Flame Scanner U2-1010

U2 Combination Viewing Head and
Signal Processors
USER MANUAL
APPLICATION
Each sensor in the U2 has a different response which is
suitable for certain applications.
The UVTRON tube detector has a peak response at 210 nm

and is primarily for gas flame monitoring. This UV detector
using pulse technology is the best for low NOx gas burners
and where a solid state sensor, using flicker technology, does
not provide satisfactory results.
The solid state UV photodiode has a peak response at 310

nm. This sensor is suitable for gas, oil and coal. The principle
of flame monitoring is flicker frequency based. User selectable
high pass filters are used to reject signals that are from
background radiation.
The solid state IR photodiode has a peak response at

1400 nm. This sensor is suitable for low NOx oil and coal
burners, low excess air oil burners, and burners with a limited
INTRODUCTION view from a windbox front plate. The principle of flame
monitoring is flicker frequency based. User selectable high
The Honeywell U2 flame monitoring system combines sensing pass filters are used to reject signals that are from background
and processing in one package. The U2 is available in several radiation.
models to provide different options. Each model includes one,
two or three sensors which share the same optical axis. The
U2 can be connected either through a detachable connector
or a pipe fitting for installations with conduit. Refer to the table
below for model numbers and options.
Contents
Introduction ....................................................................... 1
Application ........................................................................ 1
Specifications ................................................................... 2
Approvals .......................................................................... 3
Installation ........................................................................ 3
Accessories ...................................................................... 5
Operation .......................................................................... 6
Troubleshooting ................................................................ 9
Communicating Through Modbus .................................... 9
Manual Setup ................................................................... 13
Automatic Setup ............................................................... 14
Maintenance ..................................................................... 15
Safety Manual ................................................................... 22
Safety Function of the Uniscan 2 ......................... 23
Proof Test Procedure ........................................... 23
Proof Test Interval ................................................ 23
Product Decommissioning ................................... 24
66-2071-02
U2 COMBINATION VIEWING HEAD AND SIGNAL PROCESSORS
Table 1. Available models and associated features.

Connector Pipe Fit Connection UVTron
Model Connection (3/4 in. NPT) Sensor SSUV Sensor IR Sensor
U2-1010 X X X X
U2-1010-PF X X X X
U2-1010-PF-050* X X X X
U2-1010-PF-100* X X X X
U2-1012 X X
U2-1012-PF X X
U2-1016 X X
U2-1016-PF X X
U2-1018 X X X
U2-1018-PF X X X
* The U2-1010-PF-050 has a 50-ft (15m) pigtail and the U2-1010-PF-100 has a 100-ft (30m) pigtail.
All models include the following: 3. Ten (10) flicker frequency filters for solid state UV and IR
1. Electronic check (no mechanical shutter) for self-check sensor (model dependent)
of the system. 4. Gain selection
2. 24 VDC input 5. Eight (8) different file configurations
6. Resettable fuses
SPECIFICATIONS
Power: 22-26 VDC, 120 mA max Paint: Silicone-free powder coat
Output relay contacts SPST: 2 A, 30 VDC or 250 VAC Mounting/Process Connection: 1” NPT female
NOTE: Refer to for Fig. 9 and Fig. 10 mounting examples.
Ambient temperature: -40 to 70 ºC (-40 to 158 ºF)
Pipe Fit Conduit Connection (-PF): 3/4” NPT
Enclosure: IP66
FFRT: 1-3 second nominal, 2-4 second maximum
NOTE: Optional air cooling for housing is available for appli-
cations with higher ambient temperatures. Please Time Delay On: 0-3 seconds
contact your distributor or Honeywell for assistance.
Fuses: Automatically resettable
Weight: 2.8 kg (6.1 lbs)
NOTE: If one of the devices is triggered due to high power
Physical Dimensions: draw, disconnect power from the system for a mini-
Diameter: 11.7 cm (4.6 inches) mum of 30 seconds then reconnect power.
Length: 15.5 cm (6.1 inches)
66-2071—02 2
APPROVALS
The U2 is a FM approved combustion safeguard and flame
sensing system. The U2 also carries the following approvals.
Table 2. Approvals.
Market Pipe fit series (-PF) Connector series
FM-U.S. CLASS I, II, III DIV 1 GROUPS A, B, C, D, E, F, & G, T6 CLASS I, II, III DIV 2 GROUPS A, B, C, D, E, F, & G, T5
*Not for use in acidic or aliphatic hydrocarbon atmospheres. DIP / II, III / 2 / EFG / T5 Ta = -40°C to +70°C;
**Must be sealed at the enclosure. NI / I, / 2 / ABCD / T5 Ta = -40°C to +70°C;
XP / I / 1 / ABCD / T6 Ta = -40°C to +70°C; I / 2 / AEx nA nC IIC / T5 Ta = -40°C to 70°C; IP66
DIP / II, III / 1 / EFG / T6 Ta = -40°C to +70°C; 21/ AEx tb IIIC / T85°C Ta = -40°C to +70°C;
I / 1/ AEx d IIC / T6 Ta = -40°C to +70°C;
21/ AEx tb IIIC / T85°C Ta = -40°C to +70°C;
FM-Canada XP / I / 1 / ABCD / T6 Ta = -40°C to +70°C; DIP / II, III / 2 / EFG / T5 TA = -40°C TO +70°C;
DIP / II, III / 1 / EFG / T6 Ta = -40°C to +70°C; NE / I, / 2 / ABCD / T5 TA = -40°C TO +70°C;
I / 1/ Ex d IIC / T6 Ta = -40°C to +70°C; I / 2 / EX NA NC IIC / T5 TA = -40°C TO 70°C; IP66
IEC IECEx FMG 13.0023X Ex d IIC T6 Gb IP66 IECEx FMG 13.0023X Ex nA nC IIC T5 Gc IP66
Ex tb IIIC T85C Ex tb IIIC T85C
Temperature range: -40 to +185 ºF (-40 to +70 ºC) Temperature range: -40 to +185 ºF (-40 to +70 ºC)
Special conditions of use for IECEx as indicated below.
NOTES: Special Conditions for Safe Use:

1. Consult the manufacturer if dimensional information on the flameproof joints is necessary.
2. The aluminum surface of the Honeywell U2 flame monitoring system may store electrostatic charge and
become a source of ignition in applications with a low relative humidity (<30 %) where the aluminum surface
is relatively free of surface contamination such as dirt, dust or oil. Cleaning of the painted surface should
only be done with a damp cloth.
3. The apparatus has flying lead conductors that exit the enclosure. A suitably certified Ex d or Ex e terminal
box is required to be connected to apparatus enclosure for completing to external supply circuits.
WARNING
“Lockout” requires operator action.
To prevent explosion in hazardous atmospheres, do not open housing.
* Not including aliphatic hydrocarbons (hexane) and acids atmospheres in Class I, Division 1 locations.
** To reduce the risk of ignition of hazardous atmospheres, an approved sealing fitting is required at the
enclosure in Class I, Division 1 locations.
INSTALLATION
Grounding and Shielding 4. Ensure all igniter wires and cables show no signs of
wear. Replace any igniter cables or wires that are frayed
IMPORTANT or cracked.
5. The U2 must be electrically isolated from the burner
Installer must be a trained, experienced flame safe- front.
guard service technician and should be familiar with a. Electrical isolation can be accomplished by install-
the equipment operation and limitations and be ing an Ultem locking coupler adapter (R-518-PT12
aware of any applicable local codes and regulations. or R-518-PT12L) in conjunction with a locking cou-
pler (R-518-CL12-HTG or R-518-CL12-PG)
1. Connect a safety ground to the U2 housing (if applicable).
between the viewing head flange and the burner
2. The U2 and all associated cable/conduit must be at
mount.
least 12 inches (31 cm) from any source of high energy
b. The purge air line should also be isolated from the
or voltage (for example, igniter equipment).
viewing head. This can be accomplished by install-
3. Install a ground wire from the ignition transformer case
ing any insulating material, for example a rubber
to the igniter assembly.
hose, in between the purge air line and the U2.
Wiring
U2 models with a pipe fitting have slightly different wiring than models with a removable connector. Refer to the table and diagram
below for wire function, connection, and comments. Honeywell C12S cable colors are referenced for the Connector (CAB22) wires.
3 66-2071—02
NOTE: If the fault and flame contacts are wired to 220 VAC voltage and cable runs are long, it may be necessary to use
isolating/interposing relays to reduce induced noise.
Table 3. U2 Wires and their function.

