RSFC Burners
LIMELIGHT Gas Ignitors
High Energy Ignitors
Exacta Flame Scanners
Instruction
Manual
Pampa Energy
Central Termica Units 29 & 30
Piedra Buena
Buenos Aires, Argentina
Alstom Power Inc.
Contract EB0-007991
abcd
Alstom Power Inc. Instruction Manual
Pampa Energy
Central Termica Units 29 & 30
Piedra Buena
Buenos Aires, Argentina
Alstom Power Inc.
Contract EB0-002598
COPYRIGHT 2015 Alstom Power Inc.
All rights
reserved. This manual, or any part thereof, may not be
reproduced in any form without written permission of the
publisher.
 COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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I
Alstom Power Inc. Instruction Manual
INTRODUCTION
This instruction manual has been prepared to serve as a guide in operating and
maintaining the referenced equipment which has been furnished by Alstom Power
Inc. (Alstom). This instruction manual is not intended to cover all possible
variations in such equipment nor is this instruction manual intended to provide for
specific problems that may arise from the use of such equipment. Should
additional information regarding such equipment be required, Alstom or its field
representatives should be contacted.
Only competent personnel, trained in the operations and maintenance of the
equipment and familiar with the hazards and required precautions, should be
allowed in the equipment area to operate and maintain the system.
Alstom makes no warranty, express or implied, nor assumes any legal liability or
responsibility for the accuracy, completeness, or usefulness of any information,
apparatus, product, or process disclosed in this instruction manual, nor does it
represent that the use of any such information, apparatus, product, or process
would not infringe privately owned rights.
No amount of written instructions can replace intelligent thinking and reasoning
on the part of the equipment operators, especially when coping with unforeseen
operating conditions. Thus, it is the operator’s responsibility to become thoroughly
familiar not only with the immediate equipment, but also with all of the pertinent
control equipment applicable thereto as well. Satisfactory performance and safety
of such equipment depends to a great extent on the proper functioning of such
controls as well as the auxiliary equipment furnished by someone other than
Alstom.
© ALSTOM 2015. Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned,
registered or not, are the property of their respective companies. The technical and other data contained in this document is provided for information only.
Neither Alstom, its officers and employees accept responsibility for or should be taken as making any representation or warranty (whether express or implied)
as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. Alstom reserves the right
to revise or change this data at any time without further notice.
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CONTRACT: EB0-007991
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Alstom Power Inc. Instruction Manual
TABLE OF CONTENTS
TITLE
TAB
RSFC™ Burners Low NOx Firing System ........................................................................................... 1
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor .................................................................................... 2
High Energy Ignitor Retractable (HEIR) .............................................................................................. 3
Exacta Flame Scanner System Upgrade ............................................................................................. 4
Vendor Supplied Equipment ................................................................................................................ 5
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TAB 1
RSFC™ Burners Low NOx Firing System
TABLE OF CONTENTS
DESCRIPTION
PAGE NUMBER
Introduction.................................................................................................................................................... 1
RSFC Burner Description .............................................................................................................................. 2
Tertiary and Primary Combustion Air Shutoff/Biasing Dampers................................................................ 2
Three-zone Combustion Air Register ........................................................................................................ 2
Air Swirler Vane Positioners ...................................................................................................................... 3
Burner Throat Refractory ........................................................................................................................... 3
RSFC Fuel Assembly .................................................................................................................................... 3
Operation....................................................................................................................................................... 4
Commissioning .......................................................................................................................................... 4
Start-up ...................................................................................................................................................... 4
Normal Operation ...................................................................................................................................... 6
Flame Shaping........................................................................................................................................... 6
Multi-burner Balancing ............................................................................................................................... 7
Shutdown ................................................................................................................................................... 7
Gas or Oil Firing......................................................................................................................................... 7
RSFC Burner Handling and Maintenance ..................................................................................................... 8
Introduction ................................................................................................................................................ 8
RSFC Burner Hardware............................................................................................................................. 8
Vendor-Supplied Equipment ...................................................................................................................... 8
Receiving and Unloading Instructions ....................................................................................................... 9
Special Handling Instructions .................................................................................................................... 9
Maintenance ............................................................................................................................................ 10
General ................................................................................................................................................ 10
Air Register Assembly.......................................................................................................................... 10
Throat ................................................................................................................................................... 10
WRHI Air Cooled Oil Gun............................................................................................................................ 10
General .................................................................................................................................................... 10
Load Carrying Oil Guns........................................................................................................................ 11
Description ............................................................................................................................................... 11
Stationary Union ................................................................................................................................... 12
Removable Oil Gun .............................................................................................................................. 13
Operation ................................................................................................................................................. 13
Maintenance ............................................................................................................................................ 16
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Orifice Tip Wear Classification and Flow Calibration ........................................................................... 16
SAMA Control Logic Operating Description ................................................................................................ 17
Background ............................................................................................................................................. 17
References .............................................................................................................................................. 18
System Configuration & Overview ........................................................................................................... 18
