C7962B
Visible Light Flame Detector
FEATURES
• Used with 7800 SERIES Flame Safeguard controls with
R7851B Flame Amplifier.
• Has an integral collar threaded (internal 1/2-14 NPSM)
for mounting on 1/2 inch sight pipe.
• Has 1/2-in. spud (1/2-14 internal thread) for electrical
conduit wiring.
• Conduit clamp provided for flexible conduit wiring.
APPLICATION
The C7962B Visible Light Flame Detector detects the visible
light emitted by fuel oil combustion flames. The C7962B
Detector is used with Honeywell 7800 SERIES Flame
Safeguard controls to provide fuel oil flame supervision in
commercial and industrial burners.
PRODUCT DATA
Contents
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Installation ........................................................................ 2
Ordering Information ........................................................ 2
Adjustments and Checkout .............................................. 6
Troubleshooting ................................................................ 6
Maintenance ..................................................................... 7
65-0277-03
C7962B VISIBLE LIGHT FLAME DETECTOR
WARNING
SPECIFICATIONS
Model:
C7962B Visible Light Flame Detector.
Electrical Ratings:
Connections:
Two eight-foot (2.44 meters) color-coded NEC Class 1
leadwires.
Environmental Ratings:
Ambient Operating Temperature:
-40°F to +165°F (-40°C to +74°C)
Storage Temperature Rating:
-20°F to +120°F (-29°C to +49°C).
Humidity:
90% relative humidity, noncondensing.
Vibration:
0.5G.
Maximum Pressure Rating:
5 psi.
Mounting:
Collar with 1/2-14NPSM (internal thread) for mounting on a
1/2 inch sight pipe.
3-7/8 (98)
3-3/8 (86)
COLLAR WITH 1/2-14 NPSM
INTERNAL THREADS
C7962B
Fig. 1. C7962B Visible Light Flame Detector
dimensions in in. (mm).
INSTALLATION
Electrical Shock Hazard.
Can cause serious injury, death or property
damage.
Disconnect power supply before beginning installation.
More than one disconnect may be required.
8 FOOT
(2.44 METER)
LEADWIRES (2)
SPUD CONNECTOR
(1/2-14 NPSM
INTERNAL THREADS)
(25)
1
M29272
Dimensions:
See Fig. 1.
Accessory:
32007439-001 Mounting Bracket and screws. (Included with
C7962B1010)
118367A Swivel Mount.
130413 Conduit Clamp (included)
Approvals:
Underwriters Laboratories, Inc. listed: File No. MP268, Vol.
30, 31
Canadian Standards Association (CSA): 95329.
When Installing This Product…
1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.
3. Installer must be a trained, experienced, flame
safeguard control technician.
4. After installation is complete, check out product
operation as provided in these instructions.
Disconnect the power supply before beginning installation to
prevent electrical shock and equipment damage. All wiring
must comply with applicable electrical codes, ordinances and
regulations. Use NEC Class 1 (line voltage) wiring.
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® Catalog or price sheets for complete ordering 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 Automation and Control Products Sales Office (check white pages of your phone directory).
2. Honeywell Customer Care
1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9.
International Sales and 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.
65-0277—03 2
WARNING
Explosion Hazard and Electrical Shock Hazard.
Can cause serious injury, death or property
damage.
1. The C7962B Flame Detectors must be used with
Honeywell flame safeguard controls (primaries,
programmers, multiburner systems, and burner
management systems). Using with controls not
manufactured by Honeywell could result in unsafe
conditions.
2. Disconnect power supply before beginning
installation to prevent electrical shock or equipment
damage. More than one disconnect may be
involved.
3. Read the installation instructions before starting the
installation.
4. All wiring must be NEC Class 1 (line voltage).
Basic Requirements for Flame Detector Installation
It is necessary for the detector to actually see the flame.
Locate the detector as close to the flame as physical
arrangement and temperature restrictions permit.
Sighting requirements for different types of flame supervision
are:
C7962B VISIBLE LIGHT FLAME DETECTOR
If a C7962B is to be used for a blast tube installation, its
location should be determined by the burner manufacturer.
Contact the manufacturer before making any modifications to
the installation.
Prepare Hole in Wall of Combustion Chamber
Cut a hole of the proper diameter for the sight pipe in the wall
of the combustion chamber at the selected location. Flare the
hole to leave room for small adjustments of the sighting angle.
The taper of the hole should be about 1 inch for every 3 inches
(25 mm for every 76 mm) of wall thickness.