Pipe Fitting Connector
Connection (CAB19) (CAB22) Function Comments
Drain wire Shield Cable shielding Tie to ground (black)
Black Yellow/Green Ground Power ground
Red Black #10 Power Connect to 22-26 VDC
Green Yellow #3 Relay common Common for both flame and self check relays
Yellow Yellow #4 Self check relay Normally open contact
Grey Yellow #2 Flame relay Normally open contact
Brown Yellow - RS 485 communication Modbus Connection
White White + RS 485 communication Modbus Connection
Blue Black #7 Future use Future use
Orange Black #8 Current output 0-20 or 4-20 mA output corresponding to flame count. Use
ground as return line.
Purple Black #9 File select Grounded = parameter file 0
+24V = parameter file 1
NOTE: The file input wire should not be left uncon-

nected or in an unknown state. If not being
used or if using the default file 0, connect the
file input wire to ground.
Pressure
NOT USED
YELLOW
The U2 lens will withstand 500 psi. If the U2 will be exposed to
WHITE pressures over 500 psi, contact your distributor or Honeywell
for guidance.
BLACK 10 YELLOW 2
BLACK 9
Temperature
YELLOW 3
The U2 can withstand an ambient temperature of 158 ºF
(70 ºC). The case temperature of the housing must not
BLACK 8 exceed 158 ºF (70 ºC). Purge air will help reduce conducted
YELLOW 4
heat through the sight pipe and flange. A heat insulating Ultem
BLACK 7 locking coupler adapter (R-518-PT12, R-518-PT12L) is
YELLOW/GREEN
required and will reduce the conducted heat, however, direct
SHIELD M33313 radiation can cause the housing case temperature to exceed
limits. If the ambient heat (direct radiation) is excessive, then a
Fig. 1. Connector Pinout. fiber optic extension should be considered. The extension
uses a fiber optic cable assembly between the sight pipe and
NOTES: the U2, allowing the U2 to be placed further away from the
— It is recommended to use shielded pairs of cable. heat source. Refer to the Fiber Optic Manual 69-2683 or
However, any cable can be used as long as ana- contact your distributor or Honeywell for assistance with fiber
log output and communication cables are individ- optic selection and pricing.
ually shielded. Honeywell offers C12S cable with
12 conductors for use with the U2. The U2 models also have an internal sensor for measuring
— 18 AWG is recommended temperature. To access the temperature reading at the U2,
— Wiring must be in conduit or tray as permitted by refer to Fig. 2.
code. Hazardous location wiring must meet area
classifications.
Purge Air
Mounting and Sighting The U2 does not have a purge air connection directly on it, so
purge air must be provided via the mounting method. Refer to
Mounting is 1 in. NPT (F). Refer to Fig. 7 for suggested U2 the ACCESSORIES section and Fig. 7 for suggested U2
mounting. Before beginning the actual installation, determine mounting. Purge air is used to prevent very hot gases from
the best location for mounting the viewing head based upon reaching the U2 by continuously blowing cooler air through the
the following factors: sight pipe. Air required is about 0.13 Nm3/min (5 SCFM)
delivered at 25 mm (1 in.) above the maximum back pressure
as measured at the “Y” or “T” section of the purge air
66-2071—02 4
connection. Use a flexible air supply line, to allow for located during the aiming or sighting process. The “root” or
repositioning of the U2 and sight pipe until a final and intense spot may be further out than with the standard gas
permanent position has been decided. A continuous flow of air burner so it is imperative that a swivel mount be used when
must be maintained in order to reduce conducted heat and to making sighting adjustments.
keep the sight pipe and U2 lens free of dirt and debris. The air
supply must be clean, free of oils and water, and preferably As an example of proper sighting challenges, detecting flame
cool. In order to electrically isolate the U2, the purge air line in a sulfur recovery unit can present a challenge for IR flame
should be installed using an insulating material, such as a monitors. The IR detector will detect natural gas used for the
rubber hose, in between the purge air line and the U2. warm-up of the reactor. Usually the combustion air is turbulent
enough to cause a good flicker signal.
Clearance When sour gas is introduced and the natural gas is shut down,
the flame signal could potentially drop off or drop out entirely
Make sure there will be sufficient room to remove the U2 for
due to a complete change in the flicker content for the existing
servicing.
U2 sighting. In this case, optimizing the flame signal for the
sour gas by “zeroing-in” on this flame, and not the warm-up
Mounting burner, may be beneficial.
Honeywell offers a range of swivel mounts, both pipe thread or Once optimizing the sighting for the sour gas has been
flange mounting for use with sight pipes or direct windbox completed, the signal level could potentially be too low on the
mounting. Refer to the section “Accessories” on page 5. natural gas. In this case, using the UV detector for this
application may be beneficial. It may be beneficial to use two
Viewing Head Sighting sets of set points for Flame On and Flame Off, one set for
proving and detecting the natural gas flame and the other for
The sighting of the U2 should be parallel to the center line of proving and detecting the sour gas flame. The switch-over
the burner in the direction of the flame. If used, the sight pipe from the two different files should be done when removing the
should be mounted as close to the center line as possible so natural gas burner. This can be implemented from the burner
as to sight along the flame rather than across the flame. Doing management system. The switch-over and the use of different
so will ensure continuing flame detection under changing load files with independent settings is explained in the sections
conditions. Refer to Fig. 4, 5 and 6. “File” on page 8 and “Manual Setup” on page 13.
Utilizing a sighting or the sight pipe aimed at the root of the Another factor that needs to be considered when aiming the
flame (where the turbulent combustion air mixes with the viewing head is the load condition of the boiler. The flames
flame) is a good starting point for optimizing the sighting. from a burner can be radically different at different loads. This
Where practical, using a swivel mount to “zero-in” on the is one of the reasons for choosing an optimum sighting initially
highest signal will assure the maximum performance. The that will maximize signal swing due to changing loads.
optimum scanner location is parallel to the burner center line.
The use of a swivel mount allows for line of sight adjustment,
where practical to use. ACCESSORIES
Examples of U2 installation with and without a swivel mount
The following accessories are available for use with the U2.
are shown in Fig. 9 and Fig. 10. If using a sight pipe, the
diameter should be large enough to allow a reasonable field of Orifice Disks (kit M-702-6) – Used to reduce the signal
view and to allow for adjustment of the swivel mount angle. brightness in cases where the signal brightness is too strong.
Located immediately in front of the lens, it will reduce the
Pulverized coal, unburned fuel, smoke, oil mist, dirt, dust and
amount of signal to the sensors. Bag assembly contains
other impurities in the fuel can act as masking agents that
orifice disks and retaining rings. Orifice disks come with 3/8,
attenuate the ultraviolet radiation that the flame emits. As well,
1/4, 3/16 and 1/8 inch diameter holes. Contact your distributor
sour gas (H2S) can readily absorb 200nm UV wavelengths,
or Honeywell for guidance in using orifice disks.
reducing the amount of ultraviolet radiation reaching the
detector. Care should be taken to select the proper viewing Locking coupler with purge port (R-518-CL12-PG) –
head for the fuel used. Additionally, the contaminants that mask Adapter is a 1 in. NPTM locking quick disconnect/cam and
UV can be diluted by providing a strong flow of air through the groove coupler with 1/2 in. NPT purge port. Used with R-518-
sight pipe to clear a viewing path through the attenuating PT12 and R-518-PT12L insulating locking coupler adapters.
material. Refer to the Purge Air section of this manual.
Insulating locking coupler adapters (R-518-PT12 and R-
It may also be desirable to sight the detector at an area 518-PT12L) – 1 in. NPTM Ultem adapters insulate the viewing
containing fewer masking agents such as near the burner head from heat and are used with the R-518-CL12-PG purge
nozzle or near the entrance of the combustion air. Increasing air adapter or the R-518-CL12-HTG locking coupler. The R-
the viewing area of the detector by shortening the sight pipe or 518-PT12L has a quartz lens.
by increasing the diameter of the sight pipe can also reduce
the attenuating effect of masking agents. Swivel mounts (M-701-1, M-701-2, M-701-2-FLG, M-701-2-
SS, M-701-3, M-701-3P, M-701-4) – All have 1 in. NPTF
With low NOx gas burners, the UV radiation is usually much viewing head connections on one end with varying process
less in intensity and spread out. Relatively high readings can connections including 2 in. pipe slip-on, 2 in. NPTF, 2 in.
be obtained from all over the furnace when many burners are flanged, 2 in. NPT in stainless steel construction, 4.5 in.
on. This is particularly true when flue gas recirculation is used. flanged with 3 bolts, 3 in. NPTF and 2-bolt flanged.
There will however, be a relatively stronger signal near the
“root” of the flame and the more intense spot should be
5 66-2071—02
Locking coupler (R-518-CL12-HTG) – Used with the R-518- To further assist in flame discrimination setup, adjustable
PT12 and R-518-PT12L insulating locking coupler adapters. “Flame On” and adjustable “Flame Off” thresholds are also
Process connection end is 1 in. NPTF. provided. The Flame On threshold and Flame Off threshold
can then be set to monitor the target burner flame but to reject
Connector (R-518-10) – Quick disconnect connector for all background radiation from other burners.
non-pipe fitting U2 models.
In order to energize the flame relay, the flame count must be
NOTE: Connector is not included with the non-pipe fit- higher than the programmed “Flame On” threshold for greater
ting models. Order separately along with cable than the “Time Delay” value. Once the flame relay is
and required mounting accessories. energized, the flame signal can fall below the programmed
Flame On threshold setting. As long as the flame signal
Cable (C12S) – 12 conductor cable with braided shield. Sold remains above the programmed “Flame Off” setting, the
per foot. system will continue to operate. When the flame signal falls
NOTE: Cable is not included with the non-pipe fitting below the programmed “Flame Off” threshold, it will not be de-
models. Order separately along with connector energized until after the “FFRT” (flame failure response time)
and required mounting accessories. expires, unless “Flame On” is detected.
Cable+ Connector (ASY964) – Pre-assembled 15-foot The U2 includes a self check relay which should always be
(4.7m), 12-conductor cable (C12S) with quick disconnect (R- energized whenever the U2 has power. The self check relay is
518-10) for all U2 non-pipe fitting models. de-energized (failsafe) when an internal fault is detected. The
self check relay is factory wired in series with the flame relay.
Fiber Optic System Compatibility – The U2 models are One additional contact is provided for alarm purposes.
compatible with the Honeywell FASA fiber optic extension
products. The S550FOAD, S550FOADY-FT and S550FOADY-
FT-AL adapters are applicable. Contact your distributor or
Self-Checking
Honeywell for assistance with fiber optic selection and pricing. There is a small processor in all viewing heads and it is
possible that it could fail and produce erroneous viewing head
USB to RS422/RS485 Converter (COMMOD) – Protocol pulses. The self-check circuitry guards against such an
converter for use with external communication to a remote occurrence. There are several tasks that require intelligent
computer. interaction between the viewing heads and the signal
processor. If all of the interactions do not occur properly, the
flame relay will open.
OPERATION
User Interface
IR and UV Detectors A touch wheel located on the back of the U2 is used for
See Table 1 on page 2 to determine which sensors are active operator interface. The configuration menu is simple and easy
in your U2 model. to follow. Full character 4 digital scrolling LED displays are
visible in the dark or sunlight. Individual sensor LEDs (3 total
The UVTron tube sensor responds to UV radiation from located below the display) flash to indicate the output of each
different fuel flames. The UVTron sensor generates pulses sensor (green = UVT, Blue = SSUV, Red = IR). The upper
that are electronically conditioned to provide output indicated right green self-check LED provides status of the hardware
on the U2 display from 0000 to 3425 units. while the upper left red “Flame On” LED provides status of the
flame relay (main safety device).
The signals from the UVSS solid state sensor are processed
based on flicker principle using FFT (Fast Fourier Transform). NOTE: The number of LEDs is model dependent.
User selectable high pass filters are used to reject signals that
are from background radiation. The touch wheel is designed like an iPod™ to allow for slow or
fast changes by moving a finger slower or faster around the
The signals from the IR solid state sensor are processed back glass. Alternatively the user may tap  (-) or  (+) to
based on flicker principle using FFT (Fast Fourier Transform). make changes. Tap ENTER/STORE to enter a menu or store
User selectable high pass filters are used to reject signals that selected data. Tap BACK to return to the previous menu. Exiting
are from background radiation. all the menus will display the current flame count. The U2
menus are detailed below.
Each sensor allows independent adjustment for gain. For
flicker-based sensors, there is also a high pass filter setpoint.
66-2071—02 6
TWO BUTTON INTERFACE (BACK AND ENTER)