Air Flow Control.................................................................................................................................... 18
Control Scheme Review .......................................................................................................................... 21
Sheet 1 – EB0-007991-1D9328 – Index of Sheets and Symbols ............................................................ 22
Sheet 2 – EB0-007991-1D9329 – Burner Counts (El. 1 – 3) ................................................................... 22
Sheet 3 – EB0-007991-1D9330 – Burner Counts (El. 4) and Air Flow Feedback ................................... 22
Sheet 4 – EB0-007991-1D9331 – Air Flow Setpoint Development – General ........................................ 22
Sheet 5 – EB0-007991-1D9332 – Set RSFC Burner Outer Drive to Minimum Signals........................... 23
Sheet 6 – EB0-007991-1D9333 – RSFC Burner Outer Damper Purge Flag and Miscellaneous
Signals ..................................................................................................................................................... 23
Sheet 7 – EB0-007991-1D9334 – Outer (Tertiary) RSFC Damper – Air Flow Control Setpoint –
Final (El. 1) .............................................................................................................................................. 24
Sheet 8 – EB0-007991-1D9335 – RSFC Burner Outer Damper Control (El. 1) ...................................... 24
Sheet 9 – EB0-007991-1D9336 – Header Air Damper (K10) Control ..................................................... 25
Sheet 10 – EB0-007991-1D9337 – RSFC Burner Inner Damper Control ............................................... 26
Other Considerations ............................................................................................................................... 26
Fuel Flow Demand ............................................................................................................................... 26
Fuel/Air Cross-Limiting......................................................................................................................... 27
Reference 5 (Case Studies)................................................................................................................. 27
LIST OF TABLES
Table 1: RSFC Burner Operating Parameters at MCR ................................................................................. 6
Table 2: RSFC Burner Flame Shape versus NOx Emissions ....................................................................... 6
Table 3: Air Flow Scheme Summary (Present State to Future State)......................................................... 21
LIST OF FIGURES
Figure 1: Typical Low NOx RSFC Burner Air/Fuel Flow Fields ..................................................................... 2
Figure 2: Flow vs Pressure for No. 2 Oil with N19 Tip ................................................................................ 11
Figure 3: Flow vs Pressure for No. 6 Oil with N2 Tip .................................................................................. 12
Figure 4: Spray Parts for Oil Gun Nozzle Tip .............................................................................................. 14
Figure 5: Unit Burner Firing Arrangement ................................................................................................... 18
Figure 6: Current Airflow Schematic (Legacy Installation) .......................................................................... 19
Figure 7: RSFC Burner Configuration ......................................................................................................... 20
Figure 8: Future State Airflow Schematic (Post Installation) ....................................................................... 21
PAMPA AIR DAMPER CONTROL METHODOLOGY ........................................................................ REV B
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
DRAWINGS
DRAWING NUMBER
RSFC Burner General Arrangement – Sheet 1 ..............................................................EB0-007991-1E9250
RSFC Burner General Arrangement – Sheet 2 (Demolition) .........................................EB0-007991-1E9251
RSFC Burner General Arrangement – Sheet 3 (Restoration) ........................................EB0-007991-1E9252
RSFC Burner General Arrangement – Sheet 4 (Burner Locations) ...............................EB0-007991-1E9253
RSFC Burner Arrangement ............................................................................................EB0-007991-1E9258
RSFC Burner Final Assembly ........................................................................................EB0-007991-1E9259
RSFC Throat Refractory.................................................................................................EB0-007991-1E9306
RSFC Fuel Assembly .....................................................................................................EB0-007991-1E9320
SAMA Control Logic Diagram – Sheet 1 ....................................................................... EB0-007991-1D9328
SAMA Control Logic Diagram – Sheet 2 ....................................................................... EB0-007991-1D9329
SAMA Control Logic Diagram – Sheet 3 ....................................................................... EB0-007991-1D9330
SAMA Control Logic Diagram – Sheet 4 ....................................................................... EB0-007991-1D9331
SAMA Control Logic Diagram – Sheet 5 ....................................................................... EB0-007991-1D9332
SAMA Control Logic Diagram – Sheet 6 ....................................................................... EB0-007991-1D9333
SAMA Control Logic Diagram – Sheet 7 ....................................................................... EB0-007991-1D9334
SAMA Control Logic Diagram – Sheet 8 ....................................................................... EB0-007991-1D9335
SAMA Control Logic Diagram – Sheet 9 ....................................................................... EB0-007991-1D9336
SAMA Control Logic Diagram – Sheet 10 ..................................................................... EB0-007991-1D9337
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RSFC™ Burners Low NOx Firing System
INTRODUCTION
The ALSTOM Power, Radially Stratified Flame Core (RSFC) burner is designed
to burn atomized oil, and/or natural gas in industrial and utility wall-fired boilers
while maintaining unit performance and meeting environmental requirements for
opacity, nitric oxide (NOx), and carbon monoxide (CO) emission levels.
The RSFC burner applies three principles associated with low NOx fossil fuel
firing.
•
Early ignition of the fuel under fuel-rich conditions
•
Staging the combustion process
•
Increasing the residence time of fuel
To apply the above principles, the RSFC burner injects the fuel in a concentrated
stream via a fuel nozzle surrounded by three concentric air zones. Near burner
ignition is accomplished by creating a recirculation area near the fuel nozzle exit
where there is a fuel-rich zone.
To stage the combustion process, the RSFC burner swirls the cooler, higher
density combustion air around the hotter, lower density, fuel core. Centrifugal
forces created by the swirling combustion air delay the mixing process with the
fuel. Fuel residence time within the flame zone is increased by controlling the
velocities exiting the fuel nozzle and the three combustion air zones. Differences
in the velocities create internal recirculation patterns within the flame. Refer to
Figure 1.
The RSFC burner system for Pampa Energy Units 29 and 30 are composed of
the following: Refer to drawings EB0-007991-1E9250, EB0-007991-1E9251,
EB0-007991-1E9252, EB0-007991-1E9253, EB0-007991-1E9258 and EB0007991-1E9259.
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CONTRACT: EB0-007991
•
Three-zone Combustion Air Registers
•
Combustion Air Shutoff/Biasing Damper
•
Shutoff/biasing Air Damper Actuator
•
Primary & Tertiary Swirl Vane Positioners
•
Refractory Burner Throat
•
Observation Ports
•
3” Bluff Body Ignitor
•
Air Cooled Oil gun
•
Natural Gas Gun Assembly
•
Flame Scanner(s)
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
II. Macro-Mixing
I. Stratification
Air
Tertiary Air
Secondary Air
Primary Air
Fuel Gun
Fuel-Rich Core
Primary Air & Fuel Mix
to Create Fuel-Rich
Flame Core
Flame Front
Unique Throat
Design
Figure 1: Typical Low NOx RSFC Burner Air/Fuel Flow Fields
RSFC BURNER DESCRIPTION
Tertiary and Primary Combustion Air Shutoff/Biasing Dampers
The combustion air shutoff/biasing dampers are circular dampers designed to
bias the combustion air between the three air zones in the RSFC register. There
are two shutoff/biasing dampers per burner. One damper is used to control the
airflow into the tertiary air zone, while the other shutoff/biasing damper controls
the airflow into the primary zone.
The primary and tertiary air zone biasing dampers are controlled by two Rotork
electrically operated linear actuators.
The linear actuator positions the
combustion biasing air damper between two positions (closed or an optimized
open position that may not be the full open position) in order to optimize the
RSFC burner flame shape and emissions.
NOTE
Optimum position of the combustion air-biasing damper will be
determined during commissioning.
Three-zone Combustion Air Register
Combustion air is supplied to the RSFC burner through three concentric air
zones. The concentric air zones are defined as the primary, secondary, and
tertiary air zones.