Mounting the Sight Pipe (Fig. 2)
Thread one end of the pipe to fit the mounting collar on the
detector. Cut the pipe to the desired length (as short as
practicable) and at an angle so it fits flush with the wall of the
combustion chamber. Tack-weld the pipe to the wall in a trial
position. Do not permanently weld the sight pipe in place until
after completing the Adjustments and Checkout section.
NOTE: If you use a swivel mount (part no. 118367A) and you
are positive about the location and sighting angle, you
can permanently weld the pipe.
TEMPORARY
TACK WELD
1. Pilot flame only—Sighting must be along the axis of the
pilot flame. The smallest pilot flame that can be sighted
must be capable of igniting the main burner (see Pilot
Turndown Test).
2. Main flame only—Sighting must be at the most stable
part of the flame for all firing rates.
3. Pilot and main flame—Sighting must be at the junction of
both flames.
Mounting a C7962B Flame Detector
Locate the Sight Pipe
The location of the sight pipe is the most critical part of the
installation. A black iron pipe is recommended. Do not use a
stainless steel or galvanized pipe because the internal surface
blackens with use ad deposits from the combustion chamber
settle on it.
Under optimum conditions, the flame detector can detect most
oil combustion flames at a distance of six feet (1.8 meters).
The critical factors in determining the flame-detector distance
separation are the optimized flame signal (current or voltage)
and the flame detector temperature. Other factors may be
influential and are associated with the specific installation. For
minimum flame signals, see Table 1 and for ambient operating
temperatures, refer to Specifications, page 2.
Use 1/2 inch pipe for a C7962B. Since no two situations are
likely to be the same, length and sighting angle of the pipe
must be determined at the time and place of installation.
Generally, it is desirable to have the sight pipe tilting downward
to prevent soot or dirt buildup.
FLARED HOLE
BLACK IRON
SIGHT PIPE
REFRACTORY
M3019B
Fig. 2. Mounting sight pipe.
BOILER
PLATE
Sight Pipe Ventilation
It may be necessary to ventilate the sight pipe to cool the flame
detector or to clear the sight pipe of UV radiation absorbing
material such as smoke, excessive moisture or, in some
instances, unburned fuel.
For a negative pressure combustion chamber, drilling a few
holes in the section of the sight pipe outside of the combustion
chamber will allow air at atmospheric pressure to flow through
the sight pipe into the chamber. A perforated pipe nipple
between the sight pipe and the detector can also be used.
(See Fig. 3.)
For a positive pressure combustion chamber, connect a supply
of pressurized air from the burner blower through the sight pipe
into the chamber. The supply air pressure must be greater that
the chamber pressure.
Swivel Mount
To facilitate proper sighting of the flame, a swivel mount (part
number 118367A) is available. The swivel mount will require a
3/4 to 1/2 inch reducer and a 1/2 inch close nipple to mount a
C7962B. For mounting details, refer to form 50-0361 for the
118367A Swivel Mount.
3 65-0277—03
C7962B VISIBLE LIGHT FLAME DETECTOR
A
1
[27]
1
16
4-5/8 (117)
1
[32]
1
4
5
8
9
16
[14]
[16]
5
8
1 [41]
C7962B DETECTOR
136733 HEAT BLOCK
1/2-INCH SIGHT PIPE
1/2-14 NPSM
INTERNAL
THREADS
1/2-14 NPSM
EXTERNAL
THREADS
1/2-14 NPSM
INTERNAL
THREADS
HIGH TEMPERATURES (ABOVE 215°F [102°C])
DO NOT USE FOR TEMPERATURES ABOVE 266°F [130°C]
M29281
Mount the Detector (Fig. 3)
Mount the detector onto the sight pipe, pipe tee, nipple, or
other fitting. Make sure the flange gasket is in place inside the
mounting collar on the detector, and then screw the collar onto
the sight pipe or fitting.
C7962B
FLANGE
GASKET
DD PIPE TEE,
PERFORATED
NIPPLE, OR OTHER
SUITABLE DEVICE
FOR VENTILATION,
IF REQUIRED.
BLACK IRON
SIGHT PIPE
COMBUSTION
CHAMBER
WALL
Using a Heat Block with a C7962B (Fig. 4)
If the temperature of the sight pipe will become high enough to
cause the C7962B to overheat (above 165°F [74°C]) up to
266°F (130°C), screw a 136733 Heat Block (order separately)
onto the sight pipe before mounting the detector.
M20913
Fig. 3. Mounting a C7962B on a combustion chamber
(viewed from above).