HONEYWELL U2 PROGRAMMING
EVERYTHING ELSE CAN BE DONE BY SCROLLING
INTERFACE TECHNIQUES: INTERFACE MODES:
TAP: PRESS FINGER ON BUTTON AND REMOVE. FLAME DISPLAY: TAP BACK (MAY REQUIRE MORE THAN ONE TAP).
SCROLL: PRESS FINGER ON GLASS AND MOVE FINGER IN CIRCLES (TWIRL). HELP: TAP + OR - (FROM DISPLAY).
RAMP: HOLD FINGER ON THE + OR - BUTTON. LAST MENU: TAP ENTER,
MOVE THROUGH MENU WITH TAPS OR SCROLLS.
4 SUB MENUS ADJUST MODE: TAP ENTER FROM ADJUSTABLE MENU ITEM,
FACTORY DEFAULT CHANGE VALUE USING ANY TECHNIQUE.
VERSION NO YES MODE: CHANGE TO YES AND TAP STORE.
HOURS
FILE DEFAULT °F OR °C
ON READ ONLY
OFF RS485 WRITE ONLY DEFAULT
127 °F
IRDA 0->20 OR 4->20 AUTO FILTER

GAIN TUBE UV - GT32
AUTO GAIN 3425

PARITY ADDRESS- GAIN SS UV- G 32
COMMS
BACK
NONE BAUD A000 FILTER SS UV- F 09
ODD PANEL
EVEN HELP HELP
2400 4800 *F01 FILE ENTER

STORE
GAIN IR- GI32
9600 19200
38400 57600
TIME DELAY- LAST MENU FILTER IR- FI04
115200 TD03
FFRT- GAIN MA OUT-

PANEL LOCK 0000 RT01 GM32
FLAME OFF- FLAME ON-
TIME OUT MIN 0000 0600 0800
M33314
Fig. 2. User interface menu overview.

NOTE: If sensor is not available in your model, then no menu item will exist for sensor setting. See Table 1 on page 2 to
determine which sensors are active in your U2 model.
Temperature Gain SSUV

