Honeywell
C7015A
Infrared
The
C7015A
sulfide photocell that is sensitive to the infrared
radiation emitted by the combustion
as natural gas, oil, and coal.
n
Particularily
applications. supervisory applications.
Flame Detector includes a lead
offuels
suitable for combination or dual-fuel radiation is compatible with a wide range of flame
such
Flame Detector
q
When installed properly, can supervise the pilot
flame and/or the main burner flame.
w
Mounts easily on a standard
n
The lead sulfide photocell plugs into an electrical
socket in the
placeable.
n
The lead sulfide photocell’s sensitivity to infrared
C?OlSA
314
inch sight pipe.
assembly and is field re-
W
Models are available with
48 and 96 inches
W
Flexible metal cable protects and electrically
shields the detector leadwires.
q
Accessories available include a heat block, seal-off
adapter, reducer bushing, swivel mount and orifice
plate.
CONTENTS
[0.76, 1.22,2.64
leadwire
m].
lengths of 30,
F.P. * Rev.
11-91
l
OHoneywell
Inc. 1991 9 Printed in U.S.A. 9 Form Number
60-2306-5
C7015A
SPECIFICATIONS l ORDERING INFORMATION
Specifications
SUPER
SUPER TRADELINE models offer features not
TWELINE
MODELS
available on
TRADELINE or standard models, and are designed to
replace a wide range of Honeywell and competitive
controls. SUPER TRADELINE models are selected and
packaged to provide ease of stocking, ease of handling,
and maximum replacement value. Specifications of
SU-
PER TRADELINE models are the same as those of
standard models except as noted below.
SUPER TRADELINE MODEL AVAILABLE:
C7015A1126-with
104662DLead SulfidePhotocell, 110634A
FocusingLens, 105134GrificePlate,
and
390427A
48 in.
[1.22 m]
Reducer Bushing.
leadwires; includes
Bushing with
105061
HeatBlock,
SUPER TRADELINE FEATURES:
l
Gritice
plate (with
.125
in.
[3.175
mm] diameter
hex-
agonal orifice) for reducing the detector field-of-view.
=
Heat block for insulating the detector
temperatures higher than
250”
F [ 121” C].
125’
F
from
[52” C]
sight pipe
and up to
TABLE l-MODELS AVAILABLE.
Reducer bushing for mounting the detector on a
l
sight pipe; specifically, for replacing
sulfide inframd
SUPER TRADELINE pack with cross reference label
l
flame detectors.
FireyeW
l/2
lead
in.
and special Instruction sheet.
STANDARD MODELS
MODELS: See Table 6 for flame safeguard controls and
associated amplifiers.
DETECTOR
with wavelengths between 0.75 and 1 .O micron.
LEAD SULFIDE PHOTOCELL: Photoconductor
tance
AMBIENT TEMPERATURE RATING:
maximum at the lead sulfide photocell.
MOUNTING:
C7015A
104662DLeadSulfidePhotocell-twoleadsforinserting
RESPONSE: Responds to infrared radiation
resis-
decreases as incident radiant energy increases.
125’
F
[52”
Mount-knurled collar with
ternal
threads for mounting on a standard
3/4-14
NPSM in-
3/4
in. pipe
(see fig. 1).
into socket in
C7015A
(see Fig. 8).
C]
With
0.125 in.
%
insulate the detector from sight
To
mount the detector on a l/2 in. sight pipe, specifically to replace
[3.175
mm] diameter hexagonal orifice to
pipe
temperatures higher than
reduce
the detector field of view.
125’
F
[52” C]
Fireye
TM
lead sulfide infrared flame detectors.
and up to
250’
F
[121° Cl.
Order Information
When purchasing replacement and modernixation products from your Authorized Flame Safeguard Distributor or Wholesaler, refer to the
TRADELINE@
1.
Grder nwnber, SUPER TRADELINE. if desired.
2.
Length of leadwires
3.
Lead sulfide cell order number
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1.
Your local Honeywell Residential and Building Controls Division Sales Office (check white pages of phone directory).
2.
Residential and Building Controls Division Customer Satisfaction
Honeywell Inc., 1885 Douglas Drive North
Minneapolis. Minnesota 554224386 (612) 542-7500
(In Canada-Honeywell
service offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan Mexico,
Netherlands, Spain Taiwan, United Kingdom, U.S.A.
Catalog or price sheets for complete ordering number, or
(30,48. or 96 in. [0.76.1.22, or 2.44 m].
104662D.
Liited/Honeywell
Limitee, 740 Ellesmere Road, Scarborough, Ontario
2
specify-
4. Replacement parts, if desired.
5. Accessories, if desired.
MlP 2V9)
International sales and
C7015A
SPECIFICATIONS
WIRING
CONNECTIONS:
Nominal 30, 48, or 96 in.
leadwire+hvoNo.
tom;
rated
for
18
194°F
AWG,flexible-tinnedconduc-
[90”
[0.76,
1.22, or 2.44 ml
C];
twistedpair-onebrown
and one white.
Leadwires enclosed in flexible metal cable-3/8 in.
mm] maximum outer diameter.
DIMENSIONS: See Fig. 1.
APPROVALS:
Underwriters Laboratories Inc. listed: File No.
MP268.
Canadian Standards Association certified: Master file
LR-95329-1.
Factory Mutual approved.
Industrial Risk Insurers acceptable.
IMPORTANT:
cluded with
Inc. requires that this sticker beplaced on any junction
box in which
stickerprohibits routing any other wiring through the
junction box.
RRPLACFMENT
104662D
Fig. l-Mounting dimensions of
Caution, stickers,
the C7015A.
C7015A
leadwires are connected. The
form
Underwriters Laboratories
PARTS:
Lead Sulfide Photocells
96-610, are
C7015A
infrared Flame Detector and accessories, in in. [mm].
[9.6
in-
ACCESSORIES:
110634A
105134
Bushing with Focusing Lens
Orifice
Plate, to reduce
the
detector
field
of view.
Diameter of
Hexagonal Orifice
Part No.
105134
(in.)
bml
0.125 3.175
105O61HeatBlocktoinsulatethedetectorfromsightpipe
temperatures higher than 125” F
250” F
[121° Cl.
