Fireye 95DS2 Scanner User Manual
Contents
1. BELDEN 8761 Twisted shielded pair to previous wiring harness Flex Conduit Flex Conduit to Scanner to Scanner FIGURE 16 WIRING DIAGRAM FOR WIRING HARNESS COM B ORANGE COM BROWN 1 CONNECT SHIELDS RFS2 YELLOW TOGETHER 2 TAPE SHIELD AT M31 900060 LAST WIRING HARNESS 4 20 GREY RED 4 20 VIOLET FAULT RELAY N C PINK TO FLAME FAULT RELAY C RED SCANNER FLAME RELAY N O WHITE RED prewired by FLAME RELAY C WHITE BLACK factory 24VDC WHITE BLUE 24VDC BLACK CONNECT SCANNER SHIELDS TOGETHER AND GROUND AT o BURNER MANAGEMENT SYSTEM lt 59 497 n e TO CONTROL WHITE BLUE TO PREVIOUS WHITE BLACK SCANNER OR WHITE RED EC485 CONVERTER RED gt PINK VIOLET GREY RED BLUE RED YELLOW 1 CONNECT SHIELDS TOG2. UVBAND woo v UVGAN gt F wao 4 Yy UV RANGE UVR HIGH 4 J v ON THRESHOLD gt f l OFF THRESHOLD gt OFFT20 l v FFRT t om H omi NOTE 1 Dual Scanner model shown If scanner is single sensor model IR of UV only the appropriate parameter will be displayed e g SENSORS BAND GAIN RANGE NOTE 2 Communications available with S2 models only NOTE 3 The PROGRAM Key is used to accept a value change for all parameters except IR UV Gain and IR UV Band For these parameters the value change is accepted immediately FIGURE 22 TEXT DISPLAYED THE EDIT MENU DEPRESS SELECT KEY TEXT DISPLAYED POSSIBLE VALUES UP DOWN KEYS File Select FILEA S1 models A B 52 models A B C D Temperature Scale Scale C CF Comm address COMM 0 0 127 Remote File Select RFS KEY S1 models KEY LINE S2 models KEY LINE COMM File Copy A See File Copy Section Language English English Sensors UV IR Dual Sensor Models Only UV IR IR Only UV Only IR Band i70 0 IR Frequency selected Signal strength S1 Models 23 70 117 S2 Models 23 31 39 46 54 62 70 78 85 93 101 109 117 125 132 140 148 156 164 171 179 Hz IR Gain iG1 0 IR Gain selected Signal strength 1 31 IR Range
3. 95IRS2 1 95UVS2 1 95DSS2 1 95IRS1E 1 95UVS1E 1 95DSS1E 1 95IRS2E 1 95UVS2E 1 95DSS2E 1 SPECIFICATIONS MECHANICAL Housing Material Cast aluminum with gray polyester powder coat finish Housing Weight 3 16 1 41kg flange additional Environmental NEMA 4X IP66 Mounting Mounting Flange Kit Requires one of two threaded mounting flanges ordered separately see below P N 60 2692 1 NPT female pipe mount with 3 8 NPT female cooling air connection includes 1 NPT x 3 long heat insulating nipple P N 35 127 1 P N 60 2693 1 BSP female pipe mount with 3 8 BSP female cooling air connection includes 1 BSP x 3 long heat insulating nipple P N 35 127 3 Mounting Flange Weight 0 7 165 0 32kg Cooling Purge Air Requirements Source Clean dry cool Volume 4 SCFM 113 l min at 3 8 threaded mounting flange or 1 inch Y fitting mounted on scanner sight pipe Temperature near the upper limit of the scanner operating range and or use with dirty dusty fuels may require up to 15 SCFM 425 l min Pressure Adequate to overcome furnace or windbox pressure Temperature Rating Humidity ELECTRICAL Input Power Electrical Connection Relay Output Contact Rating Analog Output Status Indication Operator Interface Cable Specification 40 F to 150 F 40 C to 65 C 096 to 95 relative humidity non condensing 24 Vdc 10
4. DESCRIPTION CU 95 November 2000 INSIGHT canners TYPE 95IR 95UV 95DS MODEL 51 52 Integrated Flame Scanner with Internal Flame Relay Year 2000 Compliant in accordance with BSI document DISC 2000 1 1998 The FIREYE InSight Type 95IR 95UV and 95DS flame scanners are micro processor based flame scanners utilizing solid state infrared IR or ultraviolet UV or dual IR and UV sensors The FIREYE InSight Type 95 flame scanners incorporate an internal flame relay with adjustable ON OFF thresholds thereby eliminating the need for a remote flame amplifier The InSight scanners incorporate elements of the FIREYE Type 45FS1 and 45UVFSI Signature Scanners as well as of the Type 45RM4 flame scanners to detect the presence or absence of a tar get flame in single or multi burner applications The InSight scanners measure the amplitude of the modulations the flame flicker that occur within the targeted flame During the scanner set up procedure the modulation frequency that yields the best flame ON OFF discrimination is selected The appropriate modulation frequency and sensor gain is either manually selected S1 models or automatically selected with manual override capa bility S2 models The InSight 95IR 95UV and 95DS scanners are each available in two models differentiated by fea ture levels The Standard Model S1 has three choices of modulation frequency adjustable sensor gain adjust able flame relay ON OFF
5. IRR HIGH HIGH LOW UV Band u70 0 UV Frequency selected Signal strength S1 Models 23 70 117 S2 Models 23 31 39 46 54 62 70 78 85 93 101 109 117 125 132 140 148 156 164 171 179 Hz UV Gain uG1 0 UV Gain selected Signal strength 1 31 UV Range UVR HIGH HIGH LOW On Threshold ONT 40 5 100 Off Threshold OFFT 20 0 95 FFRT FFRT 1 1 2 8 4 5 6 seconds OTD OTD 1 1 2 8 4 5 6 seconds EXIT THE EDIT MENU Edit Returns you to STATUS loop 26 The values of the menu choices are viewed by pressing the SELECT button To exit the viewed value without changing it press the SELECT button again To change a value press the UP DOWN keys until the desired value is displayed Depress the PROGRAM button The display will scroll Parameter saved then automatically de select the menu choice as if the SELECT button had been pressed See important note below IMPORTANT NOTE In order to immediately see the effect of a setpoint change upon the Signal Strength number some parameter values are changed and saved immediately via the UP DOWN keys and do not require depressing the PROGRAM key These parameters include IR Band UV Band IR Gain and UV Gain The Signal Strength number is displayed to the right of the parameter value on the same screen providing the user instantaneous feedback Note Y
6. 015 020 030 To provide an easy method to wire the InSight scanners in a Multi drop wiring configuration for remote communications Fireye offers a wiring harness in 5 different lengths 3 10 15 20 and 30 ft The harness has a pre wired female quick disconnect to plug into the quick disconnect on the scanner The other end of the wiring harness has a conduit box with a 16 connector terminal strip Twelve 12 connectors are pre wired to the female quick disconnect Function Wiring Harness Wire cable Black Red Power 24 VDC White Blue Power 24 VDC White Black Flame Relay N O White Red Flame Relay N O Red Fault Relay N C Pink Fault Relay N C Violet 4 20 mA Grey Red 4 20 mA Blue Red File Select 1 Yellow File Select 2 Back to Control Room Burner Management System 2 3 4 5 6 7 8 9 gt Lo Brown Communications A Communications Belden 8761 85485 COM 5485 COM Belden 8761 5485 COM To previous flame scanner or 1C485 converter RS485 COM B To next flame scanner 17 FIGURE 15 SUGGESTED WIRING FOR COMMUNICATIONS RS485 communi cation For each RS485 COMMUNICATIONS individual wiring run connect 0 59 497 to ener er of the shield circuit to ground Tape and isolate other end See next page for more detail O NEXT WIRING HARNESS
7. LOW Set FEG Run the flame at low fire and press the PROGRAM button The scanner will set an appropriate inter nal front end gain level based upon the flame intensity brightness then display FEG is set EXIT Pressing the SELECT key will return the user to the Pre Edit menu choice of the main status menu Manual Set up in Edit menu S1 Models only 32 In the EDIT menu with the target flame ON at low fire observe and record the sensor signal strength and stability at each of the three modulation BANDS 23 70 and 117 Hz The signal strength display has a range of 0 999 During set up it may be necessary to adjust the sensor GAIN in order to keep the signal strength value on scale If so observe and record the sensor GAIN value 1 31 selected With dual sensor models perform this step for each sensor In the EDIT menu with the target flame OFF leaving other burners firing observe and record the sensor signal strength and stability at each of the three modulation BANDS 23 70 and 117 Hz Do not adjust the sensor GAIN at this time With dual sensor models perform this step for each sensor At each of the three modulation frequencies compare the recorded Flame ON signal strength to the recorded Flame OFF signal strength Select the modulation BAND that yielded the greatest Flame ON to Flame OFF signal ratio and or yielded the greatest stability With dual sensor models perform this step
