FLAME MONITORING SYSTEM MODEL P522 SIGNAL PROCESSOR APPLICATION MANUAL
IRIS MODEL P522 APPLICATION MANUAL 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 -------- 6 FIGURE 3 - WIRING AND ASSEMBLY VIEWING HEAD -------------------------------------- 7 OPTIONAL LTA ADAPTER ---------------------------- 7 POWER SUPPLY ----------------
IRIS MODEL P522 APPLICATION MANUAL Figure Index FIGURE 1 - P522 REAR MOTHERBOARD -------------------------------------------------------------------- 4 FIGURE 2 - WIRING OF VIEWING HEAD --------------------------------------------------------------------- 6 FIGURE 3 - WIRING AND ASSEMBLY - VIEWING HEAD ------------------------------------------------ 7 FIGURE 4 - POWER SUPPLY TABLE -------------------------------------------------------------------------- 9 FIGURE 5 - SET POINTS ---------------------------
IRIS MODEL P522 APPLICATION MANUAL RF C RF O N RF O N RF C SC C GN D +26V BAT RF O FF Before wiring or installing the P522, we recommend that you read the companion colour brochure describing the functions and attributes of this series of signal processors. RF O FF The P520 and P522 Signal Processors are used with the IRIS Model 500 Viewing Heads.
IRIS MODEL P522 APPLICATION MANUAL WIRING TO THE PLUG-IN TERMINALS and is rated at .25 Amp. On newer units (those with 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.
IRIS MODEL P522 APPLICATION MANUAL 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. be used to communicate with the P522, and the connections are made to the terminals marked +TX, TX, +RX and -RX. The transmitting, twisted pair goes to the TX terminals, and the receiving, twisted pair goes to the RX terminals.
IRIS MODEL P522 APPLICATION MANUAL IRIS CABLE 3 COND UCTO RS PLUS 1 COA X 3CO NDUCTORS: 16 AW G 19 STRAND INSULATED WITH CRO SSED-LINKED-POLYETHYLENE .017 THK CO LOR S: BLA CK-RED-GREEN 1 COAX: 16 AW G 19 STRAND INSULATED WITH CRO SSED-LINKED-POLYETHYLENE .017 THK CO LOR WH ITE 36 AW G BRAIDED SH IELD 90% CO VERA GE W ITH .
IRIS MODEL P522 APPLICATION MANUAL 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 viewing head cable runs up to 500 feet, and it should be 150 ohm for cable runs 500 feet to 1000 feet. The resistor should be installed across the SC and SIG GND terminals. A 1/4 watt resistor is suitable. Originally, specifications of the IRIS Model 500 instructed that a five-conductor cable be used, with one wire shielded.
IRIS MODEL P522 APPLICATION MANUAL 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 viewing heads use less current, but it is a good idea to figure 100 mA for each viewing head used.
IRIS MODEL P522 APPLICATION MANUAL modules in a system. Care should be taken when wiring 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” by using the terminal pairs provided, the pairs are “jumpered” by copper traces on the mother board; so, if the plug is pulled out, the jumpered connection is broken.
IRIS MODEL P522 APPLICATION MANUAL 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 processor. When the power feeding the P522 exceeds 19 volts, the processor starts the program again. The SELFCHECK O.K.
IRIS MODEL P522 APPLICATION MANUAL 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. 4-20mA REMOTE OUTPUT The standard remote meter output has a 0-20mA range and is designed to drive remote meters, as exAs well, the set points can be selected remotely through plained earlier in this manual.
IRIS MODEL P522 APPLICATION MANUAL detected). The 4-20mA output will still perform the The model S5xx series of viewing heads have in same way on the high end (i.e., on a strong signal, it place a sensor for sensing the internal temperature will saturate at the same level, slightly above 22mA). of the head. To access the reading of the viewing head temperature, press the “Reset” and the “Down” Specifications for the analog current output signal arrow key at the same time.
IRIS MODEL P522 APPLICATION MANUAL 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 burner nozzle, creating a “skirt” that blocks the UV radiation coming from the flame.
IRIS MODEL P522 APPLICATION MANUAL Note that both the SIG and SIG GND circuits are switched. However, this can cause a lockout condition if the transfer of the viewing heads is done during 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 together in parallel). This will inform the P522 that the viewing heads are being transferred, and the pulses counted during the dark period will be ignored.