[52’ C]
and up to
105172ASeal-0ffAdapter;withglasswindowtoprevent
hot gases
390427A
lf2
suljia2 infraredflame
Hookup
-R1298020;
from
reaching the lead sulfide photocell.
Reducer Bushing, to mount the detector on a
in. sight pipe;
specijically,
detectors.
to
replaceFireyeTM
Cable-
2-wire,
heat and moisture-resistant, No. 20
AWG,Teflon(TFE)insulated,ratedupto400°F[204”
C] for continuous duty; tested for operation up to 600
volts and breakdown up to 7500 volts.
118367A
Swivel Mount; provides adjustable positioning
of the
C7015A.
lead
‘COLLAR.
3/4 - 14 NPSM
INTERNAL THREADS
110634A /
BUSHING’
COLLAR,
3’4 - 14 NPSM
INTERNAL THREADS
106061
HEAT BLOCK
3!4 - 14 NPSM
INTERNAL THREAD
b/4-14NPSM
EXTERNAL THREADS
INSTALLING OR REPLACING A C7015A AND ACCESSORIES
C7615A
/
LENS 1
/
/
lO6172A
SEAL-OFF ADAPTER
105061
HEAT BLOCK
I
13’4.14
EXTERNAL THREADS
THREADS
NPSM
\W4-14NPSM
EXTERNAL THREADS
FINAL
3/4 INCH PIPE NIPPLE
THREADS
396427
REDUCER
BUSHING
3/4 - 14 NPSM
EXTERNAL THREADS
1RlNCH 5
SIGHTING PIPE
t?xza
l/2 -
14 NPSM
INTERNAL THREADS
105134
ORlFlCE
PLATE IN
314
INCH
COUPLING
314
SIGHTING
PIPE
b
INCH
REPLACING A FIREYEw LEAD SULFIED DETECTOR
3
MXM
60-2306-5
C7015A
OPERATION l INSTALLATION
Operation
OPERATION OF INFRARED DETECTORS
Infrared detectors can be used with gas, oil, coal, or
fuel flames. Since more than 90% of the total flame radiation
is infrared, these detectors receive ample radiation and can
detect weak
The lead sulfide cell used in the detector cannot
guish between the infrared radiation emitted by hot refractory and the infrared radiation from a flame. Therefore, the
infrared detection system includes an amplifier that responds only to the flickering characteristic of flame radiation
and rejects the steady radiation characteristic of hot refrac-
tory.
Unfortunately, smoke or fuel mist within the combustion
chamber can intermittently reflect, bend, or block the hot
WHEN INSTALLING THIS PRODUCT.. .
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous condition.
2. Check
product to make sure the product is suitable for your applica-
tion.
3. Installer must be a trained, experienced flame safe-
guard control service technician.
4. Afterinstallationiscomplete,checkoutproductopera-
tion as provided in these instructions.
!
A
( I \
Proper flame detector installation is the basis of a reliable
flame safeguard installation. Refer to the burner manufacturer instructions and instructions below. Carefully follow
instructions for the best possible flame detector application.
BASIC REQUIREMENTS
Because all flames produce infrared radiation, a
Infrared (lead sulfide) Flame Detector can be used to prove
the presence of a flame in a combustion chamber. The
detector is mounted outside the combustion chamber. Screw
themountingcollartooneendofasightpipeinsertedthrough
the wall of the combustion chamber. The lead sulfide photocell in the detector sights the flame through the sight pipe.
fkunes
as well as flames of higher intensity.
the
ratings given in
the
instructions and on the
CAUTION
1. Disconnect power supply before beginning installation to prevent electrical shock and equipment damage, there may be more than one
disconnect.
2. All wiring must be NBC Class 1 (line voltage).
3. Use the
sulfide photocells (part no.
signal amplifiers specified, (see Table 6).
C7015A
only with Honeywell lead
104662D)
dual-
diitin-
and flame
C7015A
refractory radiation, thus making it fluctuate. This fluctuating
action can simulate the flickering radiation from a flame,
and infrared radiation may be present even after the
refractory has visibly stopped glowing. Therefore, be very
careful when applying an
it responds only to flame.
CELL CONSTRUCTION
,The
is lead sulfide. The electrical resistance of lead sulfide decreases when exposed to infrared radiation. If a voltage is
applied across the lead sulfide photocell, current flows when
the
cell is exposed to infrared radiation.
When a flame is present, the lead sulfide photocell
detects the infrared radiation generated. The
duces
safeguard control. The amplified signal pulls in the flame
relay in the flame safeguard control to allow proper operation.
Because it is necessary for the detector to actually see the
flame, it is best to locate the detector as close to the flame as
physical arrangement, temperature, and other restrictions
permit. These restrictions are described in detail below.
DETERMINE THE LOCATION
Before beginning the actual installation, determine the
best location for mounting the flame detector. Carefully
consider the factors discussed in this section before establish-
ing the location.
TEMPERATURE
The
temperature increases. Up to
sensitivity is negligible, but temperatures above this point
must
low 125” F
unlimited. The quickest check for excessive temperature is
simply to grasp the detector-it should not be too hot to hold
comfortably in your bare hand.
Several methods are available for cooling the lead sulfide
photocell including ventilating the sight pipe and installing a
pipe nipple, seal-off adapter, and/or heat block between the
sight
page 8.
SIGHTING
The
portion of the flame being detected. The detector is com-
monly applied to detect both the gas pilot and main gas flame,
or thegaspilot and main oil
must be carefully aimed at the intersection of the pilot and
muinflame.
infrared
detection system to be sure
photosensitive material used in the infrared detector
Installation
C7015A
an
electric
sensitivity of the lead sulfide cell decreases as its
be avoided.
pipe
signal that is sent to the amplifier in the flame
125’
F
[52’ Cl,
Under normal temperature conditions (be-
[.52’ Cl,
the life of the lead sulfide cell should be
and the detector. Refer to Installing Accessories,
infrared detector must continually sight a stable
flame.ln
either case, the detector
A Swivel Mount (Honeywell part no.
pro-
the loss in
118367A)
4
C7015A
INSTALLATION
is available to facilitate flame sighting after the
mounted.
C7015A
is
pipe diameter is reduced, the effect is the same as adding an
orifice plate to the pipe as discussed below.
