B U S H I N G ’
THREADS
NPSM
I
COLLAR,
14
EXTERNAL THREADS
14 NPSM
INTERNAL THREADS
EXTERNAL THREADS
REPLACING A
LEAD
DETECTOR
3
60-2306-5
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION
l
INSTALLATION
Operation
refractory radiation, thus making it fluctuate. This fluctuating
action can simulate the flickering radiation from a flame,
and infrared radiation may be present even after the
refractory has visibly stopped glowing. Therefore, be very
careful when applying an
it responds only to flame.
OPERATION OF INFRARED DETECTORS
Infrared detectors can be used with gas, oil, coal, or
fuel flames. Since more than 90% of the total flame radiation
is infrared, these detectors receive ample radiation and can
detection system to be sure
detect weak
as well as flames of higher intensity.
The lead sulfide cell used in the detector cannot
guish between the infrared radiation emitted by hot refrac-
tory and the infrared radiation from a flame. Therefore, the
infrared detection system includes an amplifier that re-
sponds only to the flickering characteristic of flame radiation
and rejects the steady radiation characteristic of hot refrac-
CELL CONSTRUCTION
photosensitive material used in the infrared detector
is lead sulfide. The electrical resistance of lead sulfide de-
creases when exposed to infrared radiation. If a voltage is
applied across the lead sulfide photocell, current flows when
cell is exposed to infrared radiation.
tory.
Unfortunately, smoke or fuel mist within the combustion
chamber can intermittently reflect, bend, or block the hot
Installation
When a flame is present, the lead sulfide photocell
WHEN INSTALLING THIS PRODUCT.. .
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous condi-
tion.
detects the infrared radiation generated. The
pro-
duces electric signal that is sent to the amplifier in the flame
safeguard control. The amplified signal pulls in the flame
relay in the flame safeguard control to allow proper operation.
Because it is necessary for the detector to actually see the
flame, it is best to locate the detector as close to the flame as
physical arrangement, temperature, and other restrictions
permit. These restrictions are described in detail below.
2. Check
ratings given in
instructions and on the
product to make sure the product is suitable for your applica-
tion.
3. Installer must be a trained, experienced flame safe-
guard control service technician.
4. Afterinstallationiscomplete,checkoutproductopera-
tion as provided in these instructions.
DETERMINE THE LOCATION
Before beginning the actual installation, determine the
best location for mounting the flame detector. Carefully
consider the factors discussed in this section before establish-
ing the location.
CAUTION
1. Disconnect power supply before beginning in-
stallation to prevent electrical shock and equip-
ment damage, there may be more than one
disconnect.
TEMPERATURE
The sensitivity of the lead sulfide cell decreases as its
temperature increases. Up to
F
the loss in
2. All wiring must be NBC Class 1 (line voltage).
sensitivity is negligible, but temperatures above this point
3. Use the
only with Honeywell lead
must be avoided. Under normal temperature conditions (be-
sulfide photocells (part no.
and flame
low 125” F
the life of the lead sulfide cell should be
signal amplifiers specified, (see Table 6).
unlimited. The quickest check for excessive temperature is
simply to grasp the detector-it should not be too hot to hold
comfortably in your bare hand.
Proper flame detector installation is the basis of a reliable
flame safeguard installation. Refer to the burner manufac-
turer instructions and instructions below. Carefully follow
instructions for the best possible flame detector application.
Several methods are available for cooling the lead sulfide
photocell including ventilating the sight pipe and installing a
pipe nipple, seal-off adapter, and/or heat block between the
sight
and the detector. Refer to Installing Accessories,
page 8.
BASIC REQUIREMENTS
Because all flames produce infrared radiation, a
SIGHTING
Infrared (lead sulfide) Flame Detector can be used to prove
the presence of a flame in a combustion chamber. The
detector is mounted outside the combustion chamber. Screw
themountingcollartooneendofasightpipeinsertedthrough
the wall of the combustion chamber. The lead sulfide photo-
cell in the detector sights the flame through the sight pipe.
The infrared detector must continually sight a stable
portion of the flame being detected. The detector is com-
monly applied to detect both the gas pilot and main gas flame,
or thegaspilot and main oil
either case, the detector
must be carefully aimed at the intersection of the pilot and
A Swivel Mount (Honeywell part no.
4
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
is available to facilitate flame sighting after the
mounted.
is
pipe diameter is reduced, the effect is the same as adding an
orifice plate to the pipe as discussed below.
FIELD OF VIEW
A lead sulfide photocell, like other photocells, views an
area rather than a point. It is unable to pinpoint pilot flame
Fig. P-Methods of reducing
field-of-view.