Displays the processor temperature. Tapping enter will bring NOTE: If sensor is not available in your model, then no
the user into the submenu which will allow changes between menu item will exist for sensor setting. See
displaying Celsius or Fahrenheit, display the software version, Table 1 on page 2 to determine which sensors
or display the number of hours the unit has been in operation. are active in your U2 model.
Displays the solid state UV gain (adjustable 0-99) The default
Gain UVTron value is 75.
NOTE: If sensor is not available in your model, then no
menu item will exist for sensor setting. See Gain IR
Table 1 on page 2 to determine which sensors
NOTE: If sensor is not available in your model, then no
are active in your U2 model.
menu item will exist for sensor setting. See
Displays the Uvtron gain (adjustable 0-99). The default value Table 1 on page 2 to determine which sensors
is 32. are active in your U2 model.
Displays the IR gain (adjustable 0-99). The default value is 75.
Filter SSUV
Displays the current solid state UV high pass filter (adjustable 0-9). The default filter is 3. See the filter cutoff frequencies (in
Hertz) in the table below.
FILTER 0 1 2 3 4 5 6 7 8 9
HERTZ 9 16 24 33 52 75 100 155 215 300
7 66-2071—02
Filter IR
Displays the current IR high pass filter (adjustable 0-9). The default filter is 3. See the filter cutoff frequencies (in Hertz) in the
table below.
FILTER 0 1 2 3 4 5 6 7 8 9
HERTZ 9 16 24 33 52 75 100 155 215 300
mA Out When connected to 24 Vdc, the file selection = “1”. The other
means of selecting and activating a file is via the Modbus RTU
Displays the current output gain (adjustable 0-99) or “OPEN” if interface using register address 40093. Modbus interface can
the current output is open. The default value is 32. be accomplished via FlameTools software or another Modbus
RTU interface.
Flame On
Displays the flame on value (adjustable 51-3425). The flame
Panel
on value can not be adjusted below the flame off value. When Tapping the ENTER/STORE button when PANEL appears on
the flame count is greater than the flame on value for greater the menu screen will provide access to two sub-menus;
than the time delay value, the flame relay will energize. The Panel Lock and Time Out.
default value level is 800.
The Panel Lock sub-menu enables or disables a security
feature that locks the U2 interface, preventing any parameter
Flame Off modifications. To enable this feature, a special 4-digit access
Displays the flame off value (adjustable 50-3424). The flame code is required, which is available from the factory. It requires
off value can not be adjusted above the flame on value. When that same code to unlock, allowing parameter changes after it
the flame count is less than the flame off value for greater than has been enabled. Once the Panel Lock feature is enabled by
the FFRT value, the flame relay will de-energize. The default entering the code, the panel is locked out immediately from
value level is 600. Flame off is usually set to approximately 2/3 further adjustment. If a user attempts to modify any U2
the value of flame on, however this value should never be less parameters while the Panel Lock feature is enabled, a lockout
than 100. message will appear on the display. The display will show
“Bad” upon entry of an incorrect access code. If the password
is forgotten or lost, the user must contact the factory for
FFRT assistance with unlocking the panel. At that point, the user can
The flame failure response time is the time it takes for the reset or deactivate the password. Once the appropriate code
flame relay to de-energize after the flame count falls below the is entered and the Panel Lock sub-menu accessed, it is
flame off value. FFRT (flame failure response time) can be set automatically disabled. The default setting for the Panel Lock
to 1, 2, or 3 which will not exceed 2, 3, or 4 seconds feature is disabled/OFF.
respectively. The factory default value is 1 second.
The Time Out sub-menu allows the user to enter a time
allotment from 0-9999 minutes in which to allow adjustments
Time Delay of settings before the panel returns to monitoring mode and
the touch wheel disables itself if there is no menu activity.
The time it takes for the flame relay to energize after the flame Panel Time Out helps prevent accidental changes to
count rises above the flame on value. Time delay can be set to parameter settings. Once the panel has timed out, to modify
0, 1, 2, or 3. The factory default value is 3 seconds. settings, simply enter “1234” as prompted by the display. The
Panel Time Out is by default 9999 minutes.
File NOTE: If the display shows “9999”, it can also indicate
The U2 is able to store up to 8 different file configurations (file0 saturation of the UVSS and/or IR sensor. If the
– file7). Settings that are stored include: UVT gain, SSUV problem persists after checking the panel
gain, IR gain, SSUV filter, IR filter, mA output, gain, flame on, lockout feature and resetting as described
flame off. File 0 is default. NOTE: The U2 touch wheel above, refer to the Troubleshooting section of
interface allows access to all eight files for changing this document for instruction.
parameters, however, the file selection cannot be changed via
the U2 interface; it can only be changed via the “File Select”
wire input or modbus. Only two files, “0” and “1” may be Auto Gain
automatically activated by changing the voltage input to the NOTE: Auto Gain and Auto Filter cannot be used with
“File Select” wire (purple or black #9). Refer to Table 3. When U2-1016-PF model.
the file select line is grounded, the file selection = “0”.
Routine that automatically determines the gain for the IR and
NOTE: The file input wire should not be left uncon- SSUV sensors (that are on) necessary to generate a total
nected or in an unknown state. If not being used flame count of approximately 1200. Be sure that all desired
or if using the default file 0, connect the file input sensors are turned on (gain of at least 1) before the routine is
wire to ground. run.
66-2071—02 8
Auto Filter “Bad” Message

Routine that automatically determines the optimum filter for If the display shows “Bad” upon entering the access code for
the SSUV and IR sensors. This routine should only be done the PANEL Lock feature, it means the access code that was
after the AUTO GAIN routine. just entered is incorrect. Refer to the Panel section of this
manual for further details.
NOTE: While using the Auto Gain and Auto Filter modes,
the system will be adjusting to the firing condi- NOTE: Refer to “Grounding and Shielding” on page 3 for
tions at the time of implementation. This condi- further troubleshooting help in regards to proper
tion should be carefully selected to ensure grounding and shielding techniques.
discrimination through complete load changes
from minimum to maximum and from cold
burner/boiler startup to hot burner/boiler startup. COMMUNICATING THROUGH
MODBUS
Default
Tapping will access the file default and factory default sub Modbus RTU communication protocol allows the U2 to
menus. communicate with any process controllers or human-Interface
host computers that support this protocol. When
communicating through Modbus, use the following register
File Default map to access and control the U2:
Changes the settings of the current file being adjusted (see
FILE menu). — 9600 baud (default)
— 8 data bits
Factory Default — no parity (default)
— 1 stop bit
Changes all settings to factory default settings.
Communications, security, and all file settings will have to be Baud, parity, and address are all changeable via the U2
reset so only initiate factory defaults when absolutely interface in the “Comms” menu. The address is set to 0 by
necessary. default and must be changed in order to communicate with the
unit. When communicating with more than one unit ensure
that no two units share the same address.
TROUBLESHOOTING
A graphical user interface is available for remote configuration
and monitoring through Modbus called Flame Tools. Refer to
“9999” on Display Table 4 and 5 for the Modbus registers map.
“9999” on the U2 display can indicate saturation of the UVSS
and/or IR sensor in addition to the PANEL Time Out sub-menu
being accessed. First check to see if the PANEL Time Out
Comms
sub-menu has been accessed and exit the menu as described Tapping COMMS on the U2 menu will access the
in the Panel section of this document. If the problem still communications sub menus including address, baud, parity,
persists, then sensor saturation is likely. Decrease the gain for IRDA, RS485, and current output.
UVSS and/or IR sensor to 0, then gradually increase the gain
level(s) to a suitable level to prevent saturation. In rare cases, Address
an orifice disk may be required. Refer to the ACCESSORIES
section of this document for part numbers. Address for modbus communication (0-247). When
communicating with more than one unit ensure that no two
If saturation of the IR or SSUV sensor persists for greater than units share the same address. The default address is 0 so it
1 second, the flame Relay will open, and the U2 will lock out must be changed before modbus communication can take
with an error code: code 1 for SSUV saturation and code 8 for place. For applications where large quantities of U2 are used,
IR saturation. When a lockout occurs, the U2 must be reset to it is recommended to start with address 11 for burner #1, 21
continue normal operation. This is accomplished by pressing for burner #2 and so on. Refer to Fig. 3. Doing so will help
the enter key twice at the front panel. alleviate potential communication issues when adding new or
replacing existing U2 models, which have zero (0) as the
Lockout Message default address. Two units with a 0 address could seize
communications.
If a lockout message appears on the screen, the user has
attempted to access the U2 menus while the PANEL Lock
feature is enabled. The Lock feature requires a special 4-digit
Baud
code for access and modification, which is available from the Speed of modbus communications (2400, 4800, 9600, 19200,
factory. If the password is forgotten or lost, the user must 38400, 57600, or 115200). The default baud is 9600.
contact the factory for assistance with unlocking the panel.
Refer to the Panel section of this manual and/or contact the Parity
factory for assistance.
Modbus checking method (NONE, ODD, or EVEN). The
default parity is NONE.
9 66-2071—02
IRDA 0 OR 4-20
Enables or disables communications through the palm. Sets the current output to either a 0-20mA output or a 4-20mA
Enabled by default. output scale. The 4-20mA output scale is used by default.
RS485
Sets modbus to either READ ONLY or read and writable
(WRITE OK). Read and writable by default.
Table 4. Basic MODBUS Registers Map.
Register Name Description Minimum Maximum Size