8. Power 24 Vdc Power 24 Vdc Flame Relay N O Flame Relay N O Fault Relay N C Fault Relay N C 4 20 mA 4 20 mA File Select 1 File Select 2 Communications A Communications B Note Brown and orange wires are a twisted pair 13 FIGURE 11 BK BLACK RD RED WT WHITE PK PINK VT VIOLET GY GREY BU BLUE YL YELLOW BN BROWN OR ORANGE FIGURE 12 CONNECTOR ASSEMBLY INSTRUCTIONS 1 75 04 44 5 1 Inches mm HOUSING GROUNDING RING SUPPORT SLEEVE O RING COUPLING NUT E QR i N FEMALE CONTACTS PLUG CONNECTOR CONNECTOR ASSEMBLY STEPS FOR EASE OF CONNECTOR ASSEMBLY INSTALL ON END SHOWN COLOR CODE For ease of assembly install the 129 164 connector on the 59 497 cable end where the 3 white wires are clockwise to the red wire CLAMP NUT CABLE SEAL SCANNER CABLE 59 497 CABLE GRIP 1 Select 59 497 cable end with the wire color orientation as shown in Figure 10 2 Slide items along the cable as shown including coupling nut and O ring discard the black thread protector and orange grommet from plug connector 3 Strip cable connector end in accordance with Figure 11 Slide braid back and forth to loosen then fold braid back over cable jacket Cut and discard foil tape 4 Solder the wires to the contacts 14 5 Slide contacts into plug connector per wiring table until contac
9. e g Gas Oil Pilot Main Low Fire High Fire etc in these files The 51 models have two programmable files A amp B and S2 models have four A B C amp D With RFS selected as LINE one or two external switches sup plied by user will select between the files when the RFS1 or RFS2 wires are connected to 24 vdc RFS1 Blue Open Closed Open Closed RFS2 Yellow Note 1 Open Open Closed Closed File Selected Note 1 RFS2 function is available in the S2 models only Note 2 The user may also select RFS as KEY which will allow manual file selection at the scanner keypad Note 3 With FM amp CSA approved S2 models the user may also select RFS as COMM which will allow manual selection at a remote computer running Fireye software This feature is not available with CE approved S2E models Note 4 Fireye recommends the use of shielded cable for the two remote file select switches or relays The switch contacts should be rated for low current operation 3mA dc ASSEMBLY INSTRUCTIONS QUICK DISCONNECT KIT P N 129 164 ASSEMBLY Refer to Figure 11 FIGURE 10 59 497 Cable Color Black Red White Blue White Black White Red Red Pink Violet Grey Red Blue Red Yellow Brown Orange 82 models only QUICK DISCONNECT TERMINAL Pin Number of Quick Disconnect A m UO WO OG Function
10. 15 supply current 0 35 A 8 5 VA 12 pin quarter turn quick disconnect FLAME RELAY SPST N O FAULT RELAY SPST N C Minimum 10 mA 5 Vdc Maximum 2 A 30 Vdc 2 A 50 Vac CE approved models see page 4 2 240 Vac FM amp CSA models 4 20 mA dc current referenced to 24Vdc maximum connected 1oad 750 ohms Eight 8 character alpha numeric LED display scrolling capability Four 4 pushbutton style keys P N 59 497 Multi core 12 conductor color coded with foil wrap and overall braided shield Six 18 AWG and four 22 AWG conductors plus one 422 AWG twisted pair Cable Jacket Irradiated Modified Polyolefin flame retardant low smoke zero halogen Nominal O D 0 41 10 4 mm Maximum O D 0 43 10 9 mm Maximum cable length 1000 feet 305 meters INSTALLATION NOTES The InSight flame scanners determine the presence or absence of flame by monitoring the frequency spectrum of the flame The scanner should initially be mounted so that the primary combustion zone is within the scanner s line of sight The location and sighting instructions listed in the following sections are rough guidelines for the location of the scanner The scanner provides feedback via its LED display to assist in the adjustment and proper alignment of the flame scanner Refer to the setpoint procedures described in this bulletin Note An acceptable scanner location must ensure the following Reliable main flame and or ignitor fl
11. THE Keypad Legend PRE EDIT MENU LOOP S1 Models Only UP Key Scrolls through menu clockwise W DOWN Key Scrolls th Lp SELECT Key rough menu counter clockwise RUN FLAME AT SET FEG LOWEST SETTING AND PRESS PROGRAM FEG IS SET A v AIM SCANNER QV EXIT v FROM PRE EDIT ON STATUS MENU FIGURE 24 THE PRE EDIT MENU S1 Models Only TEXT DISPLAYED Aim Scanner DEPRESS SELECT KEY TEXT DISPLAYED 10 UO Possible values 0 60 DEPRESS PROGRAM KEY TEXT DISPLAYED Set FEG Run flame at lowest setting and press PROGRAM Pre Edit Returns you to STATUS loop FEG is set Pre Edit is an automatic calibration function whereby the scanner sets an appropriate internal front end gain FEG level The appropriate choice of modulation BAND flame flicker frequency and sensor GAIN is later manually set up in the EDIT menu Pre Edit and Manual Set up is performed in 3 steps In the PRE EDIT menu run the target flame at the low firing rate and physically aim the scan ner for peak signal strength as observed at the Aim Scanner prompt Depress the Program key at the Set FEG prompt and the scanner will set an appropriate internal front end gain FEG level 31 2 Inthe EDIT menu observe and record the flame ON and flame
12. TYPE 951R 95UV 95DS QUICK DISCONNECT FIREYE CABLE 59 497 PIN NUMBER COLOR CODE BLACK RED 4 20mA OUTPUT Referenced WHITE BLUE WHITE BLACK TO BMS INPUT WHITE RED FUSE Notes 6 7 RED TO BMS INPUT Notes 6 7 VIOLET GREY RED to Common REMOTE 51 1 BLUE RED d FILE SELECT 1 REMOTE FILE SELECT 2 Sw2 Model S2 only REMOTE COMMUNICATIONS Model S2 only K YELLOW ad BROWN gt TO M ORANGE COMPUTER 12 t j Note 8 Notes 3 4 Notes 1 Flame relay contacts are shown in de energized no flame condition 2 Fault relay contacts are shown in de energized fault condition 3 Brown and orange wires a twisted pair 4 Cable shield not shown 5 With Remote File Select programmed as LINE external switches SW1 SW2 not furnished will select between two 51 Models or four S2 Models internal memory files when connected to 24V dc supply 6 BMS Burner Management System by others 7 External 2 0 Amp fuses recommended 8 ground screw is provided on the scanner end plate An external ground wire must be installed if line voltage is applied to the relay contacts REMOTE FILE SELECTION The InSight scanners have more than one internal memory file The user has the option of storing different scanner setpoints for different operating conditions
13. its normally open contacts close when the signal strength is at or above the programmed flame ON threshold The flame relay is de energized when the signal strength is at or below the programmed flame OFF threshold The flame relay contact circuit will also open upon a power interruption or the detection of an internal fault see below The FAULT RELAY is energized when the scanner is powered 24 vdc and when the scanner had successfully passed all internal self checking routines The Fault relay is de energized if there is a power interruption to the scanner or if the scanner has detected an internal fault A normally open fault relay contact is wired in series with the flame relay contact internally and a normally closed contact is available for alarm indication APPLICATION Type 95IR contains an infrared flame sensor responding to infrared radiation from 700 to 1700 nanometers wavelength This sensor is best suited to coal and oil applications Type 95UV contains an ultraviolet flame sensor responding to ultraviolet radiation from 295 to 320 nanometers wavelength This sensor is best suited to gas applications Type 95DS Dual sensor contains both the infrared and ultraviolet flame sensors described above This sensor is best suited to multi fuel applications The Standard Model S1 is best suited to the many applications that do not require the level of sophistication or the remote communications capability of the Expanded Model
14. the scale by which the internal Flame Relay ON and OFF thresholds are set The Flame Quality number is determined by the input of the IR and or UV sensor in dual sensor models it is the sum of the two This sensor signal strength value can be viewed in the Status menu as Signal Strength see description below For clarity the Flame Quality number is capped at 100 while under certain firing conditions the IR or UV signal strength or their sum may normally exceed 100 maximum of 999 In normal burner operation after the scanner has been properly setup 100 will be displayed with occasional movement depending on the stability of the flame Flame ON Off This item refers to the energized de energized status of the internal Flame relay Flame ON is dis played when the flame quality rises above the relay Threshold set in the Edit menu When the flame quality drops below the relay Off Threshold Flame OFF will be displayed Temperature The scanner s present temperature in degrees expressed in either Fahrenheit or Centigrade depend ing on which was selected in the Edit menu File Selected The current running file is displayed Choices are files A B for S1 Models and files A B C D for S2 Models Signal Strength The Signal Strength number represents the intensity of the flame flicker as sensed by the IR and or UV sensor s and is a function of the individual sen