FIELD OF VIEW
A lead sulfide photocell, like other photocells, views an
area rather than a point. It is unable to pinpoint pilot flame
Fig. P-Methods of reducing
field-of-view.
locationaseasilyasaflamerod.Ifthedetectoristoproveonly
the pilot
jlame,
it must view only a part of
the
flame
so it can
detect the pilot only when it is large enough to successfully
light the main burner.
The
viewing area must not be so large
that a weak and wavering pilot flame could energize the
photocell and cause the flame relay to pull in.
The area viewed by the photocell depends on:
1.
Diameter of
the
opening in front of the cell.
2. Distance from the cell to the opening.
3. Distance from the opening to the area to be viewed.
Fig. 2 shows three ways of reducing the field of view,
assuming that the distance from the viewing opening to the
flame or refractory cannot be changed. These are (1) lengthening the sight pipe, (2) reducing the diameter of the sight
pipe, and (3) installing an orifice plate in front of the photocell. Combinations of these methods can
be
used.
CHANGING PIPE LENGTH OR SIZE (DIAMETER)
Theeffectorchangingthelengthofthesightpipeisshown
in Tables 2 and 3.
Changing the diameter of the sight pipe is not as simple as
changing the
ing accessories are all sized for
length,because
the
C7015A
3/4
mount and mount-
in. pipe. When the sight
AREA
g/j___------
\
UNRESTRICTED VIEW
3
BY LENGTHENING
THE SIGHT PIPE
C7015A
/M-
0
Detector
TABLE 2-DIAMETER OF AREA SIGHTED THROUGH VARIOUS LENGTHS OF
WITHOUT ORIFICE, IN IN.
Length of
Pip&.
7
8
6 12
1
1.5 2.3 3.1 3.9 4.7 5.5 6.3 7.1 1 8.0 8.7 9.6
1.4 2.1 2.8 3.5 4.2 4.9 5.6 6.3 1 7.1 7.7 8.5
Distance From End of Pipe To Sighted Area-in.
18
1
24
1
30
1
36
I 42I
48
I 54I
TABLE 3-DIAMETER OF AREA SIGHTED THROUGH VARIOUS LENGTHS OF
WITHOUT ORIFICE. IN MM
Length of Distance From End of Pipe To Sighted Area-mm
Pipe-mm
25.4 160.0
152.4I 304.8I 457.2
1
302.3
1
447.0
I
609.6
1
589.3
I
762.0
1
1
721.4 876.3
914.4I1066.8
I
11219.2I1371.6 I 1524.0
Over
e
1016.0
3/4
-IN. PIPE
60
1
66
1
72
10.4
9.1-
3/4
IN. PIPE
11676.4
11828.8
60-2306-5
C7015A
INSTALLATION
INSTALLING AN ORIFICE PLATE
AnorificeplatewithahexagonalorificediameterofO.125
in.
[3.2
mm] is available for the
Detector.
seal-off
The
orifice can be mounted in front
adapter
or in a standard
1.)
The size of the sighted area at various distances can be
determined
from
Table 4 or 5. For example, if the distance
C7915A
314
in. coupling. (Refer to Fig.
Infrared Flame
of
the cell in the
fromthephotocelltoa0.125
is4in.
[101.6mm],andfromtheorificetotheflamejunction
(or refractory) is 36 in.
sighted area is 2.4 in.
[70
in.
[914.4
mm].
L3.175
mm] diameterorifice
mm], the dieter of the
Fig. 3 shows how a typical orifice plate restricts the view
of a small area around the flame junction.
TABLE ADIAMEXER
6
TABLE
5-DIAMETER OF AREA SIGHTED THROUGH ORIFICE, IN MM
-
OF AREA SIGHTED THROUGH ORIFICE, IN IN.
I
1.1
1.6
2.1
2.6
3.2
Fig.
3-4sing
sniall
area of hot refrktory.
orifice plate to restrict detector field of view to intersection of pilot and main flame, or to
PILOT
\
WlTHOUT ORIFICE PLATE WITH OFilflCE PLATE
HOT REFRACTORY
\
MAIN FLAME
\
PILOT,
HOT REFRACTORY\
6
MAIN
FLAME\
C7015A
INSTALLATION
RESPONSE TO HOT REFRACTORY
Although the infrared amplifier will not respond to steady
radiation, as produced by hot refractory, be careful to protect
Fig. 4--C7015A infrared Flame Detector aimed
at side wall of combustion chamber.
the infrared detector from hot refractory radiation because of
two possible conditions,
shimmer
and
raa’iation saturation.
a. Shimmer-Turbulent hot air, steam, smoke, or fuel
spray in the combustion chamber can reflect, bend, or
block
the
steady infrared radiation emitted by a hot
refractory. These conditions can change the steady
radiation from a hot refractory into a fluctuating radiation. If these fluctuations occur at the same frequency
as that of a flickering flame, they will simulate flame
and will hold in the flame relay after the actual burner
flame has been extinguished.
b. Radiation saturation--Steady hot refractory radiation
can become strong enough to mask the fluctuating
radiation of the
flame.
This is similar to the effect of
holdingupacandleinfrontofthesun-thelightofthe
sun is so strong that the candle light cannot be seen. If
radiation saturation is extreme, the flame relay will
drop out, and the system will shut down as
flame failure has occurred.
Both of these problems will be minimized by aiming the
detector at a portion of the refractory that is:
l
as cool as possible.
l
as far from the cell as possible.
l
as small as possible reduce the field of view, see Figs.
2and3.
Refractory temperatures in the combustion chamber will
vary with combustion chamber design but generally, the end
wall of the chamber will be the hottest point. It will normally
though
a
Fig.
at a point above refractory.
BURNER
FACEPLATE
cr
I
I
i-1
be best to aim the detector at the side wall of the refractory
(Fig.
4),
at a point above the refractory (Fig.
5),
or at the floor
of the combustion chamber (Fig. 6).
\
\
5-C7015A
/
/
--_
P;-
-7
.
.
/
MAIN BURNER FLAME
----
_- --
AREA VIEWED BY C7015A
_/--
__-----
‘,
I
I
I
Infrared Flame Detector aimed
3
--
_.=’
VIEWS AREA
E
REFRACTORY
----‘n
/
,l‘-
I
! //
+--/___
--__
/cd
DETECTOf
I
ABOVE TH
&ii -
-
i&
PILOT
AND
MAIN FLAME
’
,
_--
‘Y
M245,
I
,
i
SIGHTING SUMMARY
When sighting
the
detector, two important factors to
consider are: (1) proper sighting of the flame being detected
(normally the pilot/main
Rame
junction), and (2) avoiding
hot refractory sighting.