Detector
it must view only a part of
detect the pilot only when it is large enough to successfully
light the main burner. viewing area must not be so large
so it can
AREA
that a weak and wavering pilot flame could energize the
photocell and cause the flame relay to pull in.
0
The area viewed by the photocell depends on:
UNRESTRICTED VIEW
1. Diameter of
opening in front of the cell.
2. Distance from the cell to the opening.
3. Distance from the opening to the area to be viewed.
Fig. 2 shows three ways of reducing the field of view,
assuming that the distance from the viewing opening to the
flame or refractory cannot be changed. These are (1) length-
ening the sight pipe, (2) reducing the diameter of the sight
pipe, and (3) installing an orifice plate in front of the photo-
3
BY LENGTHENING
THE SIGHT PIPE
cell. Combinations of these methods can
used.
CHANGING PIPE LENGTH OR SIZE (DIAMETER)
Theeffectorchangingthelengthofthesightpipeisshown
in Tables 2 and 3.
Changing the diameter of the sight pipe is not as simple as
changing the
the
mount and mount-
in. pipe. When the sight
ing accessories are all sized for
TABLE 2-DIAMETER OF AREA SIGHTED THROUGH VARIOUS LENGTHS OF
WITHOUT ORIFICE, IN IN.
-IN. PIPE
Distance From End of Pipe To Sighted Area-in.
Length of
6
12
18
30
36
42
54
66
72
7
8
1.5
1.4
2.3
2.1
3.1
2.8
3.9
3.5
4.7
4.2
5.5
4.9
6.3
5.6
7.1
6.3
8.0
8.7
7.7
9.6
8.5
10.4
7.1
TABLE 3-DIAMETER OF AREA SIGHTED THROUGH VARIOUS LENGTHS OF
WITHOUT ORIFICE. IN MM
IN. PIPE
Length of
Pipe-mm 152.4 304.8
25.4 160.0 302.3
Distance From End of Pipe To Sighted Area-mm
457.2
447.0
609.6
589.3
762.0
721.4
914.4 1066.8 11219.2 1371.6 1524.0 11676.4 11828.8
876.3 Over 1016.0
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
INSTALLING AN
AnorificeplatewithahexagonalorificediameterofO.125
mm] is available for the Infrared Flame
PLATE
in.
mm] diameterorifice
in.
Detector.
(or refractory) is 36 in.
mm], the dieter of the
orifice can be mounted in front of the cell in the
sighted area is 2.4 in.
mm].
seal-off adapter or in a standard
in. coupling. (Refer to Fig.
Fig. 3 shows how a typical orifice plate restricts the view
of a small area around the flame junction.
1.)
The size of the sighted area at various distances can be
determined
Table 4 or 5. For example, if the distance
OF AREA SIGHTED THROUGH ORIFICE, IN IN.
3.2
2.1
2.6
1.1
1.6
6
5-DIAMETER OF AREA SIGHTED THROUGH ORIFICE, IN MM
Fig.
orifice plate to restrict detector field of view to intersection of pilot and main flame, or to
hot
area
ORIFICE PLATE
PLATE
PILOT
HOT REFRACTORY
MAIN FLAME
PILOT,
HOT REFRACTORY\
MAIN
\
6
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
RESPONSE TO HOT REFRACTORY
Fig.
infrared Flame Detector aimed
Although the infrared amplifier will not respond to steady
radiation, as produced by hot refractory, be careful to protect
the infrared detector from hot refractory radiation because of
two possible conditions, shimmer and raa’iation saturation.
a. Shimmer-Turbulent hot air, steam, smoke, or fuel
spray in the combustion chamber can reflect, bend, or
at side wall of combustion chamber.
block
steady infrared radiation emitted by a hot
refractory. These conditions can change the steady
radiation from a hot refractory into a fluctuating radia-
tion. If these fluctuations occur at the same frequency
as that of a flickering flame, they will simulate flame
and will hold in the flame relay after the actual burner
flame has been extinguished.
MAIN BURNER FLAME
-
-
-
-
b. Radiation saturation--Steady hot refractory radiation
can become strong enough to mask the fluctuating
_-
--
AREA VIEWED BY
I
,
radiation of the
This is similar to the effect of
,
holdingupacandleinfrontofthesun-thelightofthe
sun is so strong that the candle light cannot be seen. If
radiation saturation is extreme, the flame relay will
drop out, and the system will shut down as
flame failure has occurred.
I
I
.
.
I
a
Fig.
Infrared Flame Detector aimed
at a point above refractory.