Tertiary air is supplied to the outermost concentric air zone. Swirl is induced by
the use of swirler vanes and fixed block assemblies. The adjustable swirler
vanes, located between fixed block assemblies, control the direction of the airflow
through the tertiary air zone. Depending on the position of the vanes, the tertiary
air will be introduced tangentially or radially into the tertiary air zone, creating
more or less swirl respectively.
Secondary air is supplied to the middle concentric air zone through a space
provided between the primary and tertiary air assemblies. Swirl is created by
fixed axial swirler blades. The secondary air zone produces a consistent swirl
over the entire load range of the RSFC burner.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Primary air is supplied to the inner concentric air zone. Swirl is generated by the
use of swirler vanes and block assemblies, similar to those used in the tertiary air
zone.
The adjustable swirler vanes, located between block assemblies, control the
direction of the airflow through the primary air zone. Swirler vane position is used
to vary the swirl in the primary air zone between a minimum setting to a maximum
setting (0% setting will be tangential flow and 100% is axial flow).
Depending on the position of the vanes, the primary air will be introduced
tangentially or axially into the primary air zone.
Air Swirler Vane Positioners
The tertiary and primary air swirler vanes are positioned by manual, gear-driven,
linkage mechanisms located externally on the face of the burner. The vanes are
positioned based on optimum flame structure and burner performance
established during commissioning.
Burner Throat Refractory
The burner throat refractory is designed and shaped for optimal burner
performance. The design of the refractory throat is very important for proper
flame shaping and stability. ALSTOM Power Inc. strongly recommends that "BluRam HS" plastic ramming refractory, manufactured by Vesuvius, Inc. should be
used for the refractory throats.
This refractory has proven to be durable and low maintenance when installed and
cured as recommended. Refer to drawing EB0-007991-1E9306 for the proper
throat shape and recommended curing procedure.
RSFC FUEL ASSEMBLY
The centrally located fuel assembly is capable of firing oil, or natural gas. The
fuel assembly is located in the center of the air register.
The fuel assembly consists of a flanged outer assembly, that that allows gas to
flow between the outer wall and an inner guide pipe. Natural gas is supplied
through the flanged inlet on the side of the fuel assembly and flows between the
outer wall and inner guide pipe, the gas is discharged into the furnace through a
low momentum gas nozzle at the furnace end of the fuel assembly. The center
guide pipe, allows an oil gun to be mounted in the center of the fuel assembly.
Cooling air is supplied through a connection on the center guide pipe. The
cooling air allows the oil gun to remain in the guide pipe even when the oil gun is
not in service.
Combustion air is supplied around the fuel nozzle through the three concentric air
zones. This arrangement provides for stable combustion and eliminates furnace
pulsation typically associated with multi-burner installations.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
OPERATION
The following instructions are intended to serve as a guide to the sequence of
events that should occur during the commissioning of the RSFC burner. It is not
intended to give specific instructions regarding original equipment transporting
fuel and air to the burner. Operating parameters, setpoints, and curves
necessary to operate the RSFC burners will be established during
commissioning of the burner. ALSTOM Power recommends that plant
personnel become familiar with the equipment and associated controls prior to
initial start-up and commissioning.
NOTE
The Burner Management System and Unit Combustion Control
System (supplied by others) provides for the safe
startup/shutdown sequences and operation of the RSFC burner.
The control systems incorporate required interlocks necessary to
ensure safe and correct operation of the RSFC burners and the
unit.
Commissioning
Prior to initial unit start-up, conduct a general check of all RSFC burner
components. This check should include at least the following:
1. Check the RSFC burner primary and tertiary swirler vane mechanisms to
ensure full range of travel. Stroke and calibrate the positioners.
2. Check and stroke the combustion air shutoff/biasing damper from full
open to full closed position to ensure that is does not bind.
3. Ensure that all associated trim piping to the burner has been blown clear
of debris.
4. Verify that the RSFC burner and refractory throat area is clear of debris.
5. Ensure that all commissioning checks for the fuel nozzles have been
completed.
6. Ensure that the burner components (ignitor, oil gun, gas gun, and flame
scanners etc.) are installed per the manufacturer’s instructions.
Start-up
1. The initial commissioning lightoff procedure requires that the primary
dampers are typically positioned 25.4mm (1”) open and the tertiary air
dampers are closed for the out-of-service burners.
2. Note that it may be necessary to open some of the primary and tertiary
air dampers on some of the out of service burners in order to establish
the minimum 30% airflow through the unit in preparation for the furnace
purge.
3. Maintain the primary air damper 1” open while keeping the tertiary air
dampers closed on the RSFC burner(s) that will initially be started first.
As a starting point until commissioning determines the optimum
positions, the manual gear driven primary air swirl vanes should be
positioned to the 20% tangential position. The manual gear driven
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
tertairy swirl air vanes should be positioned to 15% tangential position for
ignitor light off.
4. Establish the minimum 30% unit airflow and purge the furnace. As
required by the burner management system (supplied by others) A unit
purge will typically require a five minute purge period.
NOTE
The minimum windbox-to-furnace differential for the RSFC
burner is approximately 25.4mm (1.0" w.g.) with preheated
combustion air.
5. At the completion of the purge, leave the burner dampers and swirl vanes
in the position set during the boiler purge.
NOTE
Operate all boiler vents and drains in accordance with the original
boiler manufacturer’s operating instructions.
5. Light the gas ignitors. (Refer to the Tab 2).
NOTE
The ignitor pipe trains have been designed to light one RSFC
burner each. All damper and operation permissives must be
satisfied for ignitors and associated burners before an ignitor
start can be initiated. Refer to the burner management system
for details concerning the burner management start permissives.
6. Operate the oil gun or gas gun through the burner management and
combustion control system per manufacturer recommendations.
7. Control the firing rate to bring the unit up to temperature and pressure
according to the manufacturer’s recommendations.
8. Additional burners may be brought into service as dictated by unit load
and heat rate requirements.
9. Adjust fuel flow (firing rate) to achieve the desired steam pressure rise,
while monitoring boiler oxygen level and adjusting unit air flow as
required.
At steam flows above 30%, air flow should begin to be adjusted so that at
maximum boiler steam flow the measured oxygen operating level is
typically maintained at approximately 3%.