A typical sighting arrangement is shown in Fig. 4. The
detector is aimed at the intersection of the pilot and main
flames, and at a relatively cool side of the combustion
Fig.
at floor of combustion chamber.
chamber. The detector, in this case, would be located as close
as possible to the burner to sight the maximum depth of the
&me
and reduce the effect of variations in the main flame
pattern.
The detector can also be sighted from a point below and
close to the burner with the line-of-sight above the refractory
(Fig. 5).
The third method is to aim the detector from above the
burner, sighting a portion of the refractory floor (Fig. 6). This
type of application requires that the pilot flame be carefully
sighted from the side. The detector should not be sighted
the shoulder
of the pilot because
the
chances increase of
over
sighting a pilot too small to satisfactorily light the main flame,
Theactualareaofhotrel?actorysightedshouldbeassmall
as possible and consistent with proper sighting of the flame.
Refer to Figs. 2 and 3 for methods of reducing the
ama
of hot
refractory sighted.
\
\
\
. I
\
6-C7015A
,‘P--__
,
,
/
,
REFRACTORY FLOOR
\
’ \
AREA VIEWED BY
\
\
. .
. .
I
_M--
\L_----
_/--
M305.3
Infrared Flame Detector aimed
I
\L_---
I
I
C701
--__
CENTER LINE
___------,,,
--__
-3.
.’ 1
1-J
7
60-2306-5
C7015A
INSTALLATION
CLEARANCE
Make sure there will be enough mom to easily mount the
mounting details, refer to form 60-0361 for the 118367A
Swivel Mount)
sight pipe, flame detector, and all required accessories, and to
remove th e
flame
detecto r for troubleshooting and servicing.
REDUCER BUSHING
To mount the detector on a l/2 in. sight pipe,
INSTALLING THE SIGHT PIPE
Thelocationofthesightpipeisthemostcriticalpartofthe
installation. A
Do
rwt use
3/ 4
in. black iron sight pipe is recommended.
a stainless steel or galvanized pipe because its
internal surface blackens with use as deposits from the
combustion chamber accumulate on it. Initially, its shiny
intemalsurfacereflectsinharedradiation, whichcouldresult
in a satisfactory flame signal even though the pipe may be
improperly located. As it blackens, less
reflected and the
Because no two situations
flam e
signal becomes marginal.
a m
inhare d
radiation is
the same, the length and
sighting angle of the pipe must be determined at the time and
placeofinstallation.Generally,itisdesirabletohavethesight
pipe tilting downward to prevent soot or dirt buildup.
PREPARE HOLE IN WALL OF COMBUSTION
CHAMBER
Form a hole of the proper diameter for the sight pipe in the
walioftbecombustionchamberattheselectedlocation.Flare
the
hole (Fig. 9) to leave room for small adjustments of the
sighting angle. The taper of the hole should be about 1 in. for
every 3 in.
125. 4
mm for every 76.2 mm] of wall thickness.
if replacing a
390427 A
ORIFICE PLATE
To reduce the detector field-of-view, and restrict it to the
intersection of the pilot and main flame, or to a small area of
hotrefractory (see Fig.
or&e
coupling (Fig. 1) or into the seal-off adapter, if used.
MOUNTING SIGHT PIPE
Thmadoneendofthepipetofitthemountingcollaronthe
detector (or an accessory, if used, see Fig. 1). Cut the pipe to
the desired length (as
excessive heat back to the lead
pipeshould not extendmore than halfway
Tack weld
not
permanently weld the sight pipe in place until ajter
completing the Adjustments and Checkout, page 10.
NOTE: If you use a Swivel Mount (part no.
yo u
can permanently weld the pipe.
INSTALLING ACCESSORIES
It may be necessary or desirable to install accessories
between the sight pipe and the detector. This section
de-
scribes the installation of these accessories.
PIPE NIPPLE
be inserted between the sight pipe and the
(Fig. 1) to help cool the lead
SIGHT PIPE VENTILATION
It
may be necessary to ventilate the sight pipe to cool the
will also reduce the viewing area of the detector, see Table 2
or 3).
detector.
For a negative pressure combustion chamber, drilling a
few holes in
the
section of the sight pipe outside of the
combustion chamber allows air at atmospheric pressure to
flow through the sight pipe into the chamber. A perforated
pipe nipple between the sight pipe and the flame detector can
SEAL-OFF ADAPTER
To protect
Seal-Off Adapter (Fig. 1). The adapter has a glass window
that prevents hot gases from reaching the lead sulfide
cell.
also be used. See Fig. 7.
For a positive pressure combustion chamber, connect a
supply of pressurized air from the burner blower to flow
throughthesightpipeintothechamber.Theairpressuremust
be greater than the chamber pressure.
HEAT BLOCK
To insulate the detector from sight pipe temperatures
above 125” F
The device is made of nonheat-conductive, laminated plastic
that prevents heat
Fig.
7-Forced
DETECTOR
COOLING AIR
APPLIED UNDER
air
cooling.
PIPE NIPPLE
PIPE TEE
SIGHT
PIPE
+@a
to the detector. It can withstand temperatures up to 250” F
[121° C].
MOUNTING THE DETECTOR
Before mounting the
photocell (if not installed already).
Unscrew the bushing from the cap, plu g
the
8). The bushing also includes a
SWIVEL MOUNT
To facilitate flame sighting, a Swivel Mount (part no.
118367A )
is available. The Swivel Mount requires a reducer
of the proper size to mount it onto the sight pipe. (For
available radiation on the photocell face.
Mount the
block, orotheraccessory (Figs. 1 and 9). Screw the mounting
collar onto the sight pipe or accessory.
speci&zlly
FireyeW
lead
sulfuie
detector, install a
Reducer Bushing (Fig. 1).
3),
install a 105 134 Orifice Plate. The
plate can be inserted into a standard
short as
practical). T o
sulfide
photocell, the sight
the
pipe to the wall in a trial position (Fig. 9) .
arepositive
A
3/ 4
in. pipe nipple, 6 to 8 in. [ 152 to 203 mm] long, can
about the location and sighting angle, you
sulfide
cell. Usin g
the
detector from hot gases, install a 105 172A
3/ 4
in. pipe
avoid conducting
into
the refractory.