15. thresholds 4 20 mA analog signal strength output fault relay and two selectable programmable files to store setpoints for two different fuels or firing rates The Expanded Model S2 adds automatic programming AutoTune with manual override capability 2 choices of flame flicker frequency a total of four selectable programmable files to store setpoints plus adds remote communication capability via Fireye Windows 95 98 NT user software All FIREYE InSight scanner models are powered by 24 Vdc have a twelve pin electrical quick dis connect and contain electronic self checking no mechanical shutter required The scanners contain an eight character alpha numeric LED display and a four 4 push button keypad to enable the user to view operating parameters and select setpoints TABLE OF CONTENTS DESCRIPTION aaa 1 OPERATION MUCH SI 3 APPLICATION led E ES 3 INSIGHT SCANNER 3 OPERATOR INTERFACE 4 DIMENSIONS eee eens 4 AGENCY APPROVALS 4 SPECIFICATIONS 0000 eee eee ee eee ee 4 INSTALLATION NOTES 6 INSTALLATION PROCEDURE 6 MECHANICAL 8 ELECTRICAL ACCESSORIES 8 SCANNER WIRING 11 R
16. viewed in the Status menu is capped at 100 In dual sensor models the Flame Quality number is the sum of the IR and UV sensor signal strengths capped at 100 Pressing the UP and DOWN keys changes the frequency displayed and immediately stores the value pressing the PROGRAM key is not required The user will immediately see the effect on the signal strength number displayed on the right side of the display UV Gain The display is broken into two halves The left side displays the selected UV Gain The right half dis plays the signal strength attributed to the UV sensor The UV sensor Gain is selectable from 1 lowest to 31 highest The signal strength number can range from 0 999 Note Remember that while the signal strength number can range to 999 the Flame Quality num ber viewed in the Status menu is capped at 100 In dual sensor models the Flame Quality number is the sum of the IR and UV sensor signal strengths capped at 100 Pressing the UP and DOWN keys changes the UV Gain displayed and immediately stores the value pressing the PROGRAM key is not required The user will immediately see the effect on the signal strength number displayed on the right side of the display See MANUAL ADJUSTMENT note at the end of this section UV Range There are two selectable internal ranges for the UV sensor Gain High and Low If when Aiming the scanner a flashing UV number is observed then the signal is over ran
17. 2 40 In this case the total Flame Quality is 120 and the FQ number viewed in the Status loop would be 100 capped at 100 Each increment of the gain will increase the Signal Strength Sensor Flame Quality number for the selected sensor by 50 In the above example changing the UV sensor gain from 12 to 13 would increase the UV Signal Strength from 40 to 60 Decreasing the IR sensor gain from 30 to 29 would decrease the IR Signal Strength from 80 to 53 In this case the total Flame Quality is 103 and the FQ number as viewed in the Status loop would be 100 capped at 100 For best scanner operation the Flame ON Flame Quality number IR Signal Strength UV Signal Strength should be between 100 and 150 even though the Flame Quality display Status loop is capped at 100 In the event that an internal scanner fault is detected the scanner will turn off its output and a four digit error code will appear on the display If the scanner s internal temperature exceeds 80 176 F the scanner will turn off its output and HOT will appear on the display To clear the error code and re start the scanner the 24 vdc power must be cycled off then on When power is applied to a scanner that had experienced a fault the display will read Errors fol lowed by several digits indicating the scanner s error history Pressing any key will clear this mes sage THE PRE EDIT MENU S1 Models only FIGURE 23
18. 40 When Fireye products are combined with equipment manufactured by others and or integrated into systems designed or manufactured by others the Fireye warranty as stated it its General Terms and Conditions of Sale pertains only to the Fireye products and not to any other equipment or to the combined system or its overall performance FIREYE guarantees for one year from the date of installation or 18 months from date of manufacture of its products to replace or at its option to repair any product or part thereof except lamps elec tronic tubes and photocells which is found defective in material or workmanship or which otherwise fails to conform to the description of the product on the face of its sales order THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES AND FIREYE MAKES NO WARRANTY OF MERCHANTABILITY OR ANY OTHER WARRANTY EXPRESS OR IMPLIED Except as specifically stated in these general terms and conditions of sale remedies with respect to any product or part number manufactured or sold by Fireye shall be limited exclusively to the right to replace ment or repair as above provided In no event shall Fireye be liable for consequential or special dam ages of any nature that may arise in connection with such product or part FIREYE CU 95 3 Manchester Road NOVEMBER 2000 Derry New Hampshire 03038 www fireye com
19. ANGE includes item B 10 35 127 3 BSP 35 202 NPT 60 2692 1 NPT 60 2693 1 BSP PART NUMBER 60 1664 3 NPT 60 1664 4 BSP 35 200 NPT 35 127 1 NPT 35 127 3 BSP 35 202 NPT 60 2692 1 NPT 60 2693 1 BSP PART NUMBER 60 1664 3 NPT 60 1664 4 BSP 35 127 1 NPT 35 127 3 BSP 60 2692 1 NPT 60 2693 1 BSP 23 8 605mm 20 6 523mm 15 3 389mm FIGURE 8 PART NUMBER A SWIVEL MOUNT 60 1664 3 NPT SWIVEL MOUNT 60 1664 4 BSP B SEALING UNION W QUARTZ WINDOW 60 1199 NPT C SCANNER CABLE 59 497 SCANNER WIRING To reduce electrical noise interference the scanner cable should be installed in rigid or flexible con duit Take precautions to keep the scanner cable away from any high inductive wiring associated with high inductive loads or high voltage high energy spark ignition systems CAUTION The InSight flame scanner requires 24 Vdc power for operation Connection to a 24 Vac or 120 Vac power source will damage the scanner Refer to wiring diagrams External 2 0 Amp fuses are recommended to protect Flame Relay and Fault Relay contacts All wiring to the scanner should be rated at 90 C For runs less than 1000 feet the use of Fireye Scanner Cable Part No 59 497 12 wire is recommended For runs in excess of 1000 feet consult the factory 11 FIGURE 9 WIRING DIAGRAM INSIGHT INTEGRATED FLAME SCANNER
20. EMOTE FILE SELECTION 2 13 ASSEMBLY INSTRUCTIONS QUICK DISCONNECT 13 WIRING FOR REMOTE COMMUNICATIONS 16 GROUNDING AND SHIELDING TECHNIQUES 19 PROGRAMMING THE InSight 20 INSIGHT STRUCTURE 20 THE STATUS MENU 22 THE EDIT MENU ssl 25 FILE COPY INSTRUCTIONS s 29 ERROR 5 30 THE PRE EDIT MENU 51 Models 31 MANUAL SET UP S1 Models only 32 THE AUTOTUNE MENU S2 Models 34 ORDERING INFORMATION 36 OPERATION The InSight scanners measure the amplitude of the modulations that occur within the targeted flame During the scanner set up procedure the modulation frequency that yields the best flame ON OFF discrimination is selected The appropriate modulation frequency and sensor gain is either manually selected S1models or automatically selected with manual override capability S2 models With the appropriate modulation frequency selected the flame relay s ON and OFF thresholds are then entered This selection is set automatically with S2 models The scanner s 4 20 mA signal strength output is at minimum 4 mA with a signal strength of 0 and at maximum 20 mA at a signal strength of 100 The FLAME RELAY is energized and
21. ETHER 2 CONNECT SHIELD TO EARTH GROUND AT ORIGIN FIRST HARNESS OR PO 18 FIGURE 17 WIRING FOR REMOTE COMMUNICATIONS 1 WHEN THE DISTANCE FROM SCANNER TO CONTROL ROOM lt 200 FEET AUS 59 497 59 497 CABLE CABLE BELDEN 8761 BELDEN 8761 BELDEN 8761 RA 1 SOFTWARE RS485 RS232 BURNER BURNER BURNER CONVERTER P N 1 485 MANAGEMENT MANAGEMENT MANAGEMENT SYSTEM SYSTEM SYSTEM 2 WHEN THE DISTANCE FROM SCANNER TO CONTROL ROOM gt 200 FEET AIDS 61 6944 BELDEN 8761 BELDEN 8761 BELDEN 8761 PC WITH WIRING a RS485 FIREYE z COMA RS485 RS232 P cy SOFTWARE COM B CONVERTER P N IC485 59 497 59 497 59 497 CABLE CABLE CABLE BURNER BURNER BURNER MANAGEMENT MANAGEMENT MANAGEMENT SYSTEM SYSTEM SYSTEM GROUNDING AND SHIELDING TECHNIQUES FOR USE ON SCANNERS OR SCANNER CABLE LOCATED WITHIN 12 OF A HIGH ENERGY OR HIGH VOLTAGE SOURCE 1 Connect a safety ground to scanner housing Figure 13 2 The scanner and scanner cable preferably within flexible conduit MUST be located at least 12 from the ignition source 3 Runa ground wire from the ignition transformer chassis to the ignitor assembly 4 Replace all frayed cracked or dirty oily ignition wire Ignition wire must be in good wo