10. Using the appropriate safety measures, the boiler operator should inspect
the furnace conditions to ensure stable and safe combustion
11. With safe, stable combustion in the furnace having been confirmed,
remove the appropriate ignitors from service on that elevation and
operate main gas or oil as required.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
NOTE
The following parameters should be used as a guideline for
operation and tuning of the RSFC burner during normal full load
operation:
Primary Air Swirl Vanes (% Tangential)
Modulates with load to maintaining
windbox to furnace delta- P
20
Tertiary Air Swirl Vanes (% Tangential)
15
Furnace Pressure ( wg)
-7.62 (-0.30)
Windbox Pressure ( wg)
101.6 mm (4.0 – 4.5)
Oxygen @ Furnace Outlet (%)
3%
Tertiary Air Shutoff Damper
Table 1: RSFC Burner Operating Parameters at MCR
Normal Operation
Normal operation is defined as boiler conditions that are steady and stable at or
near full load capacity. This is the condition when RSFC burner adjustments
should be made to optimize emissions and unburned carbon loss. The following
notes should be used as guidelines to tune the burners.
Flame Shaping
The RSFC burner has been specially designed to allow control of the burner
flame shape. The physical appearance of the flame shape can be used as an
indication of NOx emission levels, opacity and/or unburned carbon levels.
Individual RSFC burner tuning can be performed by adjusting the RSFC burner
components based on visual inspection of the flame shape.
The following table characterizes the RSFC burner flame shape with respect to
NOx emissions.
UBC/Opacity
Discussion
Long and Narrow
NOx
Emissions
Lower
Moderate
Short and Wide
Higher
Lower
This is the desired RSFC flame condition.
This flame condition will usually occur with the
primary vanes set to 0 – 20% tangential
position, and the tertiary air vanes adjusted to
0 – 15% tangential.
This is not the optimum RSFC flame
condition. Temporarily moving the primary air
vanes to the 100% tangential position will
usually re-establish the proper flame shape.
Once the longer flame shape is present, the
primary air vanes can be reset to 75 - 100%
tangential.
Flame Shape
Table 2: RSFC Burner Flame Shape versus NOx Emissions
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Essential requirements that must be met when tuning RSFC burners by flame
shaping are:
•
The flame must be stable
•
The ignition point should be within 6” of the burner throat
•
The burner flame should fit within the physical constraints of the
furnace and should not contact the furnace walls or other burners
•
Superheater outlet temperature constraints must be maintained
Multi-burner Balancing
Wall fired boilers often produce combustion conditions that may be stratified
across the boiler.
In order to minimize oxygen and carbon monoxide stratification across the boiler,
several variables can be checked to determine how well the fuel/air ratios are
balanced on a per burner basis. Those variables are:
•
Percent O2 and CO across the airheater gas inlet duct of the unit
•
Unburned carbon loss and/or particulate loading
•
Superheater temperature profile
•
Individual gas or oil gun firing rate
Specific methods to gather this data will vary with unit geometry and equipment.
Two suggested methods to achieve balanced burner air/fuel ratios are:
•
Balance the fuel flow to each burner
•
Bias the primary and/or tertiary shut off dampers from burner to burner to
redistribute the air to the side of the furnace with the highest CO
measurements, or the lowest O2 measurements. Biasing of the
combustion air involves balancing the amount of combustion air going to
burners.
NOTE
Biasing the combustion air between burners may be effective at
reducing the impact of unequal fuel distribution between burners.
However, for maximum efficiency, it is often preferable to
balance the fuel flow to each burner before adjusting the biasing
air dampers.
Shutdown
Burner shutdown is essentially the reverse of the start-up procedure. When
reducing total fuel input into the furnace, ensure that the combustion airflow is
reduced in proportion to unit load reductions.
Gas or Oil Firing
1. To shutdown the burner begin reducing fuel flow to the associated
burners. Re-light the burner’s associated ignitors just before the oil or
gas gun become unstable. This will stabilize the burner at low loads to
prevent a flame failure trip due to loss of flame indication by the flame
Scanners..
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
2. When minimum burner firing condition is reached shutdown the oil or gas
gun in service. If oil firing was in service it will be necessary to scavenge
the oil guns on the burners being shut down.
3. When scavenging the oil guns the ignitors should remain in service
during the scavenge period to burn the fuel being purged from the oil
guns.
4. At the end of an oil gun scavenging period (assuming oil guns were in
service on the pair of burners being shut down), shutdown the ignitors. If
gas firing was in service the igniters can be removed from service
immediately after the gas guns have been shutdown.
5. If oil guns were in service they may now be removed for cleaning and/or
maintenance (as required) while the associated burners are out of
service.
Exercise caution when removing hot oil guns from the
burners as they can cause injury to personnel if not properly
handled.
RSFC BURNER HANDLING
AND MAINTENANCE
Introduction
Each burner is equipped with two manual rotary actuators for the control of the
primary and tertiary swirled vanes, and two Rotork electrically operated actuators
for the control of the primary and tertiary shut-off/biasing air damper.
RSFC Burner Hardware
The frequency of maintenance will vary from unit to unit and is best determined
from the actual experience. The RSFC burner hardware should not require
routine maintenance other than the repair of the refractory throat. However, the
following items should be routinely inspected during periodic outages.
•
Full range stroke the swirl vanes and biasing air damper
•
Warping or cracking of combustion air swirl vanes; swirl vane connecting
shafts and linkages; secondary air axial swirled; concentric annuli; etc.
•
Stress cracking in the welds
•
Condition of metal Throat
Vendor-Supplied Equipment
For operation and maintenance instructions on vendor-supplied equipment for the
RSFC burner, refer to Tab 4 of this manual.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Receiving and Unloading Instructions
Upon arrival at the job site, each RSFC burner should be closely inspected for
damage that may have occurred as a result of shipping or handling. Any damage
or unusual conditions should be reported to the shipping company and ALSTOM
Power Customer Services at once.
Each burner should be inspected for satisfactory rotation of both the primary and
tertiary manual swirled vanes. The primary and tertiary linear shut-off/biasing
damper should move back and forth on the wheeled track with minimal effort.
Any problems that are observed should be reported immediately.
The RSFC burners should be carefully unloaded from the shipping truck and
uncovered.
Each burner and all associated packages should be carefully inventoried and
compared to the shipping bill of materials and pertinent drawings to ensure that
all parts have been received. Any missing parts should be reported to ALSTOM
Power Customer Services immediately.
NOTE
If the RSFC burners must be stored on-site prior to installation, it
is recommended that they be kept covered in a dry indoor
location. Outside covered storage is not recommended without
the express written approval of ALSTOM Power Customer
Services.