Do
118367A )
C7015 A
the
pip e
and
Mount
nipple
photo-
[52” Cl,
install a 105061 Heat Block (Fig. 1).
hor n
being conducted from the sight pipe
”
C7015A ,
install the lead sulfide
the
photocel l into
cell mount, and screw the bushing back into the cap (Fig.
C7015 A
focu&n g
Detector onto the sight pipe, heat
lens to
concenuate
8
c701
!?A
INSTALLATION
Fig.
8-installing
CAP
\
METAL CABLE
SHIELDS LEADWIRES
EPOA
Fig. O-Mounting
lead sulfide photocell.
, MOUNTING
PHOTOCELL
SOCKET
C7015A
Infrared Flame
Detector (and accessories).
COMEUSTlON
CHAMBER WALL
TEMPORARY
TACK
wLO\
-J
p,T
PLUG-IN LEAD SULFIDE CELL
(PART NO. 104662D)
FOCUSING LENS
REFRACTORY/MAIN
FLARED HOLE
-3/4
INCH BLACK
IRON SIGHTING PIPE
I
FLAME
3. The detector comes with
30,48,
or 96 in.
[0.76,1.22,
or 2.44 m] leadwires inside a flexible metal cable. The
leadwires consist of a twisted pair-one brown and one
white. The two no. 18 AWG flexible-tinned leadwires are
rated for
194’
F
[90”
C]. The cable protects and electrically
shields the leadwires.
4. If the leadwires are not long enough to reach the
terminal strip or wiring subbase, make the required splices in
a junction box (see IMPORTANT below).
5. If splicing is necessary, use moisture-resistant no. 14
wire suitable
withaflamesafeguardprimarycontrol,oratleast 194°F
C] if used with a flame safeguard
6.
Honeywell specification no.
F leadwire. (This wire is rated up to 400” F
for
at
least 167” F
[75” C]
if
the
detector is used
[90”
programming
For splicing in high temperature installations, use
R1298020
or equivalent for the
control.
[204” Cl
for
continuous duty. It is tested for operation up to 600 volts and
breakdown up to
7500
volts.) For the other leadwire, use
moisture-resistant no. 14 wire selected for a temperature
rating above the maximum operating temperature.
IMPORTANT:
a.
Flame detector leadwires must be as short
sible. The maximum
detector to the
[15.2
m].
6.
Extensions to
leadwire lengthfrom thejlame
flame
safeguard control is 50
the flame
detector leadwires must be
run alone in either rigid orflexible metal
When
frame
detector leadwires exit a conduit, they
must be as short as possible, twisted, and not be
included in bundles or channels that contain other
wires. Rigid metal conduit is
detector leadwires are extended
conduit may be used
tfit
preferred when
butflexible
is supported to minimize
movement.
aspos-
ft
conduit.
flame
metal
TO JUNCTION
80X
OR SUBBASE
WIAmG (F&s.
I CAUTION
.
/\
10
and 11)
M304.5
Disconnect power supply before beginning installation to prevent electrical shock and equipment
damage; there may be more than one disconnect
involved.
1. All wiring must comply with applicable electrical
codes, ordinances,
,2.
Keeptheleadwiresfromtheflamedetectortotheflame
and
regulations.
Use
NRC
Class 1 wiring.
safeguard control subbase as short as possible. Capacitance
increases with
leadwire
The maximum permissible
ultimate
current/voltage.
out, page
limhingfactor
10.
length, reducing the signal strength.
in
leadwire
leadwire
Iength is fifty feet.
length is
the
frame
The
signal
Refer to Table 6, Adjustments and Check-
9
The
jlame detectorjlexible
C.
grounded to
the flame
cable shield must be
safeguard control subbase
either directly or through the metal cabinetlconduit
system that contains
subbase
When
d.
andjlame
flame
detector leadwires are routed through
junction boxes,
the
flame safeguard control
detector leadwires.
identifr
the junction boxes with the
pressure-sensitive labels provided wiih the flame
detector
UNDERWRITERS LABORATORIES INC.
‘e.
cform 96-610).
REQUIRES THAT THE JUNCTION BOX BE
MARKED TO INDICATE
THATNO
OTHER WIRING CONNECTIONS CAN BE ROUTED
THROUGH IT. APPLY CAUTION STICKER
(FORM
96410,
FURNISHED) TO THE JUNC-
TION BOX.
Maximize the separation between ignition trans-
f
former high voltage wires and the
jlame
sensor
wires to avoid ignition interference.
60-2306-5
C7015A
INSTALLATION l ADUSTMENTS AND CHECKOUT
Fig. 1 O-Typical wiring of
Flame Detector to nearby wiring subbase or Flame Detector to distant wiring subbase or
terminal
cmi5A
1
1 BROWN WIRE AND 1 WHITE WIRE FROM THE
n
FLAME SAFEGUARD CONTROL’S SUBBASE, COLOR NOT IMPORTANT,
KEEP WIRES AS SHORT AS POSSIBLE. AND TWIST THEM.
AFLEXIBLE
SUBBASE AND GROUNDED WHERE THE EXPOSED WIRES BEGIN.
strip.
FLEXIBLE CABLE (MECHANICALLY
SUPPORT TO MINIMIZE MOVEMENT)
GROUNDlNG
STRAP,
CABLE MUST BE RUN To
C7015A
FLAME
Infrared
RING
OR
C7015A.
SAFEGUARD CONTROL’S
SUBBASE
TERh
CONNECT TO
Fig. 1 l-Typical wiring of
terminal strip.
FLEXIBLE CABLE
(MECHANICALLY
SUPPORT TO
MINIMIZE
MOVEh
I
JUNCTION BOX
1 BROWN WIRE AND 1 WHITE WIRE FROM THE
lNSlDE JUNCTlON Box;
FROM JUNCTION BOX NEED NOT BE PHASED OR POLARIZED.
APPLY CAUTION STICKER, FORM NO.
Ci’O15A.
USE RIGID CONDUIT. OR SUPPORT FLEXIBLE CONDUIT TO
.MINIMIZE
CONDUIT MUST BE RUN TO FLAME SAFEGUARD CONTROL’S
SUBBASE AND GROUNDED THERE. KEEP EXPOSED WIRES AS
SHORT AS POSSIBLE AND TWIST THEM.