Both of these problems will be minimized by aiming the
detector at a portion of the refractory that is:
VIEWS AREA
REFRACTORY
l
l
l
as cool as possible.
as far from the cell as possible.
as small as possible reduce the field of view, see Figs.
ABOVE TH
BURNER
FACEPLATE
-
-
Refractory temperatures in the combustion chamber will
vary with combustion chamber design but generally, the end
wall of the chamber will be the hottest point. It will normally
be best to aim the detector at the side wall of the refractory
I
(Fig.
at a point above the refractory (Fig.
or at the floor
AND
of the combustion chamber (Fig. 6).
.
.
SIGHTING SUMMARY
.
.
When sighting
detector, two important factors to
junction), and (2) avoiding
I
I
consider are: (1) proper sighting of the flame being detected
.
(normally the pilot/main
hot refractory sighting.
A typical sighting arrangement is shown in Fig. 4. The
detector is aimed at the intersection of the pilot and main
flames, and at a relatively cool side of the combustion
chamber. The detector, in this case, would be located as close
as possible to the burner to sight the maximum depth of the
and reduce the effect of variations in the main flame
pattern.
Fig.
Infrared Flame Detector aimed
at floor of combustion chamber.
I
I
,
The detector can also be sighted from a point below and
close to the burner with the line-of-sight above the refractory
(Fig. 5).
The third method is to aim the detector from above the
burner, sighting a portion of the refractory floor (Fig. 6). This
type of application requires that the pilot flame be carefully
sighted from the side. The detector should not be sighted over
CENTER LINE
the shoulder of the pilot because
chances increase of
sighting pilot too small to satisfactorily light the main flame,
a
REFRACTORY FLOOR
AREA VIEWED BY
as possible and consistent with proper sighting of the flame.
Refer to Figs. 2 and 3 for methods of reducing the
refractory sighted.
of hot
I
7
60-2306-5
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
mounting details, refer to form 60-0361 for the 118367A
Swivel Mount)
CLEARANCE
Make sure there will be enough mom to easily mount the
sight pipe, flame detector, and all required accessories, and to
REDUCER BUSHING
remove th
felame detecto fror troubleshooting and servicing.
To mount the detector on a
in. sight pipe,
detector, install a
if replacing a
lead
INSTALLING THE SIGHT PIPE
Reducer Bushing (Fig. 1).
Thelocationofthesightpipeisthemostcriticalpartofthe
installation. A
Do
in. black iron sight pipe is recommended.
PLATE
a stainless steel or galvanized pipe because its
To reduce the detector field-of-view, and restrict it to the
intersection of the pilot and main flame, or to a small area of
internal surface blackens with use as deposits from the
combustion chamber accumulate on it. Initially, its shiny
intemalsurfacereflectsinharedradiation, whichcouldresult
in a satisfactory flame signal even though the pipe may be
hotrefractory (see Fig.
install a 105 134 Orifice Plate. The
plate can be inserted into a standard
in. pipe
improperly located. As it blackens, less
radiation is
signal becomes marginal.
coupling (Fig. 1) or into the seal-off adapter, if used.
reflected and the
MOUNTING SIGHT PIPE
Because no two situations
the same, the length and
sighting angle of the pipe must be determined at the time and
placeofinstallation.Generally,itisdesirabletohavethesight
pipe tilting downward to prevent soot or dirt buildup.
Thmadoneendofthepipetofitthemountingcollaronthe
detector (or an accessory, if used, see Fig. 1). Cut the pipe to
the desired length (as
excessive heat back to the lead
pipeshould not extendmore than halfway into the refractory.
practical). T oavoid conducting
photocell, the sight
PREPARE HOLE IN WALL OF COMBUSTION
CHAMBER
Tack weld
pipe to the wall in a trial position (Fig. 9) Do
.
Form a hole of the proper diameter for the sight pipe in the
permanently weld the sight pipe in place until ajter
completing the Adjustments and Checkout, page 10.
the hole (Fig. 9) to leave room for small adjustments of the
sighting angle. The taper of the hole should be about 1 in. for
NOTE: If you use a Swivel Mount (part no.
and
every 3 in.
mm for every 76.2 mm] of wall thickness.
yo uarepositive about the location and sighting angle, you
can permanently weld the pipe.
INSTALLING ACCESSORIES
PIPE NIPPLE
It may be necessary or desirable to install accessories
between the sight pipe and the detector. This section
scribes the installation of these accessories.
A
in. pipe nipple, 6 to 8 in. 152 to 203 mm] long, can
Mount
cell. Usin gthe pip enipple
be inserted between the sight pipe and the
(Fig. to help cool the lead
SIGHT PIPE VENTILATION
will also reduce the viewing area of the detector, see Table 2
or 3).
may be necessary to ventilate the sight pipe to cool the
detector.