During storage, it is recommended that the primary and tertiary shut-off/biasing
air damper electric linear actuators, that are shipped loose, be protected and
stored in the original shipping boxes in a dry environment. The manual rotary
vane actuators for both the primary and tertiary air swirled vanes should be kept
fully lubricated and protected from damage and moisture. The RSFC air registers
should be kept covered and dry with protection from damage and moisture during
storage.
Special Handling Instructions
Each RSFC burner is equipped with two lifting lugs that are to be utilized for
moving the burner from the ground floor of the plant up to the main operating
floor.
CAUTION
Proper rigging and lifting practices consistent with safe
industry practices must be followed when moving and
installing the RSFC burner.
Use extreme care when
handling of the RSFC burner. Do not dent, bend or twist the
air register assembly.
Each RSFC burner is also equipped with a shipping block welded to the bottom of
the tertiary air inlet zone. This block, which must be removed during installation,
is provided to maintain the burner in a level and horizontal position during storage
and shipping.
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To ensure trouble free operation of the RSFC burner, with no binding or
interference, the RSFC burner should be handled carefully. A great deal of effort
has gone into the design and fabrication of each RSFC burner in order to
maintain trouble free characteristics. ALSTOM power, Customer Services shall
not be held liable for damage caused by inadequate storage or handling
practices.
Maintenance
General
The RSFC burner is designed for minimal maintenance requirements. The
primary and tertiary air swirled vane actuators should be maintained as described
by the manufacturer. The primary and tertiary shut-off/biasing air damper electric
actuator should be maintained as recommended by the manufacturer. Reference
Tab 4 of this manual.
The RSFC burner uses premium materials and design in order to provide the
user with long operational life.
Parts of the burner that are subject to high temperatures are manufactured from
various grades of stainless steel. It is strongly recommended that the entire
RSFC burner assembly be closely inspected during each boiler outage for
erosion, wear, overheating, warpage or other signs of damage. Regular
inspection and burner maintenance will maintain the RSFC burner in good
operational condition and prevent major damage from occurring.
Air Register Assembly
The RSFC Air register assembly is designed with minimal maintenance
requirements. Other than routine outage inspections, no maintenance should be
required unless an unusual operational problem results in burner damage.
All RSFC air register linkages may be replaced from outside the windbox.
Externally replaceable spring loaded Teflon seals surround each swirler vane
stainless steel shaft, and the primary zone shut-off/biasing air damper adjustment
rod.
All swirler vanes and shut-off/biasing air dampers should be operated during each
outage to ensure that full stroke operation is possible. Any binding should be
investigated and repaired immediately.
Throat
The RSFC burner utilizes a unique throat design. Any repairs to the throat should
conform to the design as shown on the contract specific drawing EB0-0079911E9306.
WRHI AIR COOLED OIL GUN
General
Each RSFC burner assembly is equipped with a wide range horizontal Internal
Mix (WRHI), parallel pipe, air-cooled, oil gun for the firing of oil atomized by either
air or steam.
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The guide pipe can accommodate either a air atomized warm-up oil gun firing No.
2 oil or a steam atomized load carrying oil gun firing No. 6 oil. The basic
differences between the two oil gun assemblies are in the removable sections:
Load Carrying Oil Guns
Load carrying oil guns have been supplied for operating the boiler at full load
when gas firing is not in service.
The load carrying oil gun’s will fire No. 6 oil and use an N-2 oil gun tip with a 60
degree spray angle. These tips require a 103 kPa (15 psig) differential between
the oil pressure and the atomizing steam pressure. Refer to the curves in Figure
3.
Description
The oil gun consists of two major sub assemblies; the oil gun stationary union
and air-cooled oil gun removable part. Removable sections for the warm-up and
load carrying are of two sizes, but their appearance in illustrations are basically
identical.
Figure 2: Flow vs Pressure for No. 2 Oil with N19 Tip
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Figure 3: Flow vs Pressure for No. 6 Oil with N2 Tip
Stationary Union
The stationary union is attached to the 88.9 (3.5") O.D. x 4.0 (0.157”) wall oil gun
guide pipe. This air-cooled pipe is welded to the RSFC burner’s front plate.
Oil gun cooling air is provided through a 60.3 (2.37") connection on the guide tube
assembly. The cooling air passes through the inside of the connecting tube and
stationary guide pipe to provide cooling at the oil gun spray nozzle tip.
3
Cooling air supplied to each oil gun should be 2.1m /m (75 SCFM) at 1.5 to 2 kPa
(6 to 8" wg) above furnace pressure.
The stationary union, seal welded to the guide pipe assembly, admits oil,
atomizing, and scavenging air/steam to the oil gun, and serves as a coupling for
the removable oil gun. A hinged cover assembly on the stationary union provides
sealing for the connecting tube when the oil gun is removed for maintenance.
A safety air latch assembly consisting of a spring-loaded pin located at the
stationary union provides a means of latching the stationary union cover plate into
the stationary union internally.
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CAUTION
Stationary union cover plate must be latched in place whenever
the oil gun is removed. This will prevent the other oil guns and
scanners from losing their cooling air due to an open flow path
from the guide pipe.
The gun engagement limit switch, mounted on the stationary union, is actuated by
oil gun guide pin attached to the removable union of the oil gun and provides
feedback to the BMS, indicating that an oil gun is coupled.
A short pin is used with the No. 6 load carrying oil guns and provides indication
when the oil gun is coupled in place.
When coupling an oil gun into the stationary union, ensure that new gaskets are
inserted between the stationary and removable unions. The gaskets seal off the
joints between the oil and atomizing air/steam ports in the stationary and
removable unions.
Removable Oil Gun
The removable part of the oil gun consists of the removable union, two parallel oil
pipes, a flexible hose section, and a spray nozzle assembly. The purpose of the
parallel arrangement of the oil gun pipes is to separate the air/steam and oil until
the mixing point in the nozzle is reached, and to minimize the temperature effect
of one medium on the other.
The flexible hose section serves to absorb differences in expansion between the
pipes. A guide on the oil gun pipes maintains the concentric position of the gun in
the guide pipe.
The load carrying oil gun has an N-2 tip. The gun consists of a spray plate and a
back plate, which are secured to the nozzle body by means of an air cooling
nozzle cap made of type AISI 416 Stainless Steel.
The nozzle cap has a series of slots located around the outer perimeter of the
nozzle cap that allows the cooling air in the guide pipe to pass through the nozzle
cap for cooling purposes.