40001 FLAMECOUNT Flame count of active channel (read only) 0 3425 16 bit
40002 PROCSTATUS Bit mask: only 4th bit (4 of 20) is writable, other bits are read 0 255 8 bit
only
Not used (0000 0001) don’t care
Relay (0000 0010) 1=on, 0=off
Not lockout (0000 0100) 1=not lockout, 0=lockout
Not panel lock (0000 1000) 1=unlocked, 0=locked
4 to 20 (output) (0001 0000) 1 (default)=4-20mA, 0=0-
20mA
File (1110 0000) 3 bits are the file in use (0-7)
40003 FLAMEON Flame On setting for current active file 51 3425 16 bit
40005 FLAMEOFF Flame Off setting for current active file 50 3424 16 bit
40007 OUTPUTGAIN Gain of the0/4-20mA output for the current active file 0 99 8 bit
40010 IRGAIN IR sensor gain setting for current active file 0 99 8 bit
40011 IRFILT High pass IR sensor filter setting for current active file. 0=8Hz 0 9 8 bit
(default), 1=16Hz, 2=24Hz, 3=33Hz, 4=52Hz, 5=75Hz,
6=100Hz, 7=155Hz, 8=215Hz, 9=300Hz
40012 UVTGAIN UV tube gain setting for current active file 0 99 8 bit
40015 UVSSFILT High pass solid state UV sensor filter setting for current active 0 9 8 bit
file. File 0=8Hz (default), 1=16Hz, 2=24Hz, 3=33Hz, 4=52Hz,
5=75Hz, 6=100Hz, 7=155Hz, 8=215Hz, 9=300Hz
40016 UVSSGAIN Solid state UV sensor gain setting for current active file 0 99 8 bit
40019 TEMPERATURE Current internal temperature of U2 (read only) -67 261 16 bit
40021 TIMEDELAY Time Delay setting (in seconds) for current active file 0 3 8 bit
40022 FFRT FFRT (flame failure response time) setting (in seconds) for 1 3 8 bit
current active file
40023 VERSION Firmware version (read only) -32768 32767 16 bit
40085 BAUD Baud rate setting (bits/second). Only affects RS-485 24 1152 16 bit
communication, not IRDA. Default is 9600. The U2 and the
master device must have the same baud settings.
40086 PARITY Parity setting. Only affects RS-485 communication, not IRDA. 0 2 8 bit
0-no parity (default), 1=odd parity, 2=even parity
40087 ADDRESS Modbus address of U2 used by RS-485 and IRDA. Each flame 0 247 8 bit
monitor must have a unique address.
40092 NUMFILES User set limit on the number of files able to be used. Default=8. 1 8 8 bit
40093 FILE Current active file number. Default=0. 0 7 8 bit
40095 TUBEFLAME Flame count from the UV tube sensor only (read only) -32768 32767 16 bit
40096 IRFLAME Flame count from the IR sensor only (read only) -32768 32767 16 bit
40097 SSUVFLAME Flame count from the solid state UV sensor only (read only) -32768 32767 16 bit
66-2071—02 10
BOILER 1
BNR 1 BNR 2 BNR 3 BNR 4 BNR 5 BNR 6

ADDRESS 11 12 13 14 15 16
BNR 1 BNR 2 BNR 3 BNR 4

ADDRESS 31 32 33 34
BOILER 3
MODBUS
MASTER CONTROL
FOR PF VERSION CAB 19: + = WHITE

– = BROWN
FOR QD VERSION CAB 22: + = WHITE

– = YELLOW
NOTES:
– A CONVERTER MAY BE NECESSARY FOR COMMUNICATION WITH THE MODBUS MASTER CONTROL.
– USE SHIELDED CABLE FOR COMMUNICATION WIRING.
M33521
Fig. 3. Typical Communication Wiring and Recommended Addressing.
RDB(+)
RDA(–)
TDB(+)
TDA(–)
GND
PRODUCT WIRE
SIDE SIDE
A TDA(–) COMMOD USB TO RS422/485 CONVERTER
B TDB(+) CONVERTER U2 CONNECTOR U2 PIPE FITTING

DESCRIPTION
CONNECTOR (CAB22) (CAB19)
C RDA(–)
TDA (-) DATA A (-) INPUT/OUTPUT YELLOW BROWN
D RDB(+)
TDB (+) DATA B (+) INPUT/OUTPUT WHITE WHITE
E GND
RDA (-) DATA A (-) INPUT/OUTPUT
RDB (+) DATA B (+) INPUT/OUTPUT
GND GROUND SHIELD DRAIN WIRE
NOTES:
SELECT THE APPROPRIATE DIP SWITCH SETTINGS FOR RS-485 COMMUNICATION PER THE VENDOR’S INSTRUCTION SHEET.
SOFTWARE DRIVERS MAY BE DOWNLOADED FROM B&B ELECTRONICS’ WEBSITE. M33862
Fig. 4. Wiring of RS422/485 to USB Converter to U2.
11 66-2071—02
1 (25) NPT 1(25)

CONNECTION 5-3/32 (130)
4-19/32
(118)
3/4 (19) NPT

2-29/32 (73) CONNECTION
M34431
Fig. 5. U2 dimensions.
66-2071—02 12
MANUAL SETUP NOTE: Above is a simplified version of discrimination