Fig. 4. Mounting dimensions of 136733 Heat Block in in. (mm).
REPLACING C7013 OR C7014
For locations shown in Fig. 5.
65-0277—03 4
CAUTION
M29283
BLAST TUBE
“F” TERMINAL
C7013/C7014 PHOTOCELL
HOUSING AND HOLDER
M29284
BLAST TUBE
C7962
32007439 BRACKET
Fig. 5. Location of C7013/C7014 in a conventional
pressure atomizing oil burner.
1. Remove C7013/C7014.
2. Attach bracket 32007439-001 (included with
C7962B1010) onto C7962 detector using screws and
nuts provided.
3. Attach the assembled detector and bracket onto the oil
pipe going to the nozzle with the remaining screw and
nut.
4. Adjust the assembly into a location to provide adequate
clearance and for a clear view of the flame. Tighten the
screw to secure into place. See Fig. 6.
Fig. 6. Mounting a C7962 in a conventional pressure
atomizing oil burner.
WIRING
Equipment Damage Hazard.
Can cause improper operation.
The blue leadwire must be connected to the F terminal
of the flame safeguard control subbase or terminal strip
and the white leadwire to the G terminal. Failure to
observe the circuit polarity by reversing the leadwires
(even momentarily) may cause the flame detector to
improperly supervise the combustion flame.
IMPORTANT
All wiring must comply with applicable local electrical
codes, ordinances and regulations. Use NEC Class 1
(line voltage) wiring.
C7962B VISIBLE LIGHT FLAME DETECTOR
The detector has color-coded and labeled, plastic-insulated,
no. 18 AWG leadwires, eight ft. (2.44 m) long, rated for 221°F
(105°C).
1. Keep the flame signal leadwires as short as possible
from the flame detector to the terminal strip or wiring
subbase. Capacitance increases with wire length, reducing the signal strength.
NOTE: The maximum permissible leadwire length depends
on the type of leadwire and the conduit type and
diameter. The ultimate limiting factor is flame signal
leadwire length is the signal current or voltage at the
flame safeguard device.
2. If needed, splice detector leadwires for longer leadwire
runs, observing the following considerations:
a. Make required splices in a junction box.
b. Use moisture-resistant no. 14 wire suitable for at
least 167°F (75°C).
c. For high temperature installation, use Honeywell
Specification no. 32004766-003 or equivalent for the
F leadwire. This wire is rated up to 400°F (250°C) for
continuous duty. It is tested for operation up to 20 kV
and for breakdown up to 35 kV. For the other
leadwires, use moisture-resistant no. 14 wire
selected for a temperature rating above the
maximum operating temperature.
d. F and G wires must be run in their own conduit
independent of other power carrying leadwires. More
than one scanner F and G wire can be run in the
same conduit.
e. A shielded twisted pair wire may be substituted for
using conduit for routing the F leadwire. Be advised
of the capacitance per foot of shielded wire
effectively reduces the flame signal at the flame
safeguard device. Be sure to ground the shield to the
G terminal at the flame safeguard wiring subbase.
f. The detector wires need to be run in their own
conduit as well, avoiding other electrical noise
carrying wiring.
g. The scanner wires should remain separated a
minimum of two in. (51 mm) from other line voltage
wires in the main control panel to the flame
safeguard device.
3. Avoid installation considerations that can influence
detector operation and maximum leadwire length, such
as:
a. Moisture.
b. Ignition interference.
c. High resistance connections—poor grounds.
d. Leadwire capacitance.
e. Voltage fluctuations.
f. Induced line transients.
g. Floating grounds—grounds at some voltage above
earth ground.
h. No G. wire—burner used as ground.
i. Detector output less than maximum attainable for the
installation (inadequate sighting).
IMPORTANT
Do not run the flame detector wiring in the same
conduit with high voltage ignition transformer wires.
5 65-0277—03
C7962B VISIBLE LIGHT FLAME DETECTOR
WARNING
Earth Ground
The detector and the flame safeguard control must be
connected to earth ground. A convenient method of
accomplishing this is to connect the detector to the flame
safeguard control with a flexible conduit, or ensure a good
ground connection at the mounting bracket.
ADJUSTMENTS AND CHECKOUT
Before welding the C7962B sight pipe in its final location, or
before tightening the C7962B, complete both the adjustments
and checkout tests that follow and any required by the burner
manufacturer.
Adjust detector Sighting Position
With the flame detector installed and burners running, adjust
the position of the flame detector for optimum flame signal. The
flame signal will be read in voltage (Vdc).
