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FLAME MONITORING SYSTEM

MODEL P522 SIGNAL PROCESSOR

APPLICATION MANUAL

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Summary of Contents for P522

Page 1: ...FLAME MONITORING SYSTEM MODEL P522 SIGNAL PROCESSOR APPLICATION MANUAL ...

Page 2: ...NT 16 INITIAL SETUP 16 ADJUSTING SET POINTS 17 TROUBLESHOOTING GUIDE 18 NOISE INTERFERENCE AND GROUNDING 18 S506 VIEWING HEAD 19 S506 SELF CHECKING VIEWING HEAD 20 S509 VIEWING HEAD 20 S511 VIEWING HEAD 21 S512 VIEWING HEAD 21 ORIFICING 23 FIGURE 9 ORIFICING SIGNAL REDUCING CHARACTERISTICS OF DISCS 23 SIGNAL SOURCES 23 VIEWING HEAD ANGLE OF VIEW 24 FIGURE 10 VIEWING HEAD ANGLE OF VIEW DISTANCE AND...

Page 3: ...FICING SIGNAL REDUCING CHARACTERISTICS OF DISCS 23 FIGURE 10 VIEWING 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 34 FIGURE 14 MODEL P522 FRONT PANEL 35 FIGURE 15 MODEL P522 SIDE VIEW 36 FIGURE 16 S5XX VIEWING HEAD DIMENSIONS 36 FIGURE 17 ...

Page 4: ...AND INSTALLATION Before wiring or installing the P522 we recommend that you read the companion colour brochure describ ing the functions and attributes of this series of sig nal processors F1 75A GND 26V BAT SC C SC O FF SC O N SC RELAY RF C RF O FF RF O N RF C RF O FF RF O N RF RELAY F2 25A 26V SIG GND SIG 0 20mA or 4 20mA VH SEL RELAY CHAN SELECT ANALOG CURRENT DRIVE RS 422 SHUTTER DRIVE TX TX R...

Page 5: ... to the viewing head s 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 is 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 head is used you must wire to the V H A termi ...

Page 6: ...2 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 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 T...

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: ...el ops close to where the wire exits the cable s outer covering 3 Carefullyspreadafewstrandsoftheshield at the bulge making sure not to break any strands tocreateanopening andslipwire out of shield through opening 4 Carefully return shield to original shape and length by pulling gently then cover withplasticshrinktubingtopreventshorts 5 Slide nut with threads toward the cable end the washer and th...

Page 9: ...lies 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 WerecommendthatnotmorethanfourP522signalpro cessorsbesupportedbyone26VDCpowersupply For instance four P522 processors with one viewing head each equals a total of 26 watts a relatively small power supply particularly...

Page 10: ...utter will cause a lockout condition that willde energizetheflamerelay TheLOCKOUTlight on 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 has been corrected and can be performed from the front panel by pressing the RESET button or re motely through the serial communication APPROVALS TheP522andvi...

Page 11: ...FLAMEONsetpoint presstheFLAMEONbutton The set point will be displayed on the readout for about four seconds then return to normal The set points displayed willbeforthechannelthatisactive whichisindicatedby a steady illumination of push button A or B Toseetheotherchannelsetpoints firstselectthechan nel A or B then press the desired set point button For example if channel A is already ON indicating ...

Page 12: ...ime 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 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 thi...

Page 13: ...ading 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 be sufficient room to remove the h...

Page 14: ...he 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 stren...

Page 15: ...n 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 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 ...

Page 16: ...of the viewing head This can be done if a swivel joint is used at the end of the sight 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 S506 viewing head is more likely to be line of sight than the S512 infrared flicker viewing head which will read flame signals bouncing o...

Page 17: ...ow load conditions and then the readings for the burner ON and OFF under high load conditions There must be a definitive ratio between the read 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 OF...

Page 18: ...0 25Aself 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 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 h...

Page 19: ...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 wiring of the tran...

Page 20: ... 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 bent Why use self checking if the tube does...