22. OFF sensor signal strength and stability at each of the three modulation bands Select the modulation band that yields the great est Flame ON to Flame OFF signal ratio and or yields the greatest stability 3 Adjust the sensor GAIN and flame relay ON and OFF thresholds for reliable on off operation Aim Scanner When SELECT is depressed Ix Ux is displayed dual sensor models The value of x may range from 0 to 60 The value displayed represents the flame flicker intensity of the flame for the entire flicker frequency spectrum as individually sensed by the UV U sensor and or IR I sensor s The numbers should be at their peak highest numerically when the scanner is aimed at the primary combustion zone first 1 3 of the flame If the scanner is equipped with both an IR and UV sensor priority should be given to maximizing the UV intensity Run the flame at low fire rate and observe the signal intensity Physically aim the scanner at the first 1 3 of the flame to maximize the intensity reading Allow the scanner reading to stabilize two seconds after each movement If the reading is 10 or less the intensity is marginal Verify that the appropriate sensor Range parameter IR Range or UV Range in the Edit menu is set to HIGH If the reading is greater than 26 the number will blink the signal is excessive Verify that the appro priate sensor Range parameter IR Range or UV Range in the Edit menu is set to
23. S2 e g single burner boilers and furnaces duct burners etc The Expanded Model S2 is best suited to the applications that require the highest level of sophisti cation and flexibility addition choices of modulation frequencies and the time saving AutoTune function and remote communications capability e g larger multi burner boilers and furnaces InSight SCANNER FEATURES Features Basic Models S1 Expanded Models S2 95IR S1 95UV S1 9505 S1 95IR S2 95UV S2 9505 S2 Infrared Sensor X Ultraviolet Sensor Flame Relay Fault Relay 4 20 mA Output Modulation Frequency Selections Memory Files Communications AutoTune Pre Edit OPERATOR INTERFACE The InSight scanners contain an eight character alphanumeric LED display and a four 4 push but ton keypad to enable the user to view operating parameters and select setpoints For complete set up procedure refer to the PROGRAMMING section in this document DIM ENSIONS FIGURE 1 TYPE 95IR 95UV 95DS SCANNER shown with mounting flange ordered separately 10 89 276 681 425 107 95 1 11 1 2 NPT OR s 1 11 BSP PL SIGHT ones ia PIPE CONNECTION 4 62 117 35 PURGE AIR CONNECTION a 8 18 NPT UR cee HOUSING MATERIAL CAST ALUMINUM A356 3 8 19 BSP PL FINISH GRAY POLYESTER POWDER COAT AGENCY APPROVALS PART AGENCY APPROVALS NUMBER DIN DVGW 95IRS1 1 95UVS1 1 95DSS1 1
24. When the display reads Valid Password Press SELECT to change password press the SELECT key NEW is displayed the first digit 0 is adjustable For example enter NEW word of 1357 Use the UP DOWN key and the PROGRAM key as described in the above section to enter the new password When complete in this example the display will now read New pass word 1357 Depress the UP DOWN keys to return to the menu loops Signal Strength amp Flame Quality FQ Expanded Description Single sensor models Type 95IR 95UV The value of Signal Strength is the same as the Flame Quality number except that the Signal Strength value is allowed to exceed 100 maximum of 999 while Flame Quality is capped at 100 Dual sensor models Type 95DS This screen shows the individual sensor s contribution to the Flame Quality number Each value is preceded by the corresponding lower case letter indicating whether it is the IR i or UV sensor Under most firing conditions the sum of these individual values will exceed 100 maximum of 999 Important Note The Flame Quality number is the Flame Signal number but is capped at 100 In dual sensor 95DS models it is the sum of the IR UV Signal Strength numbers but the sum is capped at 100 Example 1 Single Sensor Model 95IR infrared If I 80 is displayed as signal strength you would see a Flame Quality number of FQ 80 dis played on t
25. ame detection at all air flow and furnace loads ranges of fuel fir ing Rejection of the ignitor flame if too short or in the wrong position to ignite the main flame reliably thus prohibiting the delivery of fuel to the burner Note Due to the microprocessor based design of the InSight scanner the heat insulating nipple P N 35 127 1 or 35 127 3 must be used to isolate the scanner from ground and to reduce conducted energy and noise See Figure 7 The nipple is included in mounting flange kit P N 60 2692 60 2693 INSTALLATION PROCEDURE A WARNING Protective filtered lenses should be worn when viewing flame Infrared and ultraviolet energy from the flame can be damaging to the eyes 1 The best results are obtained when the scanner is aimed so that the scanner s line of sight inter sects the burner center at a slight angle e g 5 degrees and sees a maximum of the primary com bustion zone as shown in Figure 2 If only one scanner is used per burner the line of sight should also intersect the igniting flame 2 For installations where separate scanners are used to monitor main and ignitor flames the main flame scanner should be sighted so it does not detect the ignitor flame 3 The scanner should have an unrestricted view of flame as far as possible Physical obstructions such as air register blades interfering vanes or other hardware should be cut away or notched so they do not fall within the scanner s line of sight
26. as shown in Figures 2 and 4 Note Always check with the burner manufacturer before you trim the register blades FIGURE 2 SINGLE BURNER SCANNER SIGHTING AIR REGISTER ENVELOPE BLADES TIE SCANNER LINE OF SIGHT BURNER BURNER gt gt CENTER LINE BASE PRIMARY COMBUSTION ZONE 4 Consideration must be given to burner secondary air rotation some burners have clockwise CW air rotation and others have counterclockwise CCW air rotation If combustion air enters the furnace with a rotational movement of sufficient velocity to deflect the ignitor flame in the direc tion of rotation position the scanner 10 to 30 degrees downstream of the ignitor as shown in Fig ure 3 and close to the periphery of the burner throat See Figure 2 FIGURE 3 SCANNER LOCATION VS SECONDARY AIR ROTATION IGNITOR IGNITOR SCANNER 7 E SCANNER CCW ROTATION CW ROTATION 5 Having determined the approximate location for the sight pipe cut a clearance hole for a 2 inch pipe through the burner plate Look through the hole If register vanes interfere with the desired line of sight the interfering vane s should be trimmed to assure an unrestricted viewing path at all firing levels as indicated in Figures 2 and 4 Note Always check with the burner manufacturer before you trim register vanes FIGURE 4 FLAME MUST COMPLETELY COVER SIGHT OPENING NOT THIS NOT THIS BUT THIS 6 The
27. e ON and with flame OFF background radiation present The scan ner will then select the appropriate sensor gain bandpass frequency and sensor range for optimum flame ON OFF discrimination The scanner will also select the optimum Flame Relay ON and OFF thresholds 34 AutoTune is performed 3 steps 1 Run the target flame at the low firing rate and physically aim the scanner for peak signal strength as observed at the Aim Scanner prompt 2 Depress the Program key and the scanner will memorize the flame ON condition 3 Turn the target flame OFF while leaving other burners firing and depress the Program key The scanner will memorize the flame OFF condition and select the appropriate internal set points Aim Scanner When SELECT is depressed Ix Ux is displayed dual sensor models The value of may range from 0 to 60 The value displayed represents the flame flicker intensity of the flame for the entire flicker frequency spectrum as individually sensed by the UV U sensor and or IR sensor s The numbers should be at their peak highest numerically when the scanner is aimed at the primary combustion zone first 1 3 of the flame If the scanner is equipped with both an IR and UV sensor priority should be given to maximizing the UV intensity Run the flame at low fire rate and observe the signal intensity Physically aim the scanner at the first 1 3 of the flame to maximize the intensi
28. e with various adjacent burners on and off and at various load levels This is a requirement for proper operation 33 THE AUTOTUNE MENU S2 Models only FIGURE 25 THE AUTOTUNE MENU LOOP S2 Models only Keypad Legend 4 UP Key Scrolls through menu clockwise WF DOWN Key Scrolls through menu counter clockwise Lp SELECT Key PROGRAM Key 2 TURN FLAME OFF WAIT 128 gt 0 LEARN OFF LEARN OFF AND PRESS PROGRAM COMPLETE A v RUN FLAME AT WAIT 128 0 LEARNON LOWEST SETTING LEARN ON AND PRESS PROGRAM COMPLETE v AIM SCANNER v c v TO AUTOTUNE ON STATUS MENU LOOP FIGURE 26 THE AUTOTUNE MENU S2 Models Only TEXT DISPLAYED DEPRESS SELECT KEY DEPRESS PROGRAM KEY TEXT DISPLAYED TEXT DISPLAYED Aim Scanner 10 UO Possible Values 0 60 Learn On Run Flame at Lowest setting and press WAIT 128 0 PROGRAM Counts down to 0 within 20 seconds then displays Learn OFF complete LearnOff only displayed if Learn ON had Turn Flame OFF and press PROGRAM WAIT 128 0 been performed Counts down to 0 within 20 seconds then displays Learn OFF complete AutoTune Returns you to STATUS loop AutoTune is an automatic calibration function whereby the InSight scanner scans the flame flicker frequency spectrum with flam