I
A
COLOR NOT IMPORTANT; LEADWIRES
TO THIS JUNCTION BOX. BOX MUST BE GROUNDED.
MOVEMENT.
C7015A
BX CABLE, SHIELDED
CABLE, OR TWISTED
PAIR; MUST BE ALONE
IN CONDUIT.
I
I
Infrared
FLAME SAFEGUARD
CONTROLS SUBBASE
96-610
C7015A;
CONNECT
SUPPLIED WITH
IA3046
Adjustments and Checkout
IMPORTANT: Before
location,
below and any tests required by the burner
turer.
ADJUST DETECTOR SIGHTING POSITION
For
initial burner lightoff, consult the burner manufacturer
instructions or flame
welding the sight pipe in its
complete
the AdjustmentsandCheckout
safeguatd
control instructions.
final
Tests
man@ac-
With the flame detector installed and the burner running,
adjust the sighting position of the detector
for
optimum flame
signal.
Most existing Honeywell flame safeguard controls have a
flamecurrentjackonthecontrolplug-inflameamplifier.The
flame signal (current) can be measured
with
a volt-ohmmeter
such as the Honeywell W 136A with a zero to 25 microampdc
scale. To measure the flame current (signal), a Cable Connector (part number
used with the meter. With the
tioned to the zero to 25
1%146,
microamp
included with
W136A
(or equivalent) posi-
scale, make connections
W136A)
must be
from the meter probes to the two ends of the cable connector
plug, red to
ted,
black to black The plug end of the connector
pluginsertsdirectlyintotheamplifierflamejack(seeFig. 12).
If
the
CHECP
flame safeguard control is using a
amplifier, the red flame-indicating lamp on the
R7248B AMRLI-
amplifEr
flickering (may be as high as 20 times a second). If the lamp
is ON (bright) continuously or not blinking while measuring
the flame current, replace the amplifier.
Refer to Table 6 for the minimum acceptable flame
currents for the amplifiers and associated flame safeguard
controls.
The
(AMPLI-CHECKTM)amplifiersusedwiththeBCS7700and
7800 SERIES flame safeguard controls respectively, have a
dc voltage flame signal output.
To measure flame signal voltages when using a
amplifier, a 20,000 ohm/voltmeter with a zero to 5 or 10 Vdc
scale is suggested To measure the flame signal voltage when
using
mum sensitivity of one
flame signal (voltage) measurements are made as shown in
Figs. 13 and 14. The positive (red) meter lead is
the
positive (+) control jack and the negative (black) meter
lead to the negative
SERIES controls). If the BCS 7700 and
controls have the Keyboard Display Module, a zero to five
Vdc voltage is displayed on the module. Refer to Table 6 for
minimum and maximum flame voltages for the amplifiers
should blink at
the
same rate that the flame is
R7748B AMRLI-CHECKTM
R7848A,B
amplifiers, a volt-ohm meter with a mini-
megohm/volt
(-)
control jack (Corn jack with 7800
;
R7848A
and
R7848B
R7748B
is recommended. The
connected to
7800 SERIES
C7015A
ADJUSTMENTS AND CHECKOUT
and associated flame safeguard controls.
Move the detector and
sight
pipe around to sight the flame
at various positions and angles. Try to get a maximum steady
meter reading. The signal must be above the minimum
acceptable current/voltage listed in Table 6.
Measure the
fIame
signal for the pilot alone, the main
burner flame alone, and both together (unless monitoring
only the pilot
themain
flame
burner
when using an intermittent pilot, or only
flame
when using direct spark ignition). Also
measure the flame signal at high and low firing rates and
while modulating in between (as applicable). With the detector in its final position, all required
steady and as specified in Table
fhune
6. If you
signals must be
cannot obtain the
proper signals, refer to the Troubleshooting section.
Fig. 12-Measuring
W136A
TEST
METER
microamp
SELECTOR
SWITCH,
flame Signal.
PLUG-IN FLAME
SIGNAL AMPLIFIER
196146 METER
CONNECTOR
I
Fig. K&Measuring BCS 7700 Flame Safeguard
Control flame signal voltage.
\
\
ECS
PROBES
7700
CHASSIS MODULE FOOTMOUNT
E2512A
Fig. 14-Measuring 7800 SERIES Flame
Safeguard Control flame signal voltage.
RED CONNECTOR
CK CONNECTOR
METER‘
LEAD
El 208
TABLE 6-FLAME SIGNAL
1
Minimum 1 Maximum 1 Minimum 1 Maximum
Flame
Signal
Acceptable Expected
Steady Current
Amplifier Flame Safeguard Control (microamp)
R7248A
BC7OOOL; R4075C,D,E;
2.25 5.0
R4138CD; R414OG;L;M
R7248B
BC7OOOL; R4075C,D,B; 3.5 5.0
AMF’LI-CHECK~ R4138CD; R414OGL.M
R7258A R4150
R7748B
BCS 7700
4.0
AMPLI-CHECKTM
R7848A
RM78OOE,G,L,M; RM7823A;
RM7838A,B; RM784OE,G,L,M
RM7885A: RM789OA,B;
I
I
RM7895A;B,C,D
R7848B
RM78OOE,G,L,M; RM7823A;
AMPLI-CHECX= RM7838AB; RM784OE,G,L,M;
RM7885A; RM789OA,B;
RM7895A,B,C,D
Current
(microamp)
5.5
Acceptable
Steady Voltage
(Vb)
2.2
1.25
I
1.25
Expected
Voltage
(Vdc)
4.98
5.0
5.0
11
60-2306-5
C7015A
ADJUSTMENTS AND CHECKOUT
PILOT TURNDOWN TEST
Ifthedetectorisusedtoproveapilotflamebeforethemain
fuel
valve(
can be opened, perform a Pilot Turndown Test
before welding the sight pipe into position. Follow the
procedures in the instructions for the appropriate flame
safeguard control, and
the
burner manufacturer instructions.
solids instead of liquids, or liquids instead of gases.) When
the
maximum refractory temperature is reached, close all
manual fuel shutoff valves or open theelectricalcircuit of all
automatic fuel valves. Visually observe when the burner
flame goes out. After the flame goes out, measure the time it
takes for the flamerelay 2K to drop out. Watch or listen to the
flame relay to determine when it drops out. If the flame relay
fails to drop out within four seconds, the infrared detector is
HOT REFRACTORY SATURATION TEST
Testtobesureradiationfromhotrefractorydoesnotmask
the flickering radiation of the
l&me
itself.