The atomizing air/steam entering the oil gun through the upper port of the union,
and oil entering through the lower port are carried separately through the entire
length of the gun by two parallel oil gun pipes. Oil connects to the nozzle body
outer ports and the atomizing steam connects to the inner port of the nozzle body.
The oil passes through the small inner holes in the backplate. Atomizing
air/steam passes through the outer holes of the backplate and then across the
radial cuts in the backplate where it mixes with the oil. The steam/air atomized
oil mixture is then forced from the center of the sprayplate out into the furnace.
Operation
Oil gun operation should be controlled by the BMS (BMS not supplied by
ALSTOM Power), which provides for proper operating sequences such as valve
opening and closing. The BMS also monitors operating conditions such as
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
pressure, flow, gun and valve positions, and generates an automatic shutdown
when unsatisfactory conditions are detected.
Figure 4: Spray Parts for Oil Gun Nozzle Tip
In addition to any features provided by the control system, the following basic
rules always apply:
1. Prior to initial firing:
•
Purge the furnace for at least five minutes.
•
Check fan and damper regulating equipment manually for proper
operation through the entire range.
2. If light oil preheat is required [minimum 38°C (100°F)], throttle the
recirculating valve (if manual) after placing the oil gun in service to
maintain proper oil temperature and pressure consistent with system
requirements.
3. Make sure that the ignitors associated with the oil guns to be started are
operating properly. Always use an ignitor to ignite an oil gun. Never
attempt to light off one gun from another gun in service.
4. Use proper setting of the secondary air dampers.
5. Before inserting an oil gun, inspect the gun for proper assembly of
backplate and sprayplate. Make sure stationary union gaskets are in
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place. When lighting a gun, verify by visual observation that ignition
takes place immediately after opening the oil supply valve.
If ignition does not take place or is very unstable, shut off the oil and
remove the gun for servicing after scavenging.
NOTE
Do not relight the same gun unless the cause of non-ignition has
been determined and corrected.
6. When placing an oil gun in service, always admit air/steam to the gun
before the oil.
7. When taking the oil gun out of service, it must be scavenged. Shut off
the oil first, then open the air/steam crossover (scavenge) valve,
admitting air through both ports immediately after shutdown. After
scavenging, close all valves. Cooling air to the oil gun should remain in
service
whether
or
not
the
oil
gun
is
in
operation.
Exercise Caution when removing a hot oil gun from the guide pipe for
servicing. Stationary union cover must be latched in the closed position
over the guide pipe whenever the oil gun assembly has been removed.
NOTE
•
Before an oil gun can be scavenged, the adjacent ignitor must be
in operation. If the adjacent ignitor is not available, do not
scavenge the gun. Attempt to re-establish ignitor and then
scavenge. If the oil gun is left unscavenged in a hot furnace the
oil gun tip may coke and it will be necessary to remove,
disassemble and manually clean.
•
If the oil gun is tripped due to an MFT the furnace should be
purged, ignition energy re-established then start the oil gun. If
the oil gun is to be shutdown scavenge the oil gun and then
shutdown.
If the oil gun must be removed without scavenging, exercise
extreme caution as hot oil can burn. During the removal of
un-scavenged oil gun from the guide pipe, hot oil may leak
into guide pipe. This oil has the potential to ignite.
8. It is essential to give careful attention to oil combustion conditions during
initial firing of a cold furnace. Potential damaging deposits of oil vapors
and carbon on surfaces may occur by carryover of un-burned fuel during
this critical period.
9. Poor combustion conditions are generally indicated by the following:
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•
Unstable ignition point
•
Smoky tails on the flame
•
Visible haze in the furnace outlet
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10. Incomplete combustion can be caused by the following:
•
Inadequate atomization due to low oil temperature and/or improper
oil or atomizing steam pressures
•
Fouled nozzle parts due to insufficient cleaning
•
Improper secondary air distribution due to less than optimum position
of the oil compartment damper
Maintenance
Uniform oil flow distribution throughout the furnace greatly influences satisfactory
unit operation. Uniform oil flow is a function of pressure deviations between guns,
gun cleanliness, and out-of-tolerance tip orifice dimensions due to wear.
Consequently, periodic tip calibrations and oil gun maintenance procedures are
recommended to ensure equal flow from each oil gun assembly, consistent
quality of atomization, and minor deviations in spray angle.
The resultant flow increase associated with atomizer orifice tip wear directly
influences uniform oil gun flow rate. Periodic measurement of tip orifices to
determine the degree of wear will eliminate the possibility of using tips which
exhibit wide ranges in oil flows. Classifying tips with regard to wear permits
extended usage of worn tips, provided that tips in the same percentage-of-wear
category are used uniformly in the unit.
Orifice Tip Wear Classification and Flow Calibration
The purpose of classifying orifice tips in groups, based on wear, is to define a
maximum allowable degree of wear, and to prevent simultaneous use of tips that
exhibit differing ranges of wear. Tip orifices are to be classified into three groups,
using the resultant flow increase due to wear as the criteria for group
classification. A 10% flow increase defines the maximum allowable degree of
wear. Discard tips exhibiting this level of wear.
Wear Classification
Effective Flow Increase
A
3 to 5%
B
5 to 7%
C
7 to 10%
The effective flow increase is approximately equal to the percentage of increase
of the orifice tip diameter squared.
Do not use worn tips from different wear groups (A, B, and C) simultaneously;
use of worn tips within a particular wear group, however, is permissible.
Experience and wear measurement for fuel oil and/or fuel additives causes
erosion patterns. Again, as noted above, wear measurement is not based on an
internal mechanical ID measurement. Rather, it is based on pressure versus flow
measurement results. Refer to Figures 2 and 3. This usually dictates the time
span between detailed maintenance inspections. During the initial operating
period of new oil gun tips, adhere to the following detailed maintenance
procedure every four to six weeks.
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1. Disassemble atomizer assembly (cap nut, sprayplate, and backplate) and
tag disassembled items with gun number.
2. Hang gun in rack with the nozzle body in solvent.
3. Clean oil gun parts using a solvent or similar cleaning agent.
4. Inspect nozzle body and hoses.
Clean nozzle body return holes with appropriate drill size. (Do not use a drill
motor; a "T" handle is recommended.)
To clean the spray plates, secure the front portion of the nozzle body in the vise
jaw and remove the nozzle cap.
1. Clean face of nozzle body and lap to true surface removing any
bypassing marks.