29. en the InSight scanner and the control room exceeds 200 feet 61m then a small junction box must be installed near each scanner The two communications wires must be separated out of the twelve conductor scanner cable at the junction box and wired independently in multi drop daisy chain configuration to each scanner in the loop and finally to the computer The Fireye Wiring Harness Assembly available in lengths from 3 to 30 feet 0 9 to 9 1m provides a convenient method to accomplish this On one end the harness has a female quick disconnect to connect to the InSight scanner Fireye twelve conductor cable P N 59 497 is factory wired to the quick disconnect run through flexible conduit and connected to a terminal strip within a junction box at the other end of the harness The terminal strip accepts up to 14 AWG wires and uses push type cage clamp connectors for quick and secure connections From the junction box the installer would connect all but two wires of a length of Fireye 59 497 twelve conductor cable that is run to the burner management system The two communications wires originating from the scanner would be connected from one junction box to the next and finally to the computer using a two conductor communications cable Belden 8761 22 AWG or equal 24 Volt DC Power Supplies Fireye offers two DIN rail mounted 24 vdc power supplies for use with the InSight Integrated flame scanner Model 60 2685 2 2 amp can powe
30. enu is entered from the Status menu after first entering a four digit password In the Edit menu the user is allowed to change the setpoints to optimize the scanner performance PRE EDIT MENU 51 Models only From the Pre Edit menu the user views the flame signal intensity and physically aims the scanner for optimum signal The user then commands the scanner to set an appropriate internal front end gain FEG level As with the Edit menu the Pre Edit menu is entered from the Status menu after first enter ing a four digit password AUTOTUNE MENU S2 Models Only From the AutoTune menu the user views the flame signal intensity and physically aims the scanner for optimum signal The user then commands the InSight scanner to analyze the flame ON and OFF background radiation conditions and automatically select the optimum setpoints As with the Edit menu the AutoTune menu is entered from the Status menu after first entering a four digit password FIGURE 18 INSIGHT SCANNER MENU STRUCTURE a STATUS AUTOTUNE 52 OR NOTE 1 If the password is not entered access to the PRE EDIT 51 EDIT PRE EDIT and AUTO TUNE loops are denied Pressing the UP KEY advances the display directly 52 OR PRE EDIT 51 to FQ LOOP 21 THE STATUS MENU FIGURE 19 STATUS MENU LOOP Keypad Legend UP Key Scrolls through menu clockwise DOWN Key Scrolls through men
31. for each sensor Adjust the sensor gain 1 31 so that the flame ON signal strength is well above the flame relay ON threshold and the flame OFF signal strength is well below the flame relay OFF threshold see Flame Relay Thresholds below When manually adjusting the IR and or UV Gain in the EDIT loop the display will show both the selected gain 1 31 and the Signal Strength Sensor Flame Quality number 0 999 associated with either the IR or UV sensor e g iG30 80 uG12 40 In this case the total Flame Quality is 120 and the FQ number viewed in the Status loop would be 100 capped at 100 Each increment of the gain will increase the Signal Strength Sensor Flame Quality number for the selected sensor by 50 In the above example changing the UV sensor gain from 12 to 13 would increase the UV Signal Strength from 40 to 60 Decreasing the IR sensor gain from 30 to 29 would decrease the IR Signal Strength from 80 to 53 In this case the total Flame Quality is 103 and the FQ number as viewed in the Status loop would be 100 capped at 100 For best scanner operation the Flame ON Flame Quality number IR Signal Strength UV Signal Strength should be between 100 and 150 even though the Flame Quality display Status loop is capped at 100 Example At the selected BAND the Flame ON signal ranged from 800 to 999 and the Flame OFF signal ranged from 50 to 130 a 6 1 on off ratio The user mus
32. ge and the Range should be set to LOW If when Aiming the scanner UV number of less than 10 is observed then the gain Range should be set to HIGH On Threshold This refers to the pull in threshold of the internal Flame Relay in terms of Flame Quality The ON Threshold can be set from 5 to 100 The ON Threshold must be at least 5 units higher than the OFF Threshold When the Flame Quality is equal to or greater than the ON Threshold for a time equal to the Time Delay setting see below the flame relay will energize Off Threshold This refers to the drop out threshold of the internal Flame Relay in terms of Flame Quality The OFF Threshold can be set from 0 to 95 The OFF Threshold must be at least 5 units lower than the ON Threshold When the Flame Quality is equal to or less than the OFF Threshold for a time equal to the Flame Failure Response Time setting see below the flame relay will de energize FFRT When the Flame Quality drops to or below the Flame Relay OFF Threshold the Flame relay will de energize after the selected Flame Failure Response Time FFRT The choices range from 1 to 6 sec onds The maximum allowable FFRT setting is determined by local safety code and is factory selected at 1 second OTD When the Flame Quality rises to or above the Flame Relay ON Threshold the Flame relay will ener gize after the selected On Time Delay OTD The choices ran
33. ge from 1 to 6 seconds EXIT Pressing the SELECT key will return the user to the Edit display in the Status menu FILE COPY INSTRUCTIONS You may copy from any file to a user file You are not allowed to copy from a user file to a factory file refer to FileCopy description earlier in this section You must first select the source file then select the destination file With FileCopy displayed EDIT menu depress the SELECT key The display will read with A being the source file Use the UP DOWN keys to select a different source file if desired With the desired source file displayed press the PROGRAM key The arrow will flash and the desti nation file will appear e g A Initially the destination is displayed is Use the UP DOWN keys to select the desired destination file e g gt B Press the PROGRAM key to copy the source file to the destination file The display will read File Copied Pressing the SELECT key at any time before pressing the PROGRAM key for the second time will cancel the operation Press the UP DOWN keys to scroll through the EDIT loop 29 Error Messages 30 Manual Adjustment of IR or UV Gain When manually adjusting the IR and or UV Gain in the EDIT loop the display will show both the selected gain 1 31 and the Signal Strength Sensor Flame Quality number 0 999 associated with either the IR or UV sensor e g 630 80 uG1
34. he Flame Quality screen If I 120 is displayed as signal strength you would see a Flame Quality number of FQ 100 on the Flame Quality screen because Flame Quality is capped at 100 Example 2 Dual Sensor Model 95DS If 180 u15 is displayed as signal strength you would see a Flame Quality number the IR and UV signal sum of FQ 95 displayed on the Flame Quality screen If 170 40 is displayed as signal strength although the sum is 110 you would see a Flame Quality number of FQ 100 on the Flame Quality screen because Flame Quality is capped at 100 THE EDIT MENU FIGURE 21 EDIT MENU LOOP UP Key Scrolls through menu clockwise WF DOWN Key Scrolls through menu counter clockwise Lp SELECT Key PROGRAM Key A v IR RANGE IRRHIGH ico C IR BAND gt i70 4 v SENSORS gt Uv amp IR 4 LANGUAGE gt ENGLISH 4 up N FILE COPY A 4 Ly REMOTE FILE SELECT RFS KEY 4 COMM ADDRESS commo 4 q TEMPERATURE SCALE gt J SCALE L FILE SELECT FILE A 4 v FROM EDIT ON STATUS MENU LOOP
35. his feature is not available with CE approved S2E models FileCopy This function allows the user to copy the contents of one internal scanner file to another 51 Mod els have two user configurable files A B plus two factory configured files F1 F2 52 Models add two additional user files You may copy from any file to a user file You are not allowed to copy from a user file to a factory file You must first enter the source file then the destination file Refer to FileCopy instructions at the end of this section The Factory Configured Files 1 and F2 contain factory default settings In File F1 the sensor gain is set at maximum 31 and the flicker frequency is set at 23 Hz At these settings the scanner will respond to flame but will not likely discriminate between the target flame and other nearby flames In File F2 the sensor gain is set at minimum 1 and the flicker frequency is set at 70 Hz At these settings the scanner will not likely respond to flame until the scanner gain is increased Note As shipped all user files A B C D contain the same setpoints as factory file F2 Language Affects all files This allows the user to select which language the menu system will use The available choice is English Sensors dual sensor units only Type 95DS Choices include UV only IR only or UV IR This parameter is used to manually select which