Start the burner and monitor the flame signal during the
sensing theradiation from hot refractory. Immediately terminate the firing cycle, (lower the set point of the burner
controller, or set the fuel selector switch to OFF). Do not open
the master switch.
warmupperiod.Adecreaseinsignalstrengthastherefmctory
heats up indicates hot refractory saturation. If saturation is
NOTE:
extreme, the flame relay 2K (in the flame safeguard control)
will drop out and the system will shut down as though a flame
failure has occurred.
If hot refractory saturation occurs, the condition must be
corrected. Add an orifice plate in front of
the
photocell to
restrict the viewing area. If this does not work, resight the
detector at a cooler, more distant background. Lengthening
the sight pipe or decreasing the pipe size (diameter) may also
be helpful. Continue adjustments until hot refractory satura-
tion is eliminated.
If the detector is sensing hot refractory radiation, the
condition must bc corrected. Add an orifice plate in front of
the photocell to restrict the detector viewing area. If this does
not work, resight the detector at a cooler, more distant part of
the combustion chamber. While resighting the detector,
remember that it must also properly sight the flame. LengthHOT REFRACTORY HOLD-IN TEST
Test to make certain that hot refractory will not cause the
flame relay 2K (in the flame safeguard control) to stay
in after
the
burner flame is extinguished. This condition
pulled-
ening the sight pipe or decreasing the pipe size (diameter)
may also be helpful. For details, refer to Installation. Continue adjustments until hot refractory hold-in is eliminated.
would delay response to flame failure and also would prevent
a system
restart
as
long as the infrared radiation emitted by the
IGNITION INTERFERENCE TEST
hot refractory is detected.
First check the plug-in flame signal amplifier by initiating
a burner cycle. When the programmer stops in the run
position, terminate the firing cycle while the refractory is at
a low temperature. Measure
relay 2K to drop out after
to the
flame
relay to determine when it drops out. If the flame
the
time it takes for the flame
the
flame goes out. Watch or listen
relay fails to drop out within four seconds, open the master
spark electrical noise (interference) under certain conditions.
Avoid ignition interference by locating the transformer as
close as possible to the burner ignition electrode (preferably
not on the control cabinet). You can also use an ignition cable
that suppresses electrical noise (such as the type of cable
in automobiles). Maintain maximum separation of flame
sensor and ignition wiring.
switch and replace the amplifier.
Infrared detectors can respond to infrared radiation emit-
ignition interference, complete the following test sequence:
ted by a hot refractory, even when the refractory has visibly
ceased to glow. Infrared radiation from a hot refractory is
AND MAIN
steady, whereas radiation from a flame has a flickering
characteristic.Theinliareddetectionsystemrespondsonlyto
the burner.
a flickering infrared radiation; it can reject a steady signal
from hot refractory. However, the refractory’s steady signal
can be made to fluctuate if it is reflected, bent, or blocked by
energized (momentary meter movement may be observed
when the flame safeguard control switches a load on or off).
smoke or fuel mist within the combustion chamber. Be
careful when applying an infrared system to ensure its
response to flame only.
To check a
C7015A
Inj-ared
Flame Detector for hot
refractory hold-in, operate the burner until the refractory
reaches its maximum temperature. If the installation has a
multifuel burner, burn the fuel most likely to reflect, bend, or
WELD THE SIGHT PIPE
flame signal obtained, remove the detector and weld the sight
pipe in
pipe may already be welded). Then reinstall the detector.
obscure the hot refractory’s steady infrared radiation, (burn
Some burners continue to purge their oil lines be-
tween
the
valves
and nozzles even though the fuel valve(s)
is closed. Terminating the firing cycle (instead of opening
the master switch) will allow purging of the combustion
chamber. This will reduce a buildup of fuel vapors in the
combustion chamber caused by oil line purging.
It is possible for infrared amplifiers to respond to ignition
used
To determine if an infrared flame amplifier responds to
1.
CLOSE MANUAL
FLJBL
VALVES TO THE PILOT
BURNER.
2.
Connect a flame signal meter to the amplifier and start
3. There should be no flame signal when the ignitor is
After adjustments have been made and an acceptable
its
final position, (if you are using a swivel mount, the
12
C7015A
ADJUSTMENTS AND CHECKOUT l TROUBLESHOOTING
FINAL CHECKOUT
Before putting the burner into service, check out the
installation by using
tions for the appropriate flame safeguard control. After
completing the checkout, run the burner through at least one
complete cycle to verify proper operation.
!
CAUTION
A
,
v
\
1. Be extremely careful while troubleshooting the
detector; line voltage is present on some of the
terminals on the wiring
when power is on.
2. Open the master switch to disconnect power
before removing or installing the detector, there
may be more than one disconnect involved.
If you cannot obtain a satisfactory flame signal while
adjusting the sighting position of the detector, follow these
procedures. If you encounter other problems in the system,
refer to Troubleshooting in the instructions for the appropriate flame safeguard control.
EQUIPMENT REQUIRED
1.
Voltmeter(HoneywellW136Aorequivalent)withOto
300 Vat scale.
2. Microammeter (Honeywell
with 0 to 25 microampdc range.
3.
W136ACableConnector,partno.
Meter Connector Plug or equivalent (required for some
meters).
4.A volt-ohm meter with a zero to 5 or 10 Vdc scale and
a sensitivity of 20,000 ohm/volt is suggested for
control flame signal measurements. If the control has the
Keyboard Display Module option, flame voltage is displayed
on the module.
5.
A one
scale is recommended for 7800 SERIES control flame voltage measurements. If the control has the Keyboard Display
Module option, flame voltage is displayed on the module.