IRIS MODEL P522 APPLICATION MANUAL 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 section MULTIBURNER REQUIREMENTS). These same procedures can be followed for singleburner applications, even though the adjustment refinements described here may not be necessary.
IRIS MODEL P522 APPLICATION MANUAL 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 burners. We recommend that you become knowledgeable about the characteristics of the different viewing head models available before applying them to a particular application.
IRIS MODEL P522 APPLICATION MANUAL ful discrimination, it is likely due to the automatic gain control (AGC) action (see sections on the viewing heads for a detailed explanation of this problem). When using the PbS only or the S506 (same for the S512), make sure the signal is not saturating, particularly at high load conditions. (Refer to section ORIFICING.) C. For the S550, the S552 and the S556, see corresponding manual(s). TROUBLESHOOTING GUIDE 3.
IRIS MODEL P522 APPLICATION MANUAL 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 source (i.e., GND going to plant ground – refer to section POWER SUPPLY).
IRIS MODEL P522 APPLICATION MANUAL 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 tube makes this type of detector ideal for discriminating between flame, glowing refractory, and other burners.
IRIS MODEL P522 APPLICATION MANUAL nals. The Si element is a photodiode that is operated in the photovoltaic mode (the diode generates current when exposed to light or radiation). The sensitivity range of this device in this mode is quite large, from nanoamperes to milliamperes – so some means to prevent saturation in the first stage of amplification is required. (The PbS element, on the other hand, has a rather limited dynamic range exhibiting not more than a 15:1 ratio from dark to a bright signal.
IRIS MODEL P522 APPLICATION MANUAL 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. 200 Hz) the count of 2100 can be taken as the threshold. This amplifier type saturation usually will not occur with the S512 viewing head when reading actual flames.
IRIS MODEL P522 APPLICATION MANUAL To reiterate: The nonlinearity of the Si channel caused by the AGC action has been a major contributor to discrimination problems. The background will always be less intense, because it is further away (less by the square of the distance). Being less intense means it receives more amplification (AGC action) causing a worse discrimination ratio (the ratio of flame ON to flame OFF). machined-groove inside the flange opening from the housing side.
IRIS MODEL P522 APPLICATION MANUAL Signal sources other than flame, such as incandescent 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 fluorescent tube fires on the positive AC power cycle with a less amplitude excursion on the negative cycle, resulting in a radical voltage swing in the amplifiers employed in the viewing head.
IRIS MODEL P522 APPLICATION MANUAL Area circle = πR2 The table in Figure 10 shows the various distances (L) versus the diameter of the circle of view for the S512 viewing head. πR2 = 4mm2 so R = (4/π)-2 = 1.1284 and dia = 1.1284 X 2 = 2.2568mm or dia = 0.0889 inches APPLICATION OF IRIS VIEWING HEADS Using the same two-inch, focal-length lens and making this diameter equal to d, we get: θ = 2 tan-1 d/2F θ = 2 tan-1 0.0889/2 X 2 θ = 2.
IRIS MODEL P522 APPLICATION MANUAL cies than oil burners, particularly the low NOx type burners. UV type detectors work very well on natural gas, but they are not so good on oil flames, and work poorly on pulverized coal flames. USING A PLC WITH IRIS FLAME MONITOR PLCs are inherently unsafe when used by themselves.1, 2, 3.
IRIS MODEL P522 APPLICATION MANUAL TABLE OF IRIS VIEWING HEADS AND PERFORMANCE WITH VARIOUS FUELS.
IRIS MODEL P522 APPLICATION MANUAL OIL (HEAVY OIL - air & steam atom) MODEL # TYPE COMMENTS S 506 UV DISC excellent SIG poor2 S 509 PbS Only DISC very good SIG good S 509 Si DISC poor SIG very good S511 Ge DISC fair SIG very good S 512 P bS DISC very good SIG good S 550 UV & PbS DISC excellent SIG very good S 552 PbS Only DISC very good SIG very good S 556 UV Only DISC excellent SIG poor3 PULVERIZED COAL MODEL # TYPE S 506 UV S 509 PbS Only S 509 COMMENTS DISC exce
IRIS MODEL P522 APPLICATION MANUAL function is to use an auxiliary timer, so that a time out of both the PLC and the auxiliary timer is required before light off (AND relationship). The wiring diagram in Figure 10 shows a basic igniter/burner circuit that can be used with a PLC to accomplish the safe operation of a burner or burners in a multiburner installation. Note that the burner shutdown (BURNER STOP SW) is included; this circuit is equally as critical as flame monitor protection.