adjustments.
Manual Configuration for Gas Firing Vessels equipped with a large number of burn-
ers, “T” fired units and cross fired boilers will
Applications with Multiple Burners require several adjustments including use of
multiple files for obtaining the required discrimi-
nation.
CAUTION
ALL ADJUSTMENTS SHOULD BE CARRIED OUT Manual Configuration for Oil Firing
BY A QUALIFIED PERSON.
BMS interlock(s) may require temporary bypass during Applications with Multiple Burners
configuration. This operation should be carried out
under supervised conditions and limited to minimum
time. Remove bypasses as soon as configuration and
setup is completed.
CAUTION
ALL ADJUSTMENTS SHOULD BE CARRIED OUT
Main gas control valve may include bypass PRV. Make sure at BMS interlock(s) may require temporary bypass during
least first burner is started up at minimum firing. In some configuration. This operation should be carried out
cases more than one burner may be started up at low fire under supervised conditions and limited to minimum
depending upon bypass PRV. time. Remove bypasses as soon as configuration and
setup is completed.
Follow manufacturer’s guidelines in controlling fuel flow as
additional burners are brought into service Main oil control valve may include bypass PRV. Make sure at
1. Go to menu for UVTron. least first burner is started up at minimum firing. In some
2. Adjust gain settings to 50 cases more than one burner may be started up at low fire
3. If applicable, go to UVSS menu and set UVSS gain to depending upon bypass PRV.
zero. With zero gain, flicker frequency filter need not be Follow manufacturer’s guidelines in controlling fuel flow as
adjusted. additional burners are brought into service.
4. If applicable, go to IR menu and set IR gain GI to zero.
With zero gain, flicker frequency filter need not be For vessels equipped with gas igniters follow setup procedure
adjusted. described above. For best discrimination, two channels may
5. Go to Milliamp output gain GM and set at 50 be required to accommodate two different fuels firing. As an
6. Go to Flame ON menu. Set this to 800 as an initial value. example, after the gas igniter is established, introduce oil to
7. Go to Flame OFF menu. Set Flame OFF 600 as an ini- the burner and change the file number selection.
tial value.
8. Go to Flame Failure Response Time (FFRT). Select 3 1. Go to menu for IR sensor.
seconds 2. Adjust gain settings to 50.
9. Go to Time Delay and select “0” seconds. 3. Adjust Filter set point to 1
10. Under supervised conditions, light off gas igniter. 4. If applicable, go to UVSS menu and set UVSS gain to
11. The viewing head will show in Green (UV mode) reading zero. With zero gain, flicker frequency filter need not be
between 0-3425. adjusted.
12. If necessary and when mounted on swivel mount or 5. Go to Milliamp output gain GM and set at 50
adjustable device, adjust line of sight for the viewing 6. Go to Flame ON menu. Set this to 800 as an initial
head for maximum signal. Lock up viewing head in this value.
position. 7. Go to Flame OFF menu. Set Flame OFF 600 as an ini-
13. If selected setting is not correct to recognize igniter tial value.
flame, adjust UV gain. 8. Go to Flame Failure Response Time (FFRT). Select 3
14. Start the main gas firing per manufacturer's instructions. seconds
15. REPEAT THE ABOVE FOR ALL BURNERS - ONE AT 9. Go to Time delay and select “0” seconds.
A TIME. 10. Under supervised conditions, light off oil igniter (if appli-
After all burners are in service and boiler load is above 90%, cable).
perform the following for discrimination tests and adjustments. 11. The viewing head will show in Red (IR mode) reading
between 0-3425.
a. Turn off the burner 12. Skip this step if the viewing head is already adjusted for
b. Check if background signal is below “Flame Off” gas igniter. If necessary and when mounted on swivel
threshold. If not, increase Flame Off threshold so mount or adjustable device, adjust line of sight for the
the background count is below set point viewing head for maximum signal. Lock up viewing head
c. After 1 minute, re-start burner on pilot and then in this position.
main gas fuel. 13. If selected setting is not correct to recognize oil igniter
d. Check that the U2 recognizes the pilot and main flame, adjust IR gain and filter.
flames. If the flame signal is below Flame On 14. Start the main oil firing per manufacturer's instructions.
threshold, lower Flame On threshold below flame on 15. REPEAT THE ABOVE FOR ALL BURNERS - ONE AT
signal. A TIME.
e. Repeat all tests if any changes are made to Gain,
Flicker set point, Flame On and Flame Off Threshold.
13 66-2071—02
After all burners are in service and boiler load is above 90%, For vessels equipped with gas igniters, follow setup procedure
perform the following for discrimination tests and adjustments. described above. For best discrimination, two to three files
may be required to accommodate three different fuel firings.
a. Turn off the burner
b. Check if background signal is below “Flame Off” 1. Establish igniter flame as described above.
threshold. If not, increase Flame Off threshold so 2. Start warm-up oil burner.
the background count is below set point. If the back- 3. Go to IR menu and adjust gain setting to 50.
ground flame signals are too high, increase IR filter 4. If equipped with UVSS sensor adjust gain to 0
setting to a higher value starting with 2  3  4  5. Adjust IR filter to 1 and UVSS filter to 9
5, until background count is below Flame Off thresh- 6. Go to milliamp output gain and adjust to 50
old point. 7. Go to Flame ON and adjust to 1200
8. Go to Flame off and adjust to 800
NOTE: With IR sensor, two adjustments are available: gain 9. Go To FFRT and adjust to 3 seconds
and flicker set point. Both may require adjustment to 10. Go to Time Delay and adjust to zero “0” seconds
obtain the required discrimination. In general, flicker 11. With oil firing at the minimum on the first burner - adjust
filter adjustment works better for discrimination than gain up or down to be just above 1200
gain adjustment. 12. One by one light-off the remaining burners and adjust
gain as necessary.
c. After 1 minute, re-start burner on pilot and main oil 13. When all mill burners are firing oil, start pulverizer sys-
burner. tem.
d. Check that U2 recognizes the pilot and main flames. 14. Adjust mill output to minimum coal flow as recommend
If the flame signal is below Flame On threshold, by the manufacturer.
lower Flame On threshold below flame on signal. 15. If the signal is still above Flame On for all burners asso-
e. Repeat all tests if any changes are made to Gain, ciated with the mill, no further adjustment will be neces-
Flicker set point, Flame On and Flame Off Thresh- sary.
old. 16. Repeat for at least one more mill by establishing gas
NOTE: Above is simplified version of adjustment. Ves- igniters and oil burners for the mill.
sels equipped with a large number of burners, 17. When first Mill is established, turn off the warm-up burn-
“T” fired units and cross fired boilers will require ers - one by one. If the signal falls below the Flame Off
several adjustments including use of multiple point, adjust gain to higher value so that signal remains
files for obtaining the required discrimination. above Flame Off point.
18. After all oil burners and igniters are off, adjust mill coal
flow as per manufacturer recommendations.
Manual Configuration for Coal Firing 19. Repeat for all mills.
20. Go back to first mill - reduce coal flow to minimum.
Applications with Multiple Burners 21. Establish igniter and oil burners.
In general, coal firing units are equipped with several coal 22. Stop the mill as per manufacturer's recommendations.
mills. Each coal mill may supply pulverized coal to several 23. Sweep the mill of coal and then shutdown oil burners; if
burners. igniters are in service, turn off igniters.
24. If the flame signal from the back ground is above the
For units equipped with a gas igniter and gas warm-up Flame Off point - increase Flame Off set point and/or
burners, two dedicated files for each U2 are highly increase filter frequency set point.
recommended. One file should be dedicated to the gas igniter 25. Make adjustment to all units associated with this mill.
and warm-up gas burners, and the other to main coal. 26. RE-ESTABLISH THE MIL AND REPEAT THE ABOVE
FOR THE REMAINING MILLS - ONE AT A TIME.
For units equipped with a gas igniter and oil warm-up burners,
two files are recommended; one file for the gas igniter and the NOTE: Above is simplified version of adjustment. Ves-
other for the oil warm-up burners and main coal firing. sels equipped with a large number of burners,
“T” fired units and cross fired boilers will require
NOTE: Alternately, 3 files may be used, however, only several adjustments including use of multiple
two files may be selected via the “File Select” 0/ files for obtaining the required discrimination.
24 Vdc input on the U2. The third file must be
selected via a Modbus RTU interface. Refer to
Table 3 and the “FILE” section of this document. AUTOMATIC SETUP
NOTE: For single burner systems only. Multiple burners
CAUTION require several manual adjustments to obtain the
ALL ADJUSTMENTS SHOULD BE CARRIED OUT proper discrimination.
BMS interlock(s) may require temporary bypass during
time. Remove bypasses as soon as configuration and
setup is completed.
66-2071—02 14
9. Ensure the current flame count is less than the FLAME

CAUTION
ALL ADJUSTMENTS SHOULD BE CARRIED OUT 10.
OFF value.
Restart the burner being monitored.
BY A QUALIFIED PERSON. 11. Ensure the current flame count is greater than the
BMS interlock(s) may require temporary bypass during FLAME ON value.
time. Remove bypasses as soon as configuration and MAINTENANCE
setup is completed.
The UV tube sensor has a limited lifespan. Under extreme
1. Adjust all sensor gain settings to 50. conditions, the lifespan can be as low as 10,000 hours.
2. Go to Flame ON menu. Set this to 800. However, in the most favorable conditions, the lifespan is
3. Go to Flame OFF menu. Set this to 600. 50,000 hours or more. The service life of the UV tube sensor
4. Go to the AUTO GAIN menu, tap enter, scroll to “yes” is considered terminated when the sensitivity becomes lower
then tap enter again. then 50% of the initial value.
5. Wait as instructed by the display.
A monthly sensitivity check is suggested to determine if the
After the burner is in service and boiler load is above 90%, UV tube sensor's life is terminated. The reading of the U2
perform the following for discrimination tests and adjustments. digital display should be compared to the initial reading of the
unit when it was installed. Ensure similar burner fire conditions
6. Go to the AUTO FILTER menu, tap enter. of the application, and that the same gain settings are used
7. Turn off the burner being monitored as instructed by the during each sensitivity check. If it is determined that the
display. sensitivity is below 50% of the initial value (terminated life of
8. Tap enter, scroll to “yes” then tap enter again. sensor), the sensor should be replaced.
HIGH FREQUENCY
FLICKER ZONE
DETECTOR IN GOOD
SIGHTING POSITION
(PARALLEL SIGHTING)
BURNER NOZZLE
CENTERLINE
DETECTOR IN POOR
SIGHTING POSITION
LOW FREQUENCY
FLICKER ZONE
M33285
Fig. 6. IR viewing head location.
15 66-2071—02
UV RADIATION
ZONE
UV VIEWING
HEAD SIGHTED
ON UV ZONE
BURNER NOZZLE
CENTERLINE
M33286
Fig. 7. UV viewing head location.
NO. 1 FLAME NO. 2 FLAME

ENVELOPE ENVELOPE
VIEWING HEAD VIEWING HEAD
BURNER NOZZLE NO. 1 BURNER NOZZLE NO. 2
HIGH FREQUENCY LOW FREQUENCY HIGH FREQUENCY

IR ZONE ZONE IR ZONE
(LESS THAN 36Hz) M33287
Fig. 8. Sighting opposed fired burners.
66-2071—02 16
R-518-CL12-PG
BURNER FRONT PLATE PURGE AIR COUPLER
AND R-518-PT12
INSULATING LOCKING
2 (51) NPT NIPPLE TOE COUPLER ADAPTER
M-701-2
SWIVEL MOUNT
M33524
Fig. 9. Viewing head mounting example.
BURNER FRONT PLATE

OR WINDOWBOX
R-518-CL12-PG
1 (25) PURGE AIR COUPLER
NPTF PIPE AND R-518-PT12
INSULATING LOCKING
COUPLER ADAPTER
FLANGE
(OPTIONAL)
M33628
Fig. 10. Second vertical head mounting example.
Mounting Examples (applicable to both Fig. 7 and Fig. 8):

Due to the heat and electrical insulation requirements of the U2, it is highly recommended to use the Honeywell
locking coupler adapter and locking coupler accessories for mounting, attached directly to the U2. In order to
maintain the specified U2 temperature, the minimum distance to mount the U2 from the sight pipe is 2.3 inches
(5.8 cm), using the R-518-PT12/L and the R-518-CL12-HTG locking coupler. Cooling air should be provided via a
“Y” or “T” in between the locking coupler and the sight pipe to reduce conducted heat and to keep the sight
pipe and U2 lens clean of debris and dirt. Refer to the Mounting and Sighting section on purge air requirements.
For electrical isolation reasons, the purge air line should be installed using an insulating material, such as a
rubber hose, in between the purge air line and the viewing head. Note that an extension pipe may be required to
locate the U2 further from the burner front plate to avoid high temperatures.
17 66-2071—02
Table 5. Extended Modbus Register Map.