6. Replacement parts-see Specifications.
TROUBLESHOOTING PROCEDURES
Firstperfonn
applicable procedures for either a low reading or a zero
reading on the flame signal meter. After reinstalling the
detector, recheck the meter reading. Adjust the position of the
detector to try to obtain the proper
procedures are completed and a satisfactory flame signal
cannot be obtained, replace the detector.
the
Checkout procedures in the instruc-
megohm/volt
thePreliminary
subbase
or
terminal strip
W136A
or equivalent)
196146, or 117053
BCS7700
meter with a zero to 5 or 10 Vdc
Inspection. Then follow the
fIame
signal. If the
n
PRELIMINARY INSPECTION
too lean.
switch is closed, connections are correct, and power supply
is of the correct voltage and frequency.
detector. If it exceeds 125” F
PROCEDURE FOR A LOW METER READING
a soft, clean cloth.
coated with a substance that cannot be cleaned off, replace the
110634A
detector.
sulfide cell (Fig. 8).
amplifier.
the
PROCEDURE FOR A ZERO METER READING
flame signal.
amplifier.
entire
IMPORTANT:
!
CAUTION
Do not put the system into operation until all
Checkout tests in the instructions for the appropriate flame safeguard control and any specified in the
burner installation instructions are satisfactorily
completed.
Troubleshooting
1.
Makesurethat
2. Checkfortheproperlinevoltage. Makesurethemaster
3. Check the detector wiring for defects including:
. incorrect connections.
wrong type or size of wire.
l
l
deteriorated wire.
l
open circuits.
l
short circuits.
leakage paths caused by moisture, soot, or dirt.
l
4.
With the burner running, check the temperature at the
add additional insulation between the wall of the
combustion chamber and the detector.
add a shield or screen to reflect radiated heat away
from the detector.
add cooling (refer to Sight Pipe Ventilation, see
Installation).
1.
Remove the detector and clean the focusing lens
2. If the focusing lens is broken or damaged, or if it is
Bushing (which includes the focusing lens).
3.
Clean the inside of the sight pipe before reinstalling the
4. If the meter reading is still too low, replace the lead
5.
If the meter reading is still too low, replace the plug-in
6.
If you still cannot obtain a proper flame signal, replace
C7015A
1.
Replace the lead sulfide cell (Fig. 8). Then recheck the
2. If there is still no flame signal, replace the plug-in
3. If you still cannot obtain a meter reading, replace the
C7015A
sure to perform the Adjustments and Checkout, page
10.
the flame is properly adjusted and is not
[52” Cl:
with
Infrared Flame Detector.
Infrared Flame Detector.
At the completion of troubleshooting, be
13
60-2306-5
C7015A
SERVICE
n
1
CAUTION
.
1.
Onlyusequalifiedservicetechnicianstoattempt
to service or repair flame safeguard controls and
burner systems.
2. Open the master switch to disconnect power
before removing or installing the detector.
3. If the
C7015A
(e.g., to replace
with focusing lens), you must perform the Ad-
justments and Checkout, page 11.
is disassembled for any reason
the
lead sulfide cell or bushing
PERIODIC MAINTENANCE
1.
Clean the focusing lens andsightpipe when necessary.
Remove the detector and use a
not require removal to clean it. If it is broken or damaged, or
itiscoatedwithasubstancethatcannotbecleanedoff,replace
the
110634A
2. Keep the flame detection system adjusted for the
smoothest, most reliable operation as recommended by the
burner manufacturer.
3. Replace the bushing with focusing lens or the lead
sulfide photocell (Fig. 8)
proper operation.
Bushing, which includes the focusing lens.
soft,
clean cloth.
only when necessary to obtain
lhe
lens does
14
Application and Features
1
C7015A
TABLE OF CONTENTS
Table of Contents
Page
..................................................................................................................................................
1
Specifications
Ordering Information
Dimension Drawings
Operation
Installation
Basic Requirements
Installing
Installing Accessories
Mounting the Detector
Wiring
Adjustments and Checkout
Troubleshooting
Service
Periodic Maintenance
Tables
Table I -Models available
Table 2 -Diameter of area sighted through various lengths of
Table 3 -Diameter of area sighted through various lengths of
Table 4 -Diameter of area sighted through orifice, in in
Table 5 -Diameter of area sighted through orifice, in mm
Table 6 -Flame Signal
......................................................................................................................................................................
..............................................................................................................................................
................................................................................................................................................
............................................................................................................................................................................
..........................................................................................................................................................................
..................................................................................................................................................
the Sight Pipe
.......................................................................................................................................................................
...............................................................................................................................................................
..............
..~.~“~.....~.~.“.........~....................................................................................................~ .........................
...........................................................................................................................................
................................................................................................................................................
.............................................................................................................................................
.............................................................................................................................................
.............................................................................................................................................
.......................................................................................................................................
.......................................................................................
............................................................................................................................................
2
2
3
4
4
4
8
8
8
9
10
13
14
14
2
3/4
inch pipe without orifice, in in..
3/4
inch pipe without orifice, in mm
....................................................................................
...................
..................
.5
.
6
6
11
Figures
Fig.1-Mounting dimensions of
Fig. 2 -Methods of reducing
Fig. 3 -Using orifice plate to restrict detector field-of-view to intersection of pilot
and main
Fig. 4
-C7015A
Fig. 5
-C7015A
Fig. 6
-C7015A
Fig. 7 -Forced air cooling
Fig. 8 -Installing lead sulfide photocell
Fig. 9 -Mounting
Fig. 10 -Typical wiring of
Fig. 11 -Typical wiring of
Fig. 12 -Measuring
Fig. 13 -Measuring BCS 7700 Flame Safeguard Control flame signal voltage
Fig. 14 -Measuring 7800 SERIES Flame Safeguard Control
flame,
or to small area of hot refractory
Infrared Flame Detector aimed at side wall of combustion chamber
Infrared Flame Detector aimed at a point above refractory
Infrared Flame Detector aimed at floor of combustion chamber
C7015A
microamp ilame
C7015A
C7015A
.....................................................................................................................................
Infrared Flame Detector and accessories
C7015A
C7015A
Infrared Flame Detector and
Infrared Flame Detector field-of-view
.................................................................................
................................................................................................................
to nearby wiring subbase or terminal strip
to distant wiring subbase or terminal strip
signal
........................................................................................................
Rame
accessories,
................................................................
signal voltage
inin.
[mm].
...................................................
......................................
....................................................
............................................
...............................................
................................................
.................................................
...........................................
...................
.3
5
6
7
7
7
8
9
13
10
11
11
11
15
60-2306-5
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