SEAL-OFF ADAPTER
For a negative pressure combustion chamber, drilling a
few holes in
section of the sight pipe outside of the
To protect
detector from hot gases, install a 105 172A
combustion chamber allows air at atmospheric pressure to
flow through the sight pipe into the chamber. A perforated
pipe nipple between the sight pipe and the flame detector can
also be used. See Fig. 7.
For a positive pressure combustion chamber, connect a
supply of pressurized air from the burner blower to flow
throughthesightpipeintothechamber.Theairpressuremust
be greater than the chamber pressure.
Seal-Off Adapter (Fig. 1). The adapter has a glass window
that prevents hot gases from reaching the lead sulfide
cell.
HEAT BLOCK
To insulate the detector from sight pipe temperatures
above 125” F
install a 105061 Heat Block (Fig. 1).
The device is made of nonheat-conductive, laminated plastic
that prevents heat being conducted from the sight pipe
to the detector. It can withstand temperatures up to 250” F
Fig.
air cooling.
SIGHT
PIPE
PIPE TEE
DETECTOR
PIPE NIPPLE
MOUNTING THE DETECTOR
Before mounting the
install the lead sulfide
photocell (if not installed already).
Unscrew the bushing from the cap, plu the phgotocel ilnto
the cell mount, and screw the bushing back into the cap (Fig.
COOLING AIR
APPLIED UNDER
8). The bushing also includes a
lens to
available radiation on the photocell face.
SWIVEL MOUNT
Mount the
Detector onto the sight pipe, heat
To facilitate flame sighting, a Swivel Mount (part no.
is available. The Swivel Mount requires a reducer
block, orotheraccessory (Figs. 1 and 9). Screw the mounting
collar onto the sight pipe or accessory.
of the proper size to mount it onto the sight pipe. (For
8
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
3. The detector comes with
or in.
Fig.
lead sulfide photocell.
or 2.44 leadwires inside a flexible metal cable. The
leadwires consist of a twisted pair-one brown and one
white. The two no. 18 AWG flexible-tinned leadwires are
CAP
rated for
F
C]. The cable protects and electrically
, MOUNTING
\
shields the leadwires.
PLUG-IN LEAD SULFIDE CELL
(PART NO.
4. If the leadwires are not long enough to reach the
terminal strip or wiring subbase, make the required splices in
a junction box (see IMPORTANT below).
5. If splicing is necessary, use moisture-resistant no. 14
wire suitable for at least 167” F
if the detector is used
PHOTOCELL
SOCKET
METAL CABLE
SHIELDS LEADWIRES
194°F
C] if used with a flame safeguard programming control.
6. For splicing in high temperature installations, use
I
FOCUSING LENS
Honeywell specification no.
or equivalent for the
for
F leadwire. (This wire is rated up to 400” F
continuous duty. It is tested for operation up to 600 volts and
breakdown up to
volts.) For the other leadwire, use
moisture-resistant no. 14 wire selected for a temperature
rating above the maximum operating temperature.
Fig. O-Mounting
Detector (and accessories).
Infrared Flame
IMPORTANT:
REFRACTORY
MAIN
FLAME
a . Flame detector leadwires must be as short
sible. The maximum
CHAMBER WALL
detector to the
m].
safeguard control is 50
TEMPORARY
TACK
Extensions to
detector leadwires must be
run alone in either rigid orflexible metal
When detector leadwires exit a conduit, they
must be as short as possible, twisted, and not be
included in bundles or channels that contain other
wires. Rigid metal conduit
FLARED HOLE
INCH BLACK
IRON SIGHTING PIPE
detector leadwires are extended
metal
conduit may be used
movement.
is supported to minimize
The
cable shield must be
C.
grounded to
safeguard control subbase
TO JUNCTION
OR SUBBASE
either directly or through the metal cabinetlconduit
system that contains
flame safeguard control
subbase
detector leadwires.
10 and 11)
When
detector leadwires are routed through
d.
junction boxes,
the junction boxes with the
pressure-sensitive labels provided wiih the flame
detector
I CAUTION
.
Disconnect power supply before beginning instal-
lation to prevent electrical shock and equipment
damage; there may be more than one disconnect
involved.
UNDERWRITERS LABORATORIES INC. RE-
QUIRES THAT THE JUNCTION BOX BE
MARKED TO INDICATE
OTHER WIR-
ING CONNECTIONS CAN BE ROUTED
THROUGH IT. APPLY CAUTION STICKER
1. All wiring must comply with applicable electrical
codes, ordinances, and regulations. Use
Class 1 wiring.