36. hread Schedule 40 1 11 ub NPT When the sealing union is used a 1 inch Y fitting must be used down stream of it for connection of a purge air supply plug opening See Figure 5 for piping with the sealing union Item D ELECTRICAL ACCESSORIES Scanner Cable P N 59 497 Fireye recommends P N 59 497 multi core 12 conductor color coded foil wrap and overall braided shield cable This cable includes six 18 AWG and four 22 AWG conductors plus one 22 AWG twisted pair The cable jacket is Irradiated Modified Polyolefin flame retardant low smoke zero halogen with a maximum diameter of 0 43 10 9 mm The maximum cable length is 1000 feet 305 meters per scanner This raw stock cable requires the Quick Disconnect Kit described below Refer to Figure 9 for color code and connection information Quick Disconnect Kit P N 129 164 A twelve pin male electrical connector is factory installed on the InSight scanners Fireye offers the mating female connector for field installation onto the 59 497 cable Refer to Quick Disconnect assembly instructions Scanner Cable with Factory installed Female Connector P N 59 497 XXX Fireye offers the 59 497 12 conductor cable in pre cut lengths with the female quick disconnect fac tory installed These assemblies are offered in lengths from 10 feet 3m to 300 feet 91m Wiring Harness Assembly P N 61 6944 XXX If remote communication is required Model S2 only and the distance betwe
37. nner s internal temperature within specification Flexible conduit should be used to wire the scanner from a grounded service box to the scanner MECHANICAL ACCESSORIES Surface Mounting Flange Required P N 60 2692 1 NPT female pipe mount with 3 8 NPT female cooling air connection includes locking ring and 1 NPT x 3 long heat insulating nipple P N 35 127 1 P N 60 2693 1 BSP female pipe mount with 3 8 BSP female cooling air connection includes locking ring and 1 BSP x 3 long heat insulating nipple P N 35 127 3 Swivel Mount Optional The scanner swivel mount P N 60 1664 3 NPT see Figure 8 Item A is used to adjust the scanner sighting angle after the scanner has been installed The swivel mount is used as indicated in Figures 5 6 and 7 Heat Insulating Nipple Required Heat Insulating nipple P N 35 127 1 NPT or P N 35 127 3 BSP see Figure 7 Item B is used to prevent heat transfer from the hot sight pipe to the scanner head as well as electrically isolate the scanner from ground The appropriate nipple NPT or BSP is shipped with the surface mounting flange Sealing Union with Quartz Window Optional The sealing union P N 60 1199 see Figure 8 Item B is used whenever a coupling or a seal is required for scanner piping The quartz window blocks furnace pressure hot gases and soot from coming in contact with the scanner and contaminating the lens The size is one inch U S standard taper pipe t
38. ns must be kept free of contaminants oil ash soot dirt and the scanner housing temperature must not exceed its maximum rating of 150 F 65 C Excessive temperatures will shorten scanner life Both requirements will be satisfied by a continuous injection of purge air at either the 3 8 housing inlet or the 1 Y connection ahead of the swivel mount as shown in Figures 5 and 6 Note Internal scanner temperature is available via the LED display See Status Menu under Programming the Scanner The scanner mounting may be made with provision for purge air through only the 3 8 opening as shown in Figure 7 or for purge air through either the 3 8 opening or the 1 Y connection as shown in Figure 6 In the latter arrangements normally only one of the two connections is provided with purge air and the other connection is plugged When a sealing union is used as shown in Figure 5 the 1 Y connection is used for the purge air and the 3 8 opening is plugged It is good practice to use the sealing union P N 60 1199 with NPT threads on all installations to insure against unwanted furnace pressures from damaging the scanner lens Under normal conditions with clean burning fuels and moderate ambient temperature conditions purge air flow of approximately 4 SCFM 1331 min is generally adequate Up to 15 SCFM 425 I min may be required for fuels that produce high levels of ash or soot or for hot environments to maintain the sca
39. ou may only Edit the File that the scanner is currently running For example to Edit file B you must be currently running file B See File Select section below Exceptions A change made to the Temperature Scale Comm Address Remote File Select and Language parameters can be made in any file and the new values will be automatically saved to all files File Select The user can manually choose which file to run and to Edit by selecting this menu choice provided the Remote File Select KEY choice is selected see below If the user wants to Edit the contents of a file they must first select and run that particular file See exceptions in note above Temperature Scale Affects all files The scale may be selected to be Fahrenheit or Celsius Comm Address S2 Models Only Affects all files The communications address selected may range from 0 to 127 Each scanner must have a unique address No two scanners in a communications loop can have the same address Remote File Select Affects all files Choices are KEY LINE COMM KEY allows the file selection to be made only at the scanner keypad See File Select menu choice above LINE allows the file selection to be made only via an external switch or relay COMM allows the file selection to be made only via an external computer running Fireye Software This feature is only available with FM amp CSA approved S2 models T
40. ousing Connected to Earth Ground Prewired by Factory WIRING FOR REMOTE COMMUNICATIONS S2 models only Remote communications with the InSight scanner uses an RS485 Interface to carry the communica tion signals An IBM compatible PC running Fireye software is required to communicate with the flame scanners The wiring configuration for remote communications is dependent on the dis tance between the scanner and amplifier For distances less than 200 feet wire the Fireye cable P N 59 497 to the female quick disconnect in the manner previously described and run the cable directly back to the burner management system For wiring distances greater than 200 feet remote communications requires wiring a twisted shielded pair of wires in a multi drop wiring configuration and then use a terminating resistor at the scanner located farthest from the communication source See Using Fireye Wiring Harness 16 Note The maximum distance for the communication wiring for all associated InSight scanners is 4 000 feet The maximum number of scanners connected to the communication link is 32 scanners Exceeding this total wiring length or number of scanners requires the installation of bi directional repeaters or amplifiers Consult factory for additional information Using Fireye Wiring Harness P N 61 6944 003 010
41. preferred method for mounting surface mounted scanners requires the use of a swivel mount Part No 60 1664 3 NPT shown in Figures 5 6 and 7 Center the swivel mount over the two inch hole in the burner plate and secure using three hexed cap screws not provided Install the sight pipe on the swivel mount If a swivel is not used insert the end of the sight pipe into the hole align the hole to the desired viewing angle and tack weld welding must be ade quate to temporarily support the weight of the installed scanner The sight pipe should be arranged to slant downward so that dirt and dust will not collect inside CAUTION Use no more than one foot of one inch diameter sight pipe Increase the sight pipe diameter one inch for every additional foot of sight pipe length used to avoid restrict ing the scanner s field of view 7 When a satisfactory sighting has been confirmed by operational testing secure the swivel mount s ball position in place by tightening the three hex head cap screws located on the swivel mount ring 8 Forease of use the scanner should be installed on the sight pipe so the LED display can easily be read Note Operation of the LED display is independent of position Note Due to the microprocessor based design of the InSight scanner the heat insulating nipple P N 35 127 1 or 35 127 3 must be used to isolate the scanner from ground and to reduce con ducted energy and noise See Figure 7 9 The scanner le