2. Check the nozzle cap cooling air holes to ascertain they are free from
obstruction.
3. Wear from bypassing can be determined by a light lapping of gun parts.
Worn parts are to be replaced or lapped true.
4. Reassemble gun with gun nut cap tightened 270 N-m (200 ft-lb torque
maximum).
5. Appropriately mark reassembled gun with wear classification data (when
maintenance procedures and wear classification records are complete).
Experience has proven that satisfactory unit operation is influenced by oil gun
maintenance and the regulation of pressure deviations between guns within the
allowable limits for the respected design of fuel atomization.
Do not disturb the seal formed by the machined surfaces of nozzle plates by
scraping these surfaces with a sharp object or by insufficient cleaning. When
making up a gun after cleaning, be sure that the nozzle plates are properly
assembled. Avoid overtightening the nozzle cap 270 N-m (200 ft-lb) is
recommended. Apply high temp Antiseize (Bostik Antiseize V00-1888 or
equal) compound sparingly to the nozzle threads to avoid binding under
excessive heat.
After a few weeks of operation, a proper cleaning schedule can be established
which will result in reliable operation of the oil firing equipment.
SAMA CONTROL LOGIC
OPERATING DESCRIPTION
Background
The 2015/16 project by Alstom at Pampa Units 29 and 30 involves installation of
new RSFC burners in the boilers. The burners will be able to fire natural gas or
fuel oil based on supply availability and needs at any given time.
This new equipment requires proper direction in order to run as designed. This
document explains the air flow control scheme to be used for the burners. The
reader is directed to Reference 1 to explore the specific logic implementation
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
details. It may prove useful to cross reference those drawings while reading
through each section of this write-up.
References
1. SAMA Control Logic Drawings; EB0-007991-1D9328 through EB0007991-1D9337 [Alstom Drawings]
2. RSFC Burner Final Assembly; EB0-007991-1E9259; [Alstom Drawing]
3. Pampa P&ID for Air and Exhaust Lines; B52B-1246-080(A) h2/3; [Pampa
Drawing]
4. Pampa P&ID for Fuel Oil and Gas Burners; B53B-1246-093(A); [Pampa
Drawing]
5. Pampa Air Damper Control Methodology (PowerPoint Slides); 6/24/2015;
[Alstom Transmittal]
System Configuration & Overview
The main control definition provided to accommodate the new equipment being
provided is:
1. Air flow control
Air Flow Control
References 2 and 3 are the most relevant information sources to be considered
with regard to controlling air flow to the System.
The burner layout for both Units is as shown in Figure 5. There are four (4)
elevations of burners. Each elevation has six (6) individual burner registers.
Figure 5: Unit Burner Firing Arrangement
The legacy control scheme throttles air flow on an elevation basis and utilizes
“K10” header dampers to modulate delivery to the furnace feeds. A large
manifold or plenum is fed with secondary air from two separate sources (left and
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
right). That manifold is directly tied to each of the six burners on a given
elevation. Both the left side K10 and right side K10 drives may be simultaneously
adjusted to drive the desired airflow on an elevation basis at any instant in time.
Individual air flow measurements are made on both the left hand and right hand
sides of each elevation; a total record of air flow feedback is available for each
elevation.
The present layout of actuators and primary components is shown in the Figure 6
sketch for a representative elevation.
Figure 6: Current Airflow Schematic (Legacy Installation)
In the current project each of the burners (1 through 6 in Figure 6) will be
replaced with Alstom’s RSFC burner design. Each RSFC burner contains two
actuators that may be used to modulate air flow/distribution. A 3-D rendering of
the actual burner and a corresponding simplified sketch of the control
components is shown in Figure 7.
The outer (tertiary) slide damper is shown at the left of Figure 7 shaded in red,
while the inner (primary) slide damper appears in green on the three dimensional
view. Each linear actuator drives a rod down the central axis of the burner to
modulate the slide damper. Air flowing through the slide damper enters the
burner swirl block assembly which translates the airflow into a radial or axial flow.
The manual swirl block drives are used to set what percentage of burner airflow is
radial and what percentage is axial as it leaves the burner. When fully open the
outer damper accounts for approximately 70-75% of the total airflow to the RSFC
burner, while the inner damper achieves 10-15% of the total. Approximately 10%
of air flows through an intermediate zone in between the two dampers. There is
no actuator on that “middle” cross section.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Figure 7: RSFC Burner Configuration
The small diagram on the right-hand side of Figure 7 is a means to represent the
RSFC in two dimensions and re-iterate that there are two actuated dampers
present per burner assembly. The dampers are not physically “butterfly” in type
or design; they are shown in that fashion simply to represent the fact that two
actuators are present.
Once the new burners have been installed the future state for a typical elevation
of burners is as displayed in Figure 8.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Figure 8: Future State Airflow Schematic (Post Installation)
Once the new burners are installed, having actuators at each burner register
allows air flow control to be made more directly at individual furnace fuel supply
points as opposed to being at the more coarse elevation level.
A summary of the air flow control scheme present and future state considerations
is given in Table 3.
Table 3: Air Flow Scheme Summary (Present State to Future State)
Control Scheme Review
The details of the control logic will be covered in this section of the Operating
Description document. A drawing number reference will be listed that can be
found in the Reference 1 content. A description will follow that explains what
function is shown on the specific logic page.
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
Sheet 1 – EB0-007991-1D9328 – Index of Sheets and Symbols
This page provides a list of all symbols that are used throughout the logic
drawings. A table of contents is also shown stating what logic content is found on
each Sheet.
Sheet 2 – EB0-007991-1D9329 – Burner Counts (El. 1 – 3)
A series of counts is made on this page with respect to Boiler operating status for
burner Elevations 1, 2, and 3. Each burner may be operated with either natural
gas or fuel oil at the discretion of the operator. A burner may be fully off (no fuel
being supplied), or it may be in service firing gas or in service firing oil.
Typically a burner is identified as being “in service” when the following conditions
are true:
1. All shutoff valves are proven open and the corresponding vent valve
(where applicable) is proven closed based on limit switch feedback from
the devices.
2. The control logic is directing the burner to run.
3. There is proof of flame or sufficient ignition energy available to ensure
combustion is occurring.
The final definition for “Burner in Service” should be available within the system
BMS logic.
The number of burners in service for an elevation are counted here, for both oil
and gas. Elevations that have at least one burner in service are identified. All of
these simple math counts are used as part of the balance of the logic
development on other sheets.