40017 SENSORS Bit mask: shows populated sensors (model dependent, 0 255 8 bit
read only)
UV tube (0000 0001) 1=on, 0=off
IR sensor (0000 0010) 1=on, 0=off
SSUV (0000 0100) 1=on, 0=off
Display (0000 1000) 1=on, 0=off
Wheel (0001 0000) 1=on, 0=off
40020 HIGHTEMP Stores the highest internal temperature (ºC only) the U2 0 261 8 bit
has achieved (read only)
40060 SERIALNUM Factory set identification number (read only) -32768 32767 16 bit
40061 IDNUM User set identification number -32768 32767 16 bit
40062 OP2HOURS Total run time in 2 hour increments (read only) -32768 32767 16 bit
40089 KEYTIMEOUT Time (in minutes) before the touch wheel will disable itself. 0 9999 16 bit
Default of 60. Writing a 0 will disable this function.
40094 MODEL Model number of the U2 unit (read only) -32768 32767 16 bit
40098 HIGHTIME Time, in 2 hour increments, when the highest temperature -32768 32767 16 bit
occurred. (read only)
40100 FLAMEON Flame On setting for file 0 51 3425 16 bit
40110 Flame On setting for file 1
40101 FLAMEOFF Flame Off setting for file 0 50 3424 16 bit
40111 Flame Off setting for file 1
40102 FFRT FFRT (flame failure response time) setting for file 0 1 3 8 bit
40112 FFRT (flame failure response time) setting for file 1
40103 TIMEDELAY Time Delay setting for file 0 0 3 8 bit
40113 Time Delay setting for file 1
40104 UVTGAIN UV tube gain setting for file 0 0 7 8 bit
40114 UV tube gain setting for file 1
66-2071—02 18
Table 5. Extended Modbus Register Map. (Continued)

40105 UVSSGAIN Solid state UV sensor gain setting for file 0 0 7 8 bit
40115 Solid state UV sensor gain setting for file 1
40105 UVSSFILT Solid state UV sensor filter setting for file 0 0 7 8 bit
40116 Solid state UV sensor filter setting for file 1
40107 IRFILT IR sensor filter setting for file 0 0 7 8 bit
40117 IR sensor filter setting for file 1
40108 IRGAIN IR sensor gain setting for file 0 0 7 8 bit
40118 IR sensor gain setting for file 1
40109 OUTPUTGAIN Current output gain for file 0 0 7 8 bit
40119 Current output gain for file 1
40184 DISPLAYPAR Various parameters. 0 4095 16 bit
Dim setting (11 0000 000) between 0 (dimmest)
and 24 (brightest).
Default=24.
Scroll type (00 0000 0011) 0=no pause, 1=initial
pause, 2=end pause,
3=initial+end pause
Scroll wait (00 0001 1100) between 4 (short)
and 32 (long).
Default=16l
Scroll time (00 1110 0000) between 0 (faster)
and 14 (slower).
Default=6.
40185 IWSENS Touch wheel sensitivity (default is 5). The higher the value, 1 63 8 bit
the more sensitive the touch wheel will be.
40187 IWDATA Output from touch wheel. When the wheel is touched, the 0 255 8 bit
output increases from 0 to 127 as you move your finger
clockwise around the wheel. The output is 232 when no
touched. Write a 1 to re-calibrate the U2. Other numbers
will give an error. WARNING: DO NOT TOUCH THE
WHEEL WHILE RE-CALIBRATING.
19 66-2071—02

40189 PAGECNT Counts every fourth time power is reset to the U2 (read -32768 32767 16 bit
only)
40190 IRFILTCOUNT IR filter selection for filter 0 (read only) -32768 32767 16 bit
40191 IR filter selection for filter 1
40200 UVFILTCOUNT SSUV filter selection for filter 0 (read only) -32768 32767 16 bit
40201 SSUV filter selection for filter 1
40210 to 40219 IRSAVEDCNT Saved exponential count of the IR filter when the auto-filter -32768 32767 16 bit
routine was run. Registers correspond to Filter0 through
Filter9 (read only).
40220 to 40229 UVSAVEDCNT Saved exponential count of the UV filter when the auto- -32768 32767 16 bit
filter routine was run. Registers correspond to Filter0
through Filter9 (read only).
40230 to 40239 IRSAVEGAIN400 The gain at the IR filter to give a count of 400; used when 0 99 8 bit
all 3 sensors are active to total a count of 1200. Saved at
the time the auto-filter routine was run. Registers
correspond to Filter0 through Filter9 (read only).
40240 to 40249 IRSAVEDGAIN600 The gain at the IR filter to give a count of 600; used when 2 0 99 8 bit
sensors are active to total a count of 1200. Saved at the
time the auto-filter routine was run. Registers correspond
to Filter0 through Filter9 (read only).
40250 to 40259 IRSAVEDGAIN1200 The gain at the IR filter to give a count of 1200; used when 0 99 8 bit
1 sensor is active to total a count of 1200. Saved at the
40260 to 40269 UVSAVEDGAIN400 The gain at the UV filter to give a count of 400; used when 0 99 8 bit
all 3 sensors are active to total a count of 1200. Saved at
40270 to 40279 UVSAVEDGAIN600 The gain at the UV filter to give a count of 600; used when 0 99 8 bit
2 sensors are active to total a count of 1200. Saved at the
40280 to 40289 UVSAVEDGAIN1200 The gain at the UV filter to give a count of 1200; used 0 99 8 bit
when 1 sensor is active to total a count of 1200. Saved at
40290 TUBSAVECNT Saved exponential count of the UV tube when the auto -32768 32767 16 bit
filter routine was run (read only)
66-2071—02 20

40291 IRSAVEGAIN Saved gain of the IR sensor from the current file 0 99 8 bit
determined by the auto gain function (read only)
40292 UVTUBESAVEGN Saved gain of the UV tube from the current file determined 0 99 8 bit
by the auto gain function (read only)
40293 USSSSAVEGN Saved gain of the solid state UV sensor from the current 0 99 8 bit
file determined by the auto gain function (read only)
40294 SAVEFILE Saves the active file at the time of auto gain. Reads 255 if 0 255 8 bit
the auto gain function has never been run (read only)
21 66-2071—02
SAFETY MANUAL
Uniscan 2 Product Declaration
FIT FOR USE IN A Low Demand SAFETY APPLICATION
Models: 1010, 1012, 1016, 1018, 1010-PF, 1012-PF, 1016-PF, 1018-PF
Models SIL HFT SFF PFD λS λDD λDU

1010/1010PF 3 0 >99% 1.54 X10-4 1.08 X10-5 7.22 X10-9 6.95 X10-9
1012/1012PF 3 0 >99% 1.45 X10-4 8.19 X10-7 7.22 X10-9 6.62 X10-9
1016/1016PF 3 0 >99% 7.55 X10-5 1.08 X10-5 1.97 X10-9 3.45 X10-9
1018/1018PF 3 0 >99% 1.54 X10-4 1.08 X10-5 7.22 X10-9 6.95 X10-9
System Architecture 1oo1