42. r up to five InSight scanners model 60 2685 4 4 amp can power up to ten Insight scanners see note 1 PART NUMBER DESCRIPTION 60 2685 2 24 VDC Switching Power Supply 50W 100 240 vac 50 60 Hz input 2 1 A output at 24 vdc Dimensions 3 2 82mm high x 3 5 90mm wide x 3 6 91mm deep 60 2685 4 24 VDC Switching Power Supply 100W 120 240 vac 50 60 Hz input 4 2 A output at 24 vdc Dimensions 3 2 82mm high x 5 7 145mm wide x 3 6 91mm deep 60 2539 12 DIN mounting rail 12 305mm long 60 2539 24 DIN mounting rail 24 610mm long 60 2539 36 DIN mounting rail 36 914mm long Notes 1 Rated output is when power supply is vertically mounted and with an ambient temperature of 122F 50C maximum When supply is mounted vertically at 140F 60C the output is de rated 25 2 When mounted in a row allow at least 0 79 20mm between adjacent power supplies FIGURE 5 A SWIVEL MOUNT 1 WYE C 1 CLOSE NIPPLE PART NUMBER 60 1664 3 NPT 60 1664 4 BSP 35 200 NPT 35 201 NPT D SEALING UNION W QUARTZ WINDOW 60 1199 NPT E HEAT INSULATING NIPPLE 35 127 1 NPT F 3 8 PLUG G SURFACE MOUNTING FLANGE includes item E FIGURE 6 A SWIVEL MOUNT B 1 WYE C HEAT INSULATING NIPPLE D 3 8 PLUG E SURFACE MOUNTING FLANGE includes item C FIGURE 7 A SWIVEL MOUNT B HEAT INSULATING NIPPLE C 3 8 THREADED OPENING D SURFACE MOUNTING FL
43. rking con dition 5 Electrically isolate the scanner from the burner using a heat insulating nipple provided with the sur face mounting flange 6 Cooling Purge Air must be electrically isolated from the scanner e g isolated short rubber hose SCANNER TO CONTROL ROOM SHIELDING TECHNIQUES Scanner with scanner cable 59 497 wired directly Attach drain wire to scanner quick disconnect as described Use heat insulating nipple on back to burner management system See below for scanner Connect drain wire of 59 497 to earth ground at power supply remote communications REMOTE COMMUNICATIONS LESS THAN 200 FEET Scanner with scanner cable 59 497 wired directly Attach drain wire to scanner quick disconnect as described Use heat insulating nipple on back to control room scanner Connect drain wire of 59 497 to earth ground at power supply REMOTE COMMUNICATIONS GREATER THAN 200 FEET RS485 communications for scanners wired in a multi Attach drain wire to scanner quick disconnect as described Use heat insulating nipple on drop configuration Belden 8761 using wiring scanner Connect drain wire of 59 497 to earth ground at power supply Twist together and harness or junction box tape to electrically isolate drain shields from Belden 8761 cables inside each wiring harness or junction box Connect shield drain to earth ground at RS485 source e g IBM computer 19 PROGRAMMING THE INSIGHT SCANNER Keypad Displa
44. sensor s are used in a particular file IR Band The display is broken into two halves The left side displays the selected IR flicker frequency band pass The right side displays the signal strength attributed to the IR sensor 27 28 For example with a model S2 scanner i 23 80 indicates that 23Hz is selected and the current signal strength is 80 as viewed in the Status loop Frequency choices range from 23Hz to 179Hz S2 models or from 23Hz 70Hz 117Hz S1 models The signal strength number can range from 0 999 Note Remember that while the signal strength number can range to 999 the Flame Quality num ber viewed in the Status menu is capped at 100 In dual sensor models the Flame Quality number is the sum of the IR and UV sensor signal strengths capped at 100 Pressing the UP and DOWN keys changes the frequency displayed and immediately stores the value pressing the PROGRAM key is not required The user will immediately see the effect on the signal strength number displayed on the right side of the display IR Gain The display is broken into two halves The left side displays the selected IR Gain The right half dis plays the signal strength attributed to the IR sensor The IR sensor Gain is selectable from 1 lowest to 31 highest The signal strength number can range from 0 999 Note Remember that while the signal strength number can range to 999 the Flame Quality n
45. sor Gain and Bandpass flicker frequency settings The Signal Strength number is related to the Flame Quality number see Signal Strength expanded description below Comm Address S2 Models Only This number refers to the remote communications address of the scanner The address can range from 0 to 127 as selected in the Edit menu No two scanners in a communications loop should have the same address Software Revision This displays the internal software revision Maximum Temperature This displays the highest scanner temperature recorded Password A four digit Password is required to enter the EDIT and AUTOTUNE menus If a Password is not entered pressing the UP key will advance directly to the Flame Quality display pressing the DOWN key will return to the Maximum Temperature display To enter the EDIT or AUTOTUNE menus you must enter the four digit Password The following example is for the factory installed password of 0205 1 With PASSWORD displayed depress the SELECT key will be displayed the first digit 0 is adjustable If the factory password was changed use the UP DOWN keys to select the appropriate first digit 23 24 2 With the first digit selected e g depress the PROGRAM key 00 will be displayed the second digit 0 is adjustable Depress the UP key twice to display 2 If the factory pass word was changed
46. t reduce the sensor gain so that flame ON signal strength is well above the flame relay ON threshold factory programmed at 40 and the flame OFF signal strength is well below the flame relay OFF threshold factory programmed at 20 In this example the user may reduce the gain to have a flame OFF signal of 0 and a flame ON signal of 150 Special Note for Dual Sensor Models With dual sensor models the flame relay and 4 20 mA output will operate on the SUM of both the IR and UV signals When setting the final GAIN adjustments the user should favor the sensor IR or UV which exhibited the greatest flame ON OFF signal ratio and or greatest stability If the user chooses to use the input from only one sensor and disable the input from the other he may do so by selecting IR ONLY or UV ONLY as Sensors in the Edit menu Flame Relay Thresholds The flame relay has a factory programmed FLAME ON threshold of 40 and a FLAME OFF thresh old of 20 0 100 scale With these settings it is recommended that the flame ON signal normally be at least 150 Other on and off thresholds may be selected to suit particular applications CAUTION After selecting Sensor TYPE Sensor BAND Sensor GAIN and Flame Relay ON amp OFF Thresholds proper flame detection and flame discrimination must be verified by starting and stopping the burner several times The flame relay must reliably de energize for all flame out conditions This testing should be don
47. this time by the selection of their respective gain numbers The gain settings will be selected to yield a total signal strength of between 100 and 150 which would yield a Flame Quality number of 100 The Flame relay ON and OFF thresholds will be automatically set to 40 and 20 respectively unless the off signal level is exceptionally high which usually indicates poor aiming of the scanner Note If after learning flame OFF an insufficient on off ratio is not found in at least one sensor the display will show Warning Poor discrimination try re aiming scanner EXIT Pressing the SELECT key will return the user to the AutoTune menu choice of the main menu 35 CAUTION After selecting Sensor TYPE Sensor BAND Sensor GAIN and Flame Relay ON amp OFF Thresholds proper flame detection and flame discrimination must be verified by starting and stopping the burner several times The flame relay must reliably de energize for all flame out conditions This testing should be done with various adja cent burners on and off and at various load levels This is a requirement for proper operation ORDERING INFORATION PART NUMBER STRUCTURE SENSOR MODEL HOUSING 95 Integrated internal flame IR Solid state infrared S1 Basic features FM amp CSA 220 1 NEMA 4X IP66 housing 12 relay Vac contact rating pin electrical connector UV Solid state ultraviolet S1E Basic features CE 50 Vac contact ra