(FORM
FURNISHED) TO THE JUNC-
Keeptheleadwiresfromtheflamedetectortotheflame
safeguard control subbase as short as possible. Capacitance
TION BOX.
increases with
length, reducing the signal strength.
Maximize the separation between ignition trans-
The maximum permissible
ultimate in
Iength is fifty feet.
length is signal
former high voltage wires and the
sensor
wires to avoid ignition interference.
current/voltage. Refer to Table 6, Adjustments and Check-
out, page
60-2306-5
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
l
ADUSTMENTS AND CHECKOUT
Fig. 1 l-Typical wiring of
Flame Detector to distant wiring subbase or
terminal strip.
Infrared
Fig. 1 O-Typical wiring of
Infrared
Flame Detector to nearby wiring subbase or
terminal
FLEXIBLE CABLE
(MECHANICALLY
SUPPORT TO
MINIMIZE
FLEXIBLE CABLE (MECHANICALLY
SUPPORT TO MINIMIZE MOVEMENT)
BX CABLE, SHIELDED
CABLE, OR TWISTED
PAIR; MUST BE ALONE
IN CONDUIT.
SUBBASE
FLAME SAFEGUARD
CONTROLS SUBBASE
OR
STRAP,
JUNCTION BOX
1 BROWN WIRE AND 1 WHITE WIRE FROM THE
COLOR NOT IMPORTANT; LEADWIRES
FROM JUNCTION BOX NEED NOT BE PHASED OR POLARIZED.
CONNECT
1
1 BROWN WIRE AND 1 WHITE WIRE FROM THE
CONNECT TO
APPLY CAUTION STICKER, FORM NO.
SUPPLIED WITH
FLAME SAFEGUARD CONTROL’S SUBBASE, COLOR NOT IMPORTANT,
KEEP WIRES AS SHORT AS POSSIBLE. AND TWIST THEM.
TO THIS JUNCTION BOX. BOX MUST BE GROUNDED.
USE RIGID CONDUIT. OR SUPPORT FLEXIBLE CONDUIT TO
MOVEMENT.
CABLE MUST BE RUN To
SAFEGUARD CONTROL ’S
SUBBASE AND GROUNDED WHERE THE EXPOSED WIRES BEGIN.
CONDUIT MUST BE RUN TO FLAME SAFEGUARD CONTROL’S
SUBBASE AND GROUNDED THERE. KEEP EXPOSED WIRES AS
SHORT AS POSSIBLE AND TWIST THEM.
Adjustments and Checkout
should blink at
same rate that the flame is
welding the sight pipe in
location, complete
below and any tests required by the burner
flickering (may be as high as 20 times a second). If the lamp
is ON (bright) continuously or not blinking while measuring
the flame current, replace the amplifier.
Tests
Refer to Table 6 for the minimum acceptable flame
currents for the amplifiers and associated flame safeguard
controls.
ADJ UST DETECTOR SIGHTING P OSITION
initial burner lightoff, consult the burner manufacturer
The
and
instructions or flame
control instructions.
With the flame detector installed and the burner running,
adjust the sighting position of the detector for optimum flame
signal.
7800 SERIES flame safeguard controls respectively, have a
dc voltage flame signal output.
To measure flame signal voltages when using a
amplifier, a 20,000 ohm/voltmeter with a zero to 5 or 10 Vdc
scale is suggested To measure the flame signal voltage when
Most existing Honeywell flame safeguard controls have a
flame signal (current) can be measured
a volt-ohmmeter
using
amplifiers, a volt-ohm meter with a mini-
is recommended. The
such as the Honeywell W 136A with a zero to 25 microampdc
scale. To measure the flame current (signal), a Cable Connec-
mum sensitivity of one
flame signal (voltage) measurements are made as shown in
Figs. 13 and 14. The positive (red) meter lead is connected to
the positive (+) control jack and the negative (black) meter
lead to the negative control jack (Corn jack with 7800
SERIES controls). If the BCS 7700 and
controls have the Keyboard Display Module, a zero to five
Vdc voltage is displayed on the module. Refer to Table 6 for
minimum and maximum flame voltages for the amplifiers
tor (part number
used with the meter. With the
tioned to zero to 25
included with
must be
(or equivalent) posi-
scale, make connections
from the meter probes to the two ends of the cable connector
plug, red to
black to black The plug end of the connector
12).
the flame safeguard control is using a
amplifier, the red flame-indicating lamp on the
Download from Www.Somanuals.com. All Manuals Search And Download.
ADJUSTMENTS AND CHECKOUT
and associated flame safeguard controls.
Fig.