RF RF RM TD1 OFF RF C ON RM BU RN ER STOP PB IC -T O D ADE S TA R T P.B . OFF ON RF C C O N TA C T S ON REAR PCB C O N TA C T S O N P 5 2 0 OPEN IG N VA LV E FROM PLC IG N VA LV E IC -T O TD1 NO MFT PU RG E C OMPLETE F U E L L IM IT S O .K .
IRIS MODEL P522 APPLICATION MANUAL The BASIC BURNER START CIRCUIT shown in discrete registers. For more information on Modbus Figure 12 is a basic circuit requiring only two pieces protocol, please refer to Modicon’s Modbus Protoof external hardware for each burner: col Reference Guide (PI-MBUS-300 Rev E). 1. Master Relay with at least two normally-open contacts rated for load. 2. DADE Timer, with two instant close/ timeout open contacts. *** 1.
IRIS MODEL P522 APPLICATION MANUAL Registers Map 4X OR NUMERICAL REGISTERS: 400001 400002 400002/0 400002/1 400002/2 400002/3 400002/4 400003 400004 400005 400006 400007 400008 400009 400010 400011 400012 400013 400014 400015 400016 400017 400018 400019 400020 400021 400022 400023 Flame Count Of Active Channel (read only) Processor Status (read only) View head/Channel Selected (0=Channel A) Flame On Relay Status Processor Lockout Status (0=lockout) Panel Access Disabled (0=disabled) 4-20 output Status (0=0
IRIS MODEL P522 APPLICATION MANUAL TECHNICAL HELP For technical assistance in installing this product, please contact: IRIS Systems Inc. 7583 Vantage Place Delta, B.C. V4G 1A5 Canada Phone: (604) 584-I4R7I4S7 Fax: (604) 581-9790 Factory and Repairs: IRIS Systems Inc. (J.B. Systems Inc.
IRIS MODEL P522 APPLICATION MANUAL SPECIFICATIONS ELECTRICAL Input Power (with one V.H.) ENVIRONMENTAL - 26Vdc +5%, -20%, 300mA (100mA for each additional V.H.) Ambient Temperature - Case Temperature - Viewing Head NEMA TYPE 4 P522 Signal Processor 0°C to +50°C S506, S509, S511, S512, S513* 0°C to +60°C S580* -54°C to +177°C S506, S509, S511, S512, S513* 0°C to +60°C S580* -54°C to +177°C OPTICAL Angle of View (UV Tube) - S506 4 degrees S511 1.6 degrees S580 3.6 degrees S509 3.9 degrees S512 3.
IRIS MODEL P522 APPLICATION MANUAL NO CAL YES FIGURE 14 - MODEL P522 FRONT PANEL Page 35
IRIS MODEL P522 APPLICATION MANUAL FIGURE 15 - MODEL P522 SIDE VIEW FIGURE 16 - S5XX VIEWING HEAD DIMENSIONS Page 36
IRIS MODEL P522 APPLICATION MANUAL HIGH FRE Q UENCY FLICKER ZONE DETECTOR IN G OO D SIG HTING POSITION (PARALLEL SIG HTING) BURNER NOZZLE CENTERLIN E DETECTOR IN PO OR SIG HTING POSITION LO W FREQ UENCY FLICKER ZONE FIGURE 17 - IR VIEWING HEAD LOCATION UV R ADIAT IO N ZO NE UV V IE W ING HEAD SIG H TED O N U V ZO N E BURNE R NOZ ZLE CENTERL IN E FIGURE 18 - UV VIEWING HEAD LOCATION Page 37
IRIS MODEL P522 APPLICATION MANUAL NO . 1 FLAM E ENV ELO PE NO . 2 FLAM E ENV ELO PE VIEW ING HEAD VIEW ING HEAD BURNE R NO ZZ LE NO . 1 BURNE R NO ZZ LE NO .
IRIS MODEL P522 APPLICATION MANUAL INDEX 4-20mA ................................................................. 6, 12 A AGC ........................................ 18, 21, 22, 23, 24, 25 angle of view ...................................................... 24, 15 aperture .................................................................... 22 B background flame ............................................... 16, 21 battery ................................................ 5, 9, 10, 19, 26 baud rate ....
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