48. ting DS Dual sensor IR UV S2 Expanded features FM amp CSA 220 Vac contact rating Remote Command user software S2E Expanded features CE 50 Vac contact rating Read Only user Software Example 1 To select the Fireye equipment meeting the following specification Integrated Insight scanner dual sensor expanded features CSA amp FM approved surface mounted NEMA 4X IP66 enclosure with male electrical connector Accessories to include 1 NPT mounting flange 100 feet of 12 conductor cable and female electrical connector kit Order the following QUANTITY PART NUMBER DESCRIPTION 950552 1 InSight Scanner Dual Sensor 60 2692 1 NPT mounting flange kit 100 feet 59 497 12 Conductor cable 129 164 Female electrical connector kit 36 Example 2 To select the Fireye equipment meeting the following specification Integrated Insight scanner ultraviolet sensor basic features CE approved surface mounted NEMA 4X IP66 enclosure with male electrical connector Accessories to include 1 BSP mounting flange 12 conductor cable assembly 100 feet long with factory installed female electrical connector Order the following QUANTITY PART NUMBER 95UVS1E 1 60 2693 DESCRIPTION InSight Scanner Ultraviolet 1 BSP mounting flange kit 59 497 100 12 Conductor cable assembly 100 feet with installed connector 37 38 39 NOTICE WARRANTIES
49. ts lock in place Slide coupling nut up against plug connector flange and slide O ring into groove on plug connec tor body 7 Slide support sleeve back over braid and drain wire then place braid over spring elements of sup port sleeve Clamp braid and drain wire by snapping on the metal grounding ring Screw housing onto the plug connector Torque to 27 Ib in 25 Ib in 3 05N m 0 03 N m Assemble cable seal and cable grip to the housing screw clamp nut onto housing and tighten to 27 Ib in 25 Ib in 3 05N m 0 03 N m FIGURE 13 WIRING TABLE AND PLUG CONNECTOR PIN LOCATION PLUG CONNECTOR PIN LOCATION VIEWED FROM PIN INSERTION SIDE BLACK RED 18 AWG WHITE BLUE 18 AWG WHITE BLACK 18 AWG WHITE RED 18 AWG RED 18 AWG PINK 18 AWG VIOLET 22 AWG GREY RED 22 AWG BLUE RED 22 AWG YELLOW 22 AWG BROWN 22 AWG TWISTED ORANGE 22 AWG TWISTED A B C D E F G H 15 FIGURE 14 WIRING HARNESS ASSEMBLY HARNESS ASSEMBLY NO Part No 61 6944 003 61 6944 010 61 6944 015 61 6944 020 61 6944 030 Belden 8761 Ground Screw for communication 59 497 CABLE ordered separately to other scanners TO BURNER Scanner Quick Disconnect MANAGEMENT SYSTEM Connector and Flexible IN OUT Metal Conduit EMI CONNECTOR not included For FIREYE 59 497 cable a H
50. ty reading Allow the scanner reading to stabilize two seconds after each movement If the reading is 10 or less the intensity is marginal Verify that the appropriate sensor Range parameter IR Range or UV Range in the Edit menu is set to HIGH If the reading is greater than 26 the number will blink the signal is excessive Verify that the appro priate sensor Range parameter IR Range or UV Range in the Edit menu is set to LOW Learn ON Run the flame at low fire and press the PROGRAM button The scanner will display Wait followed by a number that will count down from 128 to 0 in about 20 seconds This will temporarily store the spectrum of the monitored flame and the adjacent flames The front end gain number used in the ON OFF calculation will be stored at this time Learn Off Turn off the monitored flame leaving adjacent flames operating then press the PROGRAM button The scanner will display Wait followed by a number that will count down from 128 to 0 in about 20 seconds This will temporarily store the spectrum of the adjacent flames The ON spectrum will then be compared to the OFF spectrum and the frequency and gain for optimum discrimination will be selected The IR and UV gain settings will be automatically selected based on the proportionality of their flame ON OFF ratios On dual sensor models the contribution of the IR and UV signal strengths to the Flame Quality is also determined at
51. u counter clockwise Ly SELECT Key PROGRAM Key NOTE 1 If the password is not entered access to the EDIT PRE EDIT and AUTO TUNE loops are denied Pressing the A UP KEY advances the display directly to FQ O NOTE 2 Refer to PASSWORD section for further details NOTE 3 Dual sensor model shown IR amp UV NOTE 4 Communications available in S2 models only FIGURE 20 THE STATUS MENU START HERE PASSWORD notes 9 2 AUTOTUNE 52 OR PRE EDIT S1 gt v TO PRE EDIT S1 OR AUTOTUNE S2 MENU LOOP TO EDIT MENU LOOP TEXT DISPLAYED DESCRIPTION POSSIBLE VALUES FQ 0 Flame Quality scanner output 0 100 FLAME OFF Flame Relay status ON OFF T 46C Present Scanner temperature 32 F to 212 F 0 C to 100 C File A Scanner file in operation A B C D iO u0 Signal strength IR and UV dual sensor models 0 999 COMM 0 Communication address S2 models only 0 127 SOFTWARE REVISION Scanner software revision MAX 46C Scanner Temperature stored maximum 40 F to 185 F 40 C to 85 C PASSWORD 22 A Password is required to enter the EDIT PRE EDIT or AutoTune menus See PASSWORD section 0000 9999 Flame Quality The Flame Quality number can range from 0 to 100 It represents the scanner s 4 20 mA analog flame signal strength OUTPUT in percent and is
52. um ber viewed in the Status menu is capped at 100 In dual sensor models the Flame Quality number is the sum of the IR and UV sensor signal strengths capped at 100 Pressing the UP and DOWN keys changes the IR Gain displayed and immediately stores the value pressing the PROGRAM key is not required The user will immediately see the effect on the signal strength number displayed on the right side of the display See MANUAL ADJUSTMENT note at the end of this section IR Range There are two selectable internal ranges for the IR sensor Gain High and Low If when Aim ing the scanner a flashing IR number is observed then the signal is over range and the Range should be set to LOW If when Aiming the scanner an IR number of less than 10 is observed then the gain Range should be set to HIGH UV Band The display is broken into two halves The left side displays the selected UV flicker frequency band pass The right side displays the signal strength attributed to the UV sensor For example with a model S2 scanner u 23 80 indicates that 23Hz is selected and the current signal strength is 80 as viewed in the Status loop Frequency choices range from 23Hz to 179Hz 2 models or from 23Hz 70Hz 117Hz S1 models The signal strength number can range from 0 999 Note Remember that while the signal strength number can range to 999 the Flame Quality num ber
53. use the UP DOWN keys to select the appropriate second digit 3 With the second digit selected e g 02 depress the PROGRAM key 020x will be dis played the third digit 0 is adjustable If the factory password was changed use the UP DOWN keys to select the appropriate third digit 4 With the third digit selected e g 020 depress the PROGRAM key 0200 will be dis played the fourth digit 0 is adjustable Depress the UP key five times to display 5 If the factory password was changed use the UP DOWN keys to select the appropriate fourth digit 5 With all four digits selected e g 0205 depress the PROGRAM key If the Password was not entered correctly the display will read Wrong Password Depress the SELECT key to re enter the password If the Password was entered correctly the display will read Valid Password Press SELECT to change password If you wish to change the password at this time see the Change Password sec tion below Otherwise depress the UP key to advance to the EDIT and AUTOTUNE menus Entering the correct Password allows the user 20 minute access to the EDIT and AUTOTUNE menus Changing any parameter will re start this 20 minute time out period Change Password The user may change the password the factory set password is 0205 to any four digit code desired To change the password you first enter the current password as described above
54. y The InSight flame scanner uses an eight 8 character alphanumeric LED Display and four 4 pushbut tons to review and program the various setpoints and operating parameters The functions of the push buttons are UP DOWN The UP and DOWN buttons are used to scroll through the scanner menus When in the EDIT menu after selecting a setpoint to edit see SELECT button the UP and DOWN buttons are used to change that setpoint SELECT When in the EDIT menu the UP DOWN buttons are used to display the setpoints Depressing the SELECT button displays the stored value of the setpoint allowing it to be changed PROGRAM The PROGRAM button saves a change made to a setpoint It is also used to execute the Auto Tune function S2 Models only or Pre Edit function 5 1 Models only INSIGHT MENU STRUCTURE 20 For ease of operation the InSight scanner contains three menus or loops accessed via the keypad and viewed on the scanner s display STATUS MENU The Status menu is the default display and appears as soon as power is applied Use the UP and DOWN buttons to scroll through the menu and view the current operating status No operating parame ters can be changed from the Status menu To change any setpoint you must enter a four digit password then enter the Edit or Pre Edit S1 or AutoTune 52 menus EDIT MENU The Edit Menu contains all the user selected setpoints for the InSight scanner The Edit m
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