BCS 7700 Flame Safeguard
Move the detector and sight pipe around to sight the flame
at various positions and angles. Try to get a maximum steady
meter reading. The signal must be above the minimum
acceptable current/voltage listed in Table 6.
Control flame signal voltage.
Measure the
burner flame alone, and both together (unless monitoring
only the pilot when using an intermittent pilot, or only
signal for the pilot alone, the main
burner flame when using direct spark ignition). Also
measure the flame signal at high and low firing rates and
while modulating in between (as applicable). With the detec-
tor in its final position, all required
signals must be
steady and as specified in Table 6. If you cannot obtain the
proper signals, refer to the Troubleshooting section.
Fig.
flame Signal.
PLUG-IN FLAME
PROBES
SIGNAL AMPLIFIER
7700 CHASSIS MODULE
I
SELECTOR
SWITCH,
196146 METER
CONNECTOR
TEST
Fig.
7800 SERIES Flame
Safeguard Control flame signal voltage.
RED CONNECTOR
CK CONNECTOR
M E T E R ‘
LEAD
El 208
TABLE 6-FLAME SIGNAL
Minimum
Maximum
Minimum
Acceptable
Steady Voltage
Maximum
Expected
Voltage
Acceptable
Steady Current
(microamp)
Expected
Current
(microamp)
Flame
Signal
Amplifier
Flame Safeguard Control
2.25
5.0
5.0
5.5
3.5
4.0
4.98
5.0
2.2
BCS 7700
1.25
5.0
1.25
60-2306-5
Download from Www.Somanuals.com. All Manuals Search And Download.
ADJUSTMENTS AND CHECKOUT
PILOT TURNDOWN TEST
solids instead of liquids, or liquids instead of gases.) When
maximum refractory temperature is reached, close all
manual fuel shutoff valves or open theelectricalcircuit of all
automatic fuel valves. Visually observe when the burner
flame goes out. After the flame goes out, measure the time it
takes for the flamerelay 2K to drop out. Watch or listen to the
flame relay to determine when it drops out. If the flame relay
fails to drop out within four seconds, the infrared detector is
sensing theradiation from hot refractory. Immediately termi-
nate the firing cycle, (lower the set point of the burner
controller, or set the fuel selector switch to OFF). Do not open
the master switch.
Ifthedetectorisusedtoproveapilotflamebeforethemain
fuel
can be opened, perform a Pilot Turndown Test
before welding the sight pipe into position. Follow the
procedures in the instructions for the appropriate flame
safeguard control, and
burner manufacturer instructions.
HOT REFRACTORY SATURATION TEST
Testtobesureradiationfromhotrefractorydoesnotmask
the flickering radiation of the
itself.
Start the burner and monitor the flame signal during the
heats up indicates hot refractory saturation. If saturation is
extreme, the flame relay 2K (in the flame safeguard control)
will drop out and the system will shut down as though a flame
failure has occurred.
If hot refractory saturation occurs, the condition must be
corrected. Add an orifice plate in front of photocell to
restrict the viewing area. If this does not work, resight the
detector at a cooler, more distant background. Lengthening
the sight pipe or decreasing the pipe size (diameter) may also
be helpful. Continue adjustments until hot refractory satura-
tion is eliminated.
Some burners continue to purge their oil lines be-
tween
valves and nozzles even though the fuel valve(s)
is closed. Terminating the firing cycle (instead of opening
the master switch) will allow purging of the combustion
chamber. This will reduce a buildup of fuel vapors in the
combustion chamber caused by oil line purging.
If the detector is sensing hot refractory radiation, the
condition must corrected. Add an orifice plate in front of
the photocell to restrict the detector viewing area. If this does
not work, resight the detector at a cooler, more distant part of
the combustion chamber. While resighting the detector,
remember that it must also properly sight the flame. Length-
ening the sight pipe or decreasing the pipe size (diameter)
may also be helpful. For details, refer to Installation. Con-
tinue adjustments until hot refractory hold-in is eliminated.
HOT REFRACTORY HOLD-IN TEST
Test to make certain that hot refractory will not cause the
flame relay 2K (in the flame safeguard control) to stay
in after
burner flame is extinguished. This condition
would delay response to flame failure and also would prevent
a system
hot refractory is detected.
long as the infrared radiation emitted by the
IGNITION INTERFERENCE TEST
It is possible for infrared amplifiers to respond to ignition
spark electrical noise (interference) under certain conditions.
Avoid ignition interference by locating the transformer as
close as possible to the burner ignition electrode (preferably
not on the control cabinet). You can also use an ignition cable
that suppresses electrical noise (such as the type of cable
in automobiles). Maintain maximum separation of flame
sensor and ignition wiring.
