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IRIS P522 manual

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Table of contents for the manual

  • Page 1

    FLAME MONITORING SYSTEM MODEL P522 SIGNAL PROCESSOR APPLICATION MANUAL[...]

  • Page 2

    IRIS MODEL P522 APPLICATION MANUAL Page 2 Table of Contents IRIS MODEL P522 --------------------------------------- 4 WIRING AND INSTALLATION ------------------------ 4 FIGURE 1 - P522 REAR MOTHERBOARD ------- 4 WIRING TO THE PLUG-IN TERMINALS ---------- 5 WIRING OF VIEWING HEAD ------------------------- 6 FIGURE 2 - WIRING OF VIEWING HEAD --------[...]

  • Page 3

    IRIS MODEL P522 APPLICATION MANUAL Page 3 Figure Index FIGURE 1 - P522 REAR MOTHERBOARD -------------------------------------------------------------------- 4 FIGURE 2 - WIRING OF VIEWING HEAD --------------------------------------------------------------------- 6 FIGURE 3 - WIRING AND ASSEMBLY - VIEWING HEAD ---------------------------------------[...]

  • Page 4

    IRIS MODEL P522 APPLICATION MANUAL Page 4 IRIS MODEL P522 The P520 and P522 Signal Processors are used with the IRIS Model 500 Viewing Heads. The P522 Signal Processor is a relay panel mount ver- sion of the P520 plug-in module, and replaces the M502 motherboard and its two plug-in daughter boards, the A513 and the D504. WIRING AND INST ALLA TION B[...]

  • Page 5

    IRIS MODEL P522 APPLICATION MANUAL Page 5 WIRING T O THE PLUG-IN TERMINALS Figure 1 illustrates the plug-in terminals on the rear mother board and how they are connected internally. The flame relay and self-checking relay contacts are situated together in the upper right portion of the diagram. RF C refers to the common terminal of the flame relay [...]

  • Page 6

    IRIS MODEL P522 APPLICATION MANUAL Page 6 one cycle regardless of the new set points, allowing channel changes “on the fly,” so to speak. If the new flame OFF set point is equal to or greater than the current signal count, then the flame relay will de-energize on the subsequent cycle. The pair of terminals designated RMT METER (to the left of t[...]

  • Page 7

    IRIS MODEL P522 APPLICATION MANUAL Page 7 I RI S CABL E 3 COND UCT O RS PLUS 1 COA X 3 CO NDUCT ORS : 16 A W G 1 9 STRAND I NS UL A TED W I TH CRO S SED-LI NKED- P OL YETHYL ENE . 017 T HK CO L OR S: BLA CK- RED-GREEN 1 COAX: 16 A W G 19 STRAND I NSULA T E D WIT H CRO S SED-LI NKED- PO L YETHYL E NE . 017 THK CO LO R W H I TE 36 A W G B RAI DED SH [...]

  • Page 8

    IRIS MODEL P522 APPLICATION MANUAL Page 8 A source impedance resistor is required when using the P522 module with a S550 viewing head. This resistor should be 330 ohm (factory installed) for view ing head cable runs up to 500 feet, and it should be 150 ohm for cable runs 500 feet to 1000 feet. The re sistor should be installed across the SC and SIG[...]

  • Page 9

    IRIS MODEL P522 APPLICATION MANUAL Page 9 prevent the power from feeding into the 24 VDC supply. Each P522 module draws approximately 150 mA, and each viewing head draws about 100 mA of power (26 VDC). Actually, the S506 and S511 view- ing heads use less current, but it is a good idea to figure 100 mA for each viewing head used. Also, the amount of[...]

  • Page 10

    IRIS MODEL P522 APPLICATION MANUAL Page 10 modules in a system. Care should be taken when wir- ing multiple P522s to ensure the selected bus wires will carry the current. The plug-in terminals on the P522 will accommodate a wire size up to 14AWG, allowing for relatively high currents. Note that, if the power wiring (26 VDC) is “daisy chained” b[...]

  • Page 11

    IRIS MODEL P522 APPLICATION MANUAL Page 11 blinking, SELF-CHECK O.K. light on the front panel will go out, and the flame relay will de-energize. Please note that the S509 and S512 viewing heads will shut down at about 17.0 volts; these heads have their own power-monitoring capability, and will shut down on their own, independent of the signal proce[...]

  • Page 12

    IRIS MODEL P522 APPLICATION MANUAL Page 12 lecting the set points. For instance, selecting a flame out set point that is equal to or greater than the flame on set point will result in this error indication. As well, the set points can be selected remotely through the serial communication port using a host computer – explained in greater detail la[...]

  • Page 13

    IRIS MODEL P522 APPLICATION MANUAL Page 13 detected ). The 4-20mA output will still perform the same way on the high end (i.e., on a strong sig nal, it will saturate at the same level, slightly above 22mA). Specifications for the analog current output signal are provided in SPECIFICATIONS Figure 13 . INST ALLA TION OF VIEWING HEAD Before beginning [...]