Page 21: ...lockwise 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 narrower spectral range 750 nm to 1900 nm than the lead sulfide cell used in the S509 and S512 viewing heads It will detect all types of flames...

Page 22: ... 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 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 fluores...

Page 23: ...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 is first installed by positioning the ring in t...

Page 24: ...ce 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 sembleasquarewavecausedbywaveform clipping of the operational amplifiers If this signal is saturated then switching fr...

Page 25: ...g absorbed and blocked by non hydrocarbon elements and unburned fuel as explained 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 TheS509 two colour photodetectorviewingheadhas been very successful in sulfur recovery applications Claus reactors in the gas processing and petro...

Page 26: ...rols the fuel valve repre sents a dangerous installation with the po tential for a serious explosion USING A PLC WITH IRIS FLAME MONITOR PLCs are inherently unsafe when used by them selves 1 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...

Page 27: ...G T O N 1 1 5 S e G r i a f C S I D 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 ...

Page 28: ...o o g y r e v 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 r e v C S I D d o o g y r e v 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 r o o p G I S 3 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 ...

Page 29: ...tact wear caused by inductive arcing when contacts are open 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 4 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 interrupted igniter operation ...

Page 30: ...T O P P B O F F R F C O N P L C IN T E R FA C E IN T E R FA C E P L C IC T O IC T O D A D E S TA R T P B O P E N IG N VA LV E F R O M P L C F R O M P L C B R N VA LV E O P E N TO P L C IN T E R FA C E IN T E R FA C E TO P L C O F F O N R F C F L A M E O F F F L A M E O N L 2 R F C O N O F F C O N TA C T S O N P 5 2 0 C O N TA C T S O N R E A R P C B FIGURE 12 BASIC BURNER START CIRCUIT ...

Page 31: ...ntroduction 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 discrete registers For more information on Modbus protocol please refer to Modicon s Modbus Proto col Reference Guide PI MBUS 300 Rev E Communi...

Page 32: ...adable 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 driv...

Page 33: ...nstalling this product please contact Sales Corporate Office IRIS Systems Inc 205 19138 26th Ave Surrey B C V3S 3V7 Canada Phone 604 584 I4R7I4S7 Fax 604 581 9790 Manufacturing IRIS Systems Inc J B Systems Inc 4944 113th Avenue North Clearwater Fl 33760 Phone 727 545 3900 Fax 727 547 9589 ...

Page 34: ...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 35: ...IRIS MODEL P522 APPLICATION MANUAL Page 35 NO CAL YES FIGURE 14 MODEL P522 FRONT PANEL ...

Page 36: ...IRIS MODEL P522 APPLICATION MANUAL Page 36 FIGURE 15 MODEL P522 SIDE VIEW FIGURE 16 S5XX VIEWING HEAD DIMENSIONS ...

Page 37: ...FIGURE 18 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 38: ...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 39: ...d sulfide PbS 20 lens 13 15 20 22 23 24 25 lockout 10 11 15 18 20 32 lockout condition 10 11 low NOx 16 25 26 M memory 10 11 modbus communication 31 N natural gas 14 17 20 21 23 25 noise 12 18 O oil 14 15 16 20 22 23 25 P PbS channel 17 21 22 PLC 26 29 31 32 power failure 10 pressure 13 15 26 propane 20 21 23 pulverized coal 14 20 23 25 pulses counted 10 15 R relay contacts 5 29 remote meter 6 9 1...

Page 40: ...IRIS MODEL P522 APPLICATION MANUAL Page 40 NOTES ...

Page 41: ...MIM Battery Power 22 24 VDC 130mA plus 100mA View Head ENVIRONMENTAL Ambient Temp 0 o C to 52 o C CSA Rating 0 o C to 60 o 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 24VDC OUT 50mA MAXIMUM INPU...

Page 42: ...26 VDC 130mA BatteryV Main V plus 100mA View Head ENVIRONMENTAL Ambient Temp 0 o C to 52 o C CSA Rating 0 o C to 60 o 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 7 5 ...

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