First check the plug-in flame signal amplifier by initiating
a burner cycle. When the programmer stops in the run
position, terminate the firing cycle while the refractory is at
a low temperature. Measure
relay 2K to drop out after
time it takes for the flame
flame goes out. Watch or listen
to the flame relay to determine when it drops out. If the flame
relay fails to drop out within four seconds, open the master
switch and replace the amplifier.
Infrared detectors can respond to infrared radiation emit-
ted by a hot refractory, even when the refractory has visibly
ceased to glow. Infrared radiation from a hot refractory is
steady, whereas radiation from a flame has a flickering
To determine if an infrared flame amplifier responds to
ignition interference, complete the following test sequence:
1. CLOSE MANUAL
AND MAIN
VALVES TO THE PILOT
2. Connect a flame signal meter to the amplifier and start
the burner.
a flickering infrared radiation; it can reject a steady signal
from hot refractory. However, the refractory’s steady signal
can be made to fluctuate if it is reflected, bent, or blocked by
smoke or fuel mist within the combustion chamber. Be
careful when applying an infrared system to ensure its
response to flame only.
3. There should be no flame signal when the ignitor is
energized (momentary meter movement may observed
when the flame safeguard control switches a load on or off).
WELD THE SIGHT PIPE
To check a
Flame Detector for hot
After adjustments have been made and an acceptable
flame signal obtained, remove the detector and weld the sight
refractory hold-in, operate the burner until the refractory
reaches its maximum temperature. If the installation has a
multifuel burner, burn the fuel most likely to reflect, bend, or
obscure the hot refractory’s steady infrared radiation, (burn
pipe in
final position, (if you are using a swivel mount, the
pipe may already be welded). Then reinstall the detector.
12
Download from Www.Somanuals.com. All Manuals Search And Download.
ADJUSTMENTS AND CHECKOUT
l
TROUBLESHOOTING
FINAL CHECKOUT
CAUTION
Before putting the burner into service, check out the
installation by using
Checkout procedures in the instruc-
Do not put the system into operation until all
Checkout tests in the instructions for the appropri-
ate flame safeguard control and any specified in the
burner installation instructions are satisfactorily
completed.
tions for the appropriate flame safeguard control. After
completing the checkout, run the burner through at least one
complete cycle to verify proper operation.
Troubleshooting
PRELIMINARY INSPECTION
1.
the flame is properly adjusted and is not
CAUTION
too lean.
1. Be extremely careful while troubleshooting the
detector; line voltage is present on some of the
2. Checkfortheproperlinevoltage. Makesurethemaster
switch is closed, connections are correct, and power supply
is of the correct voltage and frequency.
terminals on the wiring
when power is on.
or terminal strip
3. Check the detector wiring for defects including:
. incorrect connections.
2. Open the master switch to disconnect power
before removing or installing the detector, there
may be more than one disconnect involved.
wrong type or size of wire.
l
l
l
l
l
deteriorated wire.
open circuits.
short circuits.
leakage paths caused by moisture, soot, or dirt.
If you cannot obtain a satisfactory flame signal while
adjusting the sighting position of the detector, follow these
procedures. If you encounter other problems in the system,
refer to Troubleshooting in the instructions for the appropri-
ate flame safeguard control.
4. With the burner running, check the temperature at the
detector. If it exceeds 125” F
add additional insulation between the wall of the
combustion chamber and the detector.
add a shield or screen to reflect radiated heat away
from the detector.
add cooling (refer to Sight Pipe Ventilation, see
Installation).
EQUIPMENT REQUIRED
1.
300
scale.
PROCEDURE FOR A LOW METER READING
1. Remove the detector and clean the focusing lens
a soft, clean cloth.
2. Microammeter (Honeywell
with 0 to 25 microampdc range.
3.
Meter Connector Plug or equivalent (required for some
meters).
or equivalent)
196146, or 117053
2. If the focusing lens is broken or damaged, or if it is
coated with a substance that cannot be cleaned off, replace the
Bushing (which includes the focusing lens).
3. Clean the inside of the sight pipe before reinstalling the
detector.
4. A volt-ohm meter with a zero to 5 or 10 Vdc scale and
a sensitivity of 20,000 ohm/volt is suggested for
control flame signal measurements. If the control has the
Keyboard Display Module option, flame voltage is displayed
on the module.
4. If the meter reading is still too low, replace the lead
sulfide cell (Fig. 8).
5. If the meter reading is still too low, replace the plug-in
amplifier.
5. A one
meter with a zero to 5 or 10 Vdc
scale is recommended for 7800 SERIES control flame volt-
age measurements. If the control has the Keyboard Display
Module option, flame voltage is displayed on the module.