  • Page 14

    IRIS MODEL P522 APPLICATION MANUAL Page 14 The effectiveness of the sighting will depend upon both the type of viewing head as well as the fuel. UV flame detection works fine on natural gas, but will cause problems with fuels that either block or absorb the UV signal. For example: in a pulverized coal burner, there can be unburned fuel at the burne[...]

  • Page 15

    IRIS MODEL P522 APPLICATION MANUAL Page 15 Note that both the SIG and SIG GND circuits are switched. However, this can cause a lockout condi- tion if the transfer of the viewing heads is done dur- ing the dark period. This problem can be avoided by changing channels when switching heads (i.e., by wiring the two terminal blocks V.H. SEL and CHAN SEL[...]

  • Page 16

    IRIS MODEL P522 APPLICATION MANUAL Page 16 SETUP AND ADJUSTMENT PROCEDURES Multiburner applications require the most care in adjustments to ensure proper flame out operation under worst-case conditions (refer to previous sec- tion MULTIBURNER REQUIREMENTS) . These same procedures can be followed for single- burner applications, even though the adju[...]

  • Page 17

    IRIS MODEL P522 APPLICATION MANUAL Page 17 The above settings will be satisfactory for most applications, but are used only as a starting point. So many variables can affect the readings that it is impossible to catalogue all the settings, and each viewing head has its own characteristics for the different types of fuels and burn- ers. We recommend[...]

  • Page 18

    IRIS MODEL P522 APPLICATION MANUAL Page 18 ful discrimination, it is likely due to the automatic gain control (AGC) action (see sections on the viewing heads for a de- tailed explanation of this problem). When using the PbS only or the S506 (same for the S512), make sure the sig- nal is not saturating, particularly at high load conditions. (Refer t[...]

  • Page 19

    IRIS MODEL P522 APPLICATION MANUAL Page 19 ing head male receptacle has an internal tab that grounds this connection to the viewing head housing. The terminal marked GND connects to the chassis ground of the P522. This ground is made through the etch on the rear side of the PC board to the metal base. It is important that the AC power be a grounded[...]

  • Page 20

    IRIS MODEL P522 APPLICATION MANUAL Page 20 tion is present). Its output is randomly-spaced pulses, with an average pulse rate proportional to the UV radiation present. The digital count when reading natural gas will be about the same as the S512, and probably will be less when reading a heavy oil flame. The very narrow spectral response of the UV t[...]

  • Page 21

    IRIS MODEL P522 APPLICATION MANUAL Page 21 nals. The Si element is a photodiode that is oper- ated in the photovoltaic mode (the diode generates current when exposed to light or radiation). The sen- sitivity range of this device in this mode is quite large, from nanoamperes to milliamperes – so some means to prevent saturation in the first stage [...]

  • Page 22

    IRIS MODEL P522 APPLICATION MANUAL Page 22 you should definitely turn off the Si channel, which cannot contribute to the flame signal from the burner (when it is gas) but can only read background glow – which will certainly cause a discrimination problem. An important aspect of using the S512 instead of the S509 has to do with linearity. The non-[...]

  • Page 23

    IRIS MODEL P522 APPLICATION MANUAL Page 23 To reiterate: The nonlinearity of the Si channel caused by the AGC action has been a major con- tributor to discrimination problems. The background will always be less intense, because it is further away (less by the square of the distance). Being less in- tense means it receives more amplification (AGC ac[...]

  • Page 24

    IRIS MODEL P522 APPLICATION MANUAL Page 24 Signal sources other than flame, such as incandes- cent or fluorescent light, can cause false readings that should be understood. For example: fluorescent light is nonsinusoidal in character, meaning that there is a sharp peak when the fluores- cent tube fires on the positive AC power cycle with a less amp[...]

  • Page 25

    IRIS MODEL P522 APPLICATION MANUAL Page 25 Area circle = π R 2 π R 2 = 4mm 2 so R = (4/ π ) -2 = 1.1284 and dia = 1.1284 X 2 = 2.2568mm or dia = 0.0889 inches Using the same two-inch, focal-length lens and mak- ing this diameter equal to d, we get: θ = 2 tan -1 d/2F θ = 2 tan -1 0.0889/2 X 2 θ = 2.545° The equation for angel of view of a cam[...]

  • Page 26

    IRIS MODEL P522 APPLICATION MANUAL Page 26 cies than oil burners, particularly the low NOx type burners. UV type detectors work very well on natu- ral gas, but they are not so good on oil flames, and work poorly on pulverized coal flames. LO W NOx APPLICA TIONS Since the advent of low NOx burners and combustion techniques to reduce emissions, the a[...]

  • Page 27

    IRIS MODEL P522 APPLICATION MANUAL Page 27 TABLE OF IRIS VIEWING HEADS AND PERFORMANCE WITH VARIOUS FUELS. (DISC = discrimination between burners and flaming background*, SIG = signal strength) GAS (HYDROGEN, PROPANE AND NATURAL GAS) GAS LOW NO X BURNERS # L E D O ME P Y TS T N E M M O C 6 0 5 SV Ut n e l l e c x e C S I Dd o o g y r e v G I S 9 0 [...]