The R7851B Amplifier used with the 7800 SERIES controls,
has a dc voltage flame signal output.
For the R7851B Amplifier, a volt-ohmmeter with a zero to 5 of
10 Vdc scale and a minimum sensitivity of 1 megohm/volt is
suggested. See Fig. 5.
Measure the flame signal for the pilot flame alone, the main
burner flame alone, and both together (unless monitoring pilot
only when using an intermittent pilot or supervising the main
flame only when using direct spark ignition). Also, measure the
flame signal at low and high firing rates and while modulating
(if applicable).
With the flame detector in its final position, all flame signals
must be steady with a voltage value as indicated for the device.
If the minimum signal cannot be obtained or is unstable, refer
to the Troubleshooting section.
Pilot Turndown Test
If the detector is used to prove a pilot flame before the main
fuel valve can be opened, perform a Pilot Turndown Test.
Follow the procedures in both the instructions for the
appropriate flame safeguard control and in the burner
manufacturer instructions.
Final Checkout
Before putting the burner into service, check out the installation
using the procedures in the Checkout section of the
instructions for the appropriate flame safeguard control. After
completing the checkout, run the burner through at least one
complete cycle to verify correct operation.
POSITIVE (+)
METER LEAD
NEGATIVE (-)
METER LEAD
Fig. 7. Measuring flame signal voltage of
7800 SERIES controls.
Measure the flame signal voltage as illustrated in Fig. 5. Be
careful to connect the positive meter lead to the positive (+)
amplifier jack and the negative meter lead to the negative (-)
amplifier jack for a 7800 SERIES control. If the 7800 SERIES
control has the optional Keyboard Display Module (KDM), a
zero to five Vdc reading will be displayed on the KDM.
Move the flame detector and sight pipe (if not permanently
attached to the burner/boiler) to view the flame from various
positions. Allow a few seconds for the meter reading to
stabilize. A maximum steady voltage reading is desirable. The
flame signal must be above the minimum acceptable level for
the flame safeguard control and associated amplifier.
ONE MEGOHM/VOLT
METER
M7382
TROUBLESHOOTING
Electrical Shock Hazard.
Can cause serious injury, death or property
damage.
Be extremely careful while troubleshooting the
detector; line voltage is present on some of the
terminals when power is on.
Open the master switch to disconnect power before
removing or installing the detector.
Inadequate Flame Signal
If a satisfactory flame signal cannot be obtained while adjusting
the sighting position of the detector, perform the procedures
indicated in steps 1 through 7, below. If other difficulties are
encountered in the system, refer to Troubleshooting in the
instructions for the appropriate Honeywell flame safeguard
control.
1. Check for proper line voltage. Make sure the master
switch is closed, connections are correct, and power
supply is the correct voltage and frequency.
2. Check the detector wiring for defects, including:
a. incorrect connections.
b. wiring type or size of wire.
c. deteriorated wire.
d. open circuits.
e. short circuits.
f. leakage paths caused by moisture, soot, or dirt.
3. With the burner running, check the temperature at the
detector. When it exceeds 165°F (74°C):
a. use a heat block (part number 136733).
b. add the additional insulation between the wall of the
combustion chamber and the detector.
65-0277—03 6
C7962B VISIBLE LIGHT FLAME DETECTOR
c. add a shield or screen to reflect radiated heat away
from the detector, or
d. add cooling (refer to Sight Pipe Ventilation).
4. Remove the detector and clean the viewing window with
a soft, clean cloth.
5. Clean the inside of the sight pipe (if one is used) before
reinstalling the detector.
6. If the flame signal continues to be too low, replace the
plug-in amplifier (if the control has one).
7. If you still cannot obtain a proper flame signal, replace
the C7962B Flame Detector.
IMPORTANT
At the completion of troubleshooting, be sure to perform the Adjustments and Checkouts.
MAINTENANCE
Periodic Maintenance
1. Clean the viewing window and sight pipe (if used) when
necessary. Remove the detector and use a soft, clean
cloth to remove accumulated contaminants from the cell
surface.
2. Replace the C7962B if it is damaged in any way.
3. Keep the flame detection system adjusted for the
smoothest, most reliable operation as recommended by
the burner manufacturer.
7 65-0277—03
C7962B VISIBLE LIGHT FLAME DETECTOR
Automation and Control Solutions
Honeywell International Inc. Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9
customer.honeywell.com
® U.S. Registered Trademark
© 2009 Honeywell International Inc.
65-0277—03 M.S. Rev. 05-09
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