6. Replacement parts-see Specifications.
6. If you still cannot obtain a proper flame signal, replace
the
Infrared Flame Detector.
PROCEDURE FOR A ZERO METER READING
1. Replace the lead sulfide cell (Fig. 8). Then recheck the
flame signal.
TROUBLESHOOTING PROCEDURES
2. If there is still no flame signal, replace the plug-in
amplifier.
Firstperfonn
Inspection. Then follow the
applicable procedures for either a low reading or a zero
reading on the flame signal meter. After reinstalling the
detector, recheck the meter reading. Adjust the position of the
3. If you still cannot obtain a meter reading, replace the
entire
Infrared Flame Detector.
detector to try to obtain the proper
procedures are completed and a satisfactory flame signal
cannot be obtained, replace the detector.
signal. If the
IMPORTANT: At the completion of troubleshooting, be
sure to perform the Adjustments and Checkout, page
10.
60-2306-5
13
Download from Www.Somanuals.com. All Manuals Search And Download.
SERVICE
PERIODIC MAINTENANCE
1. Clean the focusing lens andsightpipe when necessary.
CAUTION
Remove the detector and use a soft, clean cloth.
lens does
1.
not require removal to clean it. If it is broken or damaged, or
to service or repair flame safeguard controls and
burner systems.
the
Bushing, which includes the focusing lens.
2. Keep the flame detection system adjusted for the
smoothest, most reliable operation as recommended by the
burner manufacturer.
3. Replace the bushing with focusing lens or the lead
sulfide photocell (Fig. 8) only when necessary to obtain
proper operation.
2. Open the master switch to disconnect power
before removing or installing the detector.
3. If the
is disassembled for any reason
lead sulfide cell or bushing
(e.g., to replace
with focusing lens), you must perform the Ad-
justments and Checkout, page 11.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
Table of Contents
Page
1
..................................................................................................................................................
Application and Features
2
2
3
......................................................................................................................................................................
Specifications
Ordering Information
Dimension Drawings
..............................................................................................................................................
................................................................................................................................................
4
............................................................................................................................................................................
..........................................................................................................................................................................
Operation
4
4
8
8
8
9
Installation
..................................................................................................................................................
Basic Requirements
...........................................................................................................................................
the Sight Pipe
Installing Accessories
Mounting the Detector
................................................................................................................................................
.............................................................................................................................................
.......................................................................................................................................................................
Wiring
10
.............................................................................................................................................
Adjustments and Checkout
13
...............................................................................................................................................................
.........................
Troubleshooting
Service
..............
Periodic Maintenance
.............................................................................................................................................
Tables
Table I -Models available
2
.......................................................................................................................................
Table 2 -Diameter of area sighted through various lengths of
Table 3 -Diameter of area sighted through various lengths of
Table 4 -Diameter of area sighted through orifice, in in
inch pipe without orifice, in in..
...................
.
6
6
inch pipe without orifice, in mm
..................
....................................................................................
Table 5 -Diameter of area sighted through orifice, in mm
............................................................................................................................................
11
Table 6 -Flame Signal
Figures
Fig.
Fig. 2 -Methods of reducing
.3
in in. [mm].
accessories,
Infrared Flame Detector field-of-view
Fig. 3 -Using orifice plate to restrict detector field-of-view to intersection of pilot
1
-Mounting dimensions of
Infrared Flame Detector and
...................
5
...................................................
6
7
7
7
8
9
.................................................................................
or to small area of hot refractory
and main
Infrared Flame Detector aimed at side wall of combustion chamber
......................................
....................................................
Fig. 4
Fig. 5
Infrared Flame Detector aimed at a point above refractory
Infrared Flame Detector aimed at floor of combustion chamber
............................................
Fig. 6
.....................................................................................................................................
Fig. 7 -Forced air cooling
Fig. 8 -Installing lead sulfide photocell
................................................................................................................
................................................................
Infrared Flame Detector and accessories
Fig. 9 -Mounting
13
10
11
11
11
...............................................
................................................
Fig. 10 -Typical wiring of
Fig. 11 -Typical wiring of
Fig. 12 -Measuring
Fig. 13 -Measuring BCS 7700 Flame Safeguard Control flame signal voltage
Fig. 14 -Measuring 7800 SERIES Flame Safeguard Control
to nearby wiring subbase or terminal strip
to distant wiring subbase or terminal strip
........................................................................................................
signal
.................................................
...........................................
signal voltage
60-2306-5
15
Download from Www.Somanuals.com. All Manuals Search And Download.
|