  • Page 28

    IRIS MODEL P522 APPLICATION MANUAL Page 28 OIL (HEAVY OIL - air & steam atom) PULVERIZED COAL * Flaming backgrounds such as wood waste, black liquor etc. 1 Not so good if background fuel is wood waste grate fired. 2 Usually inconsistent, not reliable. 3 Can be very good depends on the amount of Atom. steam or air # L E D O ME P Y TS T N E M M O[...]

  • Page 29

    IRIS MODEL P522 APPLICATION MANUAL Page 29 function is to use an auxiliary timer, so that a time out of both the PLC and the auxiliary timer is re- quired before light off (AND relationship). The wiring diagram in Figure 10 shows a basic ig- niter/burner circuit that can be used with a PLC to accomplish the safe operation of a burner or burners in [...]

  • Page 30

    IRIS MODEL P522 APPLICATION MANUAL Page 30 RM RF RF RM TD1 TD1 TD1 IG N VA LV E IG N VA LV E RF RF L1 NO MF T PU RG E CO MPL ETE FUEL L IMI TS O . K. BU RNER STO P PB OFF RF C ON PLC IN T E R F A C E IN T E R F A C E PLC IC -T O IC -T O DA D E ST ART P. B . OPEN IG N VA LV E FROM PL C FRO M PLC BR N V AL VE OPEN TO PLC I N T ERF ACE I N T ERF ACE T[...]

  • Page 31

    IRIS MODEL P522 APPLICATION MANUAL Page 31 The BASIC BURNER START CIRCUIT shown in Figure 12 is a basic circuit requiring only two pieces of external hardware for each burner: 1. Master Relay with at least two nor- mally-open contacts rated for load. 2. DADE Timer, with two instant close/ timeout open contacts. * * * 1. Bryant, Design of Fail-Safe [...]

  • Page 32

    IRIS MODEL P522 APPLICATION MANUAL Page 32 Registers Map 4X OR NUMERICAL REGISTERS: 400001 Flame Count Of Active Channel (read only) 400002 Processor Status (read only) 400002/0 View head/Channel Selected (0=Channel A) 400002/1 Flame On Relay Status 400002/2 Processor Lockout Status (0=lockout) 400002/3 Panel Access Disabled (0=disabled) 400002/4 4[...]

  • Page 33

    IRIS MODEL P522 APPLICATION MANUAL Page 33 TECHNICAL HELP For technical assistance in installing this product, please contact: IRIS Systems Inc. 7583 Vantage Place Delta, B.C. V4G 1 A5 Canada Phone: (604) 584-I 4 R 7 I 4 S 7 Fax: (604) 581-9790 Factory and Repairs: IRIS Systems Inc. (J.B. Systems Inc.) 4944 - 113th Avenue North Clearwater , Fl 3 37[...]

  • Page 34

    IRIS MODEL P522 APPLICATION MANUAL Page 34 SPECIFICA TIONS ELECTRICAL Input P ower - 26Vdc +5%, -20%, 300mA (with one V .H.) (100mA f or each additional V .H.) ENVIRONMENTAL - Viewing Head NEMA TYPE 4 Ambient T emperature - P522 Signal Processor 0°C to +50°C - S506, S509, S511, S512, S513* 0°C to +60°C S580* -54°C to +177°C Case T emperature [...]

  • 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

    IRIS MODEL P522 APPLICATION MANUAL Page 37 FIGURE 17 - IR VIEWING HEAD LOCATION FIGURE 18 - UV VIEWING HEAD LOCATION DET ECTO R I N GOOD SI G H TI NG POSIT I ON ( P ARAL LEL S I G HTI NG) BURN ER NOZZ LE CENT ERLI NE DET ECTO R I N POOR SI G H TI NG POSIT I ON LOW FRE QU EN CY FLICKER Z ON E HI GH FR EQUENC Y FLICKER Z ON E UV VI EWI NG HEAD SI GH [...]

  • Page 38

    IRIS MODEL P522 APPLICATION MANUAL Page 38 FIGURE 19 - OPPOSED FIRED VIEWING HEAD SIGHTING FIGURE 20 - VIEWING HEAD MOUNTING VIEWI N G HEA D BURNER NOZZLE NO. 1 NO. 1 FL AM E ENVELOPE NO. 2 FL AM E ENVELOPE VIEWI N G HEA D BURNER NOZZLE NO. 2 HI GH FREQUENCY IR ZO N E LOW FREQUENCY ZO N E ( LESS THAN 36 H z) HI GH FREQUENCY IR ZO N E 2 “ NPT NI P[...]

  • Page 39

    IRIS MODEL P522 APPLICATION MANUAL Page 39 INDEX Rev April 2000 4-20mA ................................................................. 6, 12 A AGC ........................................ 18, 21, 22, 23, 24, 25 angle of view ...................................................... 24, 15 aperture ....................................................[...]

  • Page 40

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