MTTR 8 hours
Proof Test Interval 5 years
Fit for use in SIL 3 environment
Definitions
Term Definition
Dangerous Failure Failure which has the potential to put the safety-related system in a hazardous or fail-to-function
state
Safety-Related System A system that implements the required safety functions required to achieve or maintain a safe
state and is intended to achieve on its own or with other systems the necessary safety integrity for
the required safety functions.
Safety Function Defined function, which is performed by a safety-related system with the aim of achieving or
maintaining a safe state for the plant, in respect of a specified hazardous event.
Proof Test Periodic test performed to detect failures in a safety-related system so that, if necessary, the
system can be restored to an “as new” condition or as close as practical to this condition.
MTTR (Mean Time To The average duration required for restoration of operations after a failure.
Restoration)
λsd Rate of safe detectable failures per one billion hours.
For example, if λsd = 3000, then it is estimated that there will be about 3000 safe detectable
failures during every one billion hours of operation.
For λsd = 3000, this is about one safe detectable failure every 38 years.
λsu Rate of safe undetectable failures per one billion hours.
λdd Rate of dangerous detectable failures per one billion hours.
λdu Rate of dangerous undetectable failures per one billion hours.
HFT Hardware Fault Tolerance
System Architecture Specific configuration of hardware and software elements in a system.
PFDAVG (Average Probability Average Probability of Failure on Demand. In this case regarding the Uniscan 2.
of Failure on Demand)
FIT (Failures in Time) A unit of measurement representing one failure per billion hours. 1,000,000,000 hours is
approximately 114,155.25 years.
66-2071—02 22
Safety Function of the Uniscan 2 Flame Relay to be energized if the Self Check Relay is not
energized. To reduce the chance of a false flame on condition
The safety function of the Uniscan 2 signal processor consists due to welded Flame Relay contacts, it is recommended that
of a Flame Relay which comprises its safety function and the user wire the Flame and Self Check Relays in series.
behaves as follows:
Also, as another added safety feature, neither relay can be
The Flame Relay (Normally Open) driven by a simple continuously high or continuously low
signal which could potentially be caused by a fault. Each relay
• The Flame Relay will be energized when the product is must be driven by an alternating signal of the proper
powered and a flame on condition is detected for longer frequency and duty cycle from the processor.
than the time delay value.
• The Flame Relay will be de-energized when the product is
powered, a flame off condition is detected, and the FFRT Proof Test Interval
(Flame Failure Response Time) has elapsed. The Proof test must be conducted every 1 to 5 years. This
• The Flame Relay will be de-energized when the product is range is given to allow for the test to be performed during the
powered and detects a fault condition. normally scheduled burner shutdown period. It is the
• The Flame Relay will be de-energized when power to the responsibility of the user to perform the proof test in the
product is off. specified time frame.
The following diagram for the U2-1010 shown for example,

All Uniscan 2 signal processor models contain a Self Check presents the dependence of the PFDAVG on the proof test
Relay designed to be energized during normal operation of interval. The PFDAVG increases as the proof test interval
the signal processor and de-energized during detection of a increases.
fault or power down. Due to the logic circuitry which energizes
the coil of the Flame Relay, it is physically impossible for the
3.50E-04
3.00E-04
2.50E-04
2.00E-04
PFDAVG
1.50E-04
1.00E-04
5.00E-05
0.00E+00
0 1 2 3 4 5 6 7 8 9 10
TIME (YEARS) M34953
Fig. 11. 1010 PFDAVG over time.
Proof Test Procedure Setup

1. Ensure the Uniscan 2 signal processor is fully opera-
EQUIPMENT tional.
• Powered Uniscan 2 signal processor 2. While performing the proof test, disconnect or disregard
• Multimeter able to take voltage and resistance the signal processor outputs so that any outputs due to
measurements testing do not affect the overall safety system and
• 22V DC to 26V DC power supply potentially cause a hazardous situation.
• Light source* capable of generating a flame on condition. 3. Record all previously entered user programmable set-
* Generally an incandescent bulb will work for IR viewing head tings so that you can restore them to their desired val-
sensors and a deep UV light or flame will work for UV view- ues after the proof test.
ing head sensors
23 66-2071—02
Tests 6. Change one of the settings of the signal processor and

store the changed setting. Remove power to the signal
1. Remove power to the signal processor and, using a processor for 10 seconds. Restore power to the signal
multimeter, ensure there is no continuity between the processor and ensure the stored value has remained
relay common and self check wires (see chart below for unchanged.
color codes). 7. Use your light source to generate flamecounts of
2. Reapply power to the signal processor and, using a between 1200 and 2600 in the signal processor. Note
multimeter, ensure continuity between the relay com- the flamecount.
mon and self check wires. a. Increase the gain and store the setting. Ensure the
3. Use a light source to generate a flame on condition and, flamecount increased.
using a multimeter, ensure continuity between the relay b. Decrease the gain and store the setting. Ensure the
common and flame relay wires. flamecount decreased.
4. Remove any light source to generate a flame off condi- 8. Restore all original settings as recorded in Setup and
tion and, using a multimeter, ensure there is no continu- reconnect the signal processor to the safety system.
ity between the relay common and flame relay wires,
after the FFRT (Flame Failure Response Time) has
elapsed. Product Decommissioning
5. Measure the current draw of the U2 and ensure it is less
When required, decommissioning of the Uniscan 2
than 120 mA.
flamescanner should be performed in accordance with
requirements of the overall safety system.
Automation and Control Solutions

Honeywell International Inc.
1985 Douglas Drive North
® U.S. Registered Trademark
Golden Valley, MN 55422 © 2013 Honeywell International Inc.
66-2071—02 M.S. Rev. 07-13
customer.honeywell.com Printed in United States

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U2 Combination Viewing Head and

The UVTRON tube detector has a peak response at 210 nm

The solid state UV photodiode has a peak response at 310

The solid state IR photodiode has a peak response at

Table 1. Available models and associated features.

Special conditions of use for IECEx as indicated below.

NOTES: Special Conditions for Safe Use:

Table 3. U2 Wires and their function.

NOTE: The file input wire should not be left uncon-

TWO BUTTON INTERFACE (BACK AND ENTER)

IRDA 0->20 OR 4->20 AUTO FILTER

AUTO GAIN 3425

2400 4800 *F01 FILE ENTER

FFRT- GAIN MA OUT-

TIME OUT MIN 0000 0600 0800

Fig. 2. User interface menu overview.

Temperature Gain SSUV

Auto Filter “Bad” Message

Table 4. Basic MODBUS Registers Map.

Register Name Description Minimum Maximum Size

BNR 1 BNR 2 BNR 3 BNR 4 BNR 5 BNR 6

BNR 1 BNR 2 BNR 3 BNR 4

FOR PF VERSION CAB 19: + = WHITE

FOR QD VERSION CAB 22: + = WHITE

Fig. 3. Typical Communication Wiring and Recommended Addressing.

A TDA(–) COMMOD USB TO RS422/485 CONVERTER

B TDB(+) CONVERTER U2 CONNECTOR U2 PIPE FITTING

SOFTWARE DRIVERS MAY BE DOWNLOADED FROM B&B ELECTRONICS’ WEBSITE. M33862

Fig. 4. Wiring of RS422/485 to USB Converter to U2.

1 (25) NPT 1(25)

3/4 (19) NPT

MANUAL SETUP NOTE: Above is a simplified version of discrimination

9. Ensure the current flame count is less than the FLAME

Fig. 6. IR viewing head location.

Fig. 7. UV viewing head location.

NO. 1 FLAME NO. 2 FLAME

VIEWING HEAD VIEWING HEAD

BURNER NOZZLE NO. 1 BURNER NOZZLE NO. 2

HIGH FREQUENCY LOW FREQUENCY HIGH FREQUENCY

Fig. 8. Sighting opposed fired burners.

Fig. 9. Viewing head mounting example.

BURNER FRONT PLATE

Fig. 10. Second vertical head mounting example.

Mounting Examples (applicable to both Fig. 7 and Fig. 8):

Table 5. Extended Modbus Register Map.

Register Name Description Minimum Maximum Size

Table 5. Extended Modbus Register Map. (Continued)

Register Name Description Minimum Maximum Size

Table 5. Extended Modbus Register Map. (Continued)

Register Name Description Minimum Maximum Size

Table 5. Extended Modbus Register Map. (Continued)

Register Name Description Minimum Maximum Size

Models SIL HFT SFF PFD λS λDD λDU

System Architecture 1oo1

The following diagram for the U2-1010 shown for example,

Fig. 11. 1010 PFDAVG over time.

Proof Test Procedure Setup

Tests 6. Change one of the settings of the signal processor and

Automation and Control Solutions