Sheet 3 – EB0-007991-1D9330 – Burner Counts (El. 4) and Air Flow
Feedback
The same logic shown on Sheet 2 is repeated here for Elevation 4. On a single
11 x 17” drawing it was not possible to show the same information for all four
elevations and have it be legible. As a result the material was split between two
separate drawings.
Additional count logic is used to check how many elevations have no burners
operating (not burning any fuel).
The bottom section of the sheet takes the feedback information from all of the
header air flow rate transmitters (for both the right and left hand header sides;
see purple flow elements in Figures 6 and 8) and performs some simple addition.
The total secondary air flow rates to each elevation, and to the overall boiler are
computed.
Sheet 4 – EB0-007991-1D9331 – Air Flow Setpoint Development – General
A series of calculations is made on this page that tracks the preferred air flow
rates required for individual burner firing based on fuel type (oil/gas), fuel flow rate
per burner, and overall Unit load level.
These computed values indicate how much air flow would be necessary to
achieve exactly proper combustion throughout the Unit’s full load range. In
practice, proper air-to-fuel cross-limiting must be incorporated into the logic to
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
ensure safe operation at all times. As such, these individual calculations are
strictly available for comparison, reference information. They are not directly
used within the Logic, itself, to set individual air flow setpoint values. The reader
is directed to the Sheet 7 description to learn more about air flow setpoint
development for individual levels (elevations).
Sheet 5 – EB0-007991-1D9332 – Set RSFC Burner Outer Drive to Minimum
Signals
Some high level overrides are incorporated into the RSFC burner outer (tertiary)
drive control actions. These high level overrides will drive individual RSFC
burners to fixed output percentages under the conditions that are explained in this
section.
A tertiary air damper will be set to a minimum percentage open position when
either of the following conditions is true:
1. Boiler load is greater than 30% MCR AND the burner under consideration
is not in service
2. Boiler load is less than 30% MCR AND the burner under consideration is
not in service AND at least one of the other burners on the same
elevation is operational AND at least one of the other boiler elevations
has no burners running
The Unit has a minimum constraint where total airflow must never fall below a set
low threshold number (there must always be a minimum airflow provided
sweeping through the furnace). To help achieve the minimum airflow when the
Unit is fully off, air is directed through all elevations to ensure the requirement is
achieved. An additional air flow constraint is related to air flow transmitter
capability on each elevation (see the purple FM meters as shown in Figures 6
and 4). These transmitters can only physically register flow with any degree of
accuracy down to a minimum threshold rate. Anything lower than that value, and
the meter cannot output a usable air flow number for use in closed loop control
(the device signal output is constrained to 0 standard cubic meters per hour).
Once individual burners on some elevations begin to be activated, the control
scheme attempts to fix the other damper drives on those same elevations at a
minimum percentage open position. This helps to deliver sufficient air flow to the
elevation to maintain proper transmitter operation, while simultaneously trying to
route the local airflow required to support combustion.
To compensate for those actions, air must then be supplied to other regions
within the furnace in order to make sure the total minimum airflow constraint to
the Unit is still satisfied. That is why point 2. above is defined in the manner that it
is.
Sheet 6 – EB0-007991-1D9333 – RSFC Burner Outer Damper Purge Flag and
Miscellaneous Signals
Five minutes after an MFT occurrence each of the RSFC outer damper positions
are set at a fixed percentage open “purge position”. The RSFC outer dampers
help set the Unit airflow for purging during this period. NFPA code requires a
furnace to be sufficiently purged before an MFT may be cleared. Once a
successful purge execution has taken place via receipt of the “Purge Complete”
signal from the BMS, the dampers are released from this operating condition.
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In the second half of the page, total air flow based on flow meter feedback is
made for elevations where at least some combustion is taking place. If an
elevation has at least one burner in service, then the corresponding air flow for
that elevation is added to any other elevations that have at least one burner in
service. This yields an overall Unit air flow for the elevations that have some
combustion ongoing. If no combustion is occurring whatsoever throughout the
furnace then this total computed value is 0.
Sheet 7 – EB0-007991-1D9334 – Outer (Tertiary) RSFC Damper – Air Flow
Control Setpoint – Final (El. 1)
The existing DCS control logic as supplied in drawing C30B-1636-002(A) shows
the development of a boiler master signal that generates individual elevation air
flow setpoints that are fuel-cross limited. These setpoint(s) [four total, one
representative logic shown] help drive damper positions to achieve the necessary
Unit airflow for combustion. These existing signals should be re-used and
properly integrated with the new Alstom equipment.
If an elevation has combustion ongoing, or will have combustion progressing
soon, then the air flow setpoint for the DCS shall provide the value to feed the
downstream PI controller.
In the event that no airflow is required to support combustion (all burner fuel
feeds are closed and no combustion is expected) a check is made at the bottom
of the control loop with transfer switch T4. If total Unit operation is at or below
30% MCR, and no burners are in service on the given elevation, then a minimum
elevation airflow setpoint is generated. This value is used to ensure that the
minimum, overall Unit airflow need is still achieved. The minimum threshold air
flow for the entire Unit is taken and the actual air flow being delivered to any
elevations with at least some combustion ongoing is subtracted. That results in
the balance of airflow that must be passed through the Unit to ensure enough
sweep airflow is still present. The number is then divided by the number of
elevations that have no burners in service to compute the individual airflow
setpoint for those elevations.
The computed airflow rate for the elevation is conditioned one last time prior to
being finalized for outgoing signal 2/8 (on Sheet 7 defined as Elevation 1 Air Flow
Setpoint). A correction to the computed signal is made based on O2 trim. Within
the flue gas of the Boiler piping O2 sensors should be installed. The O2 sensors
continuously monitor the amount of oxygen present in the discharge gas to
atmosphere. If the detected O2 content is too low, the O2 trim computation
requests additional airflow via an increase in the feed setpoint. Conversely if the
O2 content is too high, the O2 trim computation directs less airflow via a
reduction in the feed setpoint.
O2 trim is used on boilers to help correct for for uncertainty in air flow sensor
measurement.
Sheet 8 – EB0-007991-1D9335 – RSFC Burner Outer Damper Control (El. 1)
This page provides the final control loop for the outer (tertiary) RSFC dampers.
Recall from Table 1 that these devices are used to set the air flow rate to
individual burner registers.
During full “auto” operating periods a PI computation is used to set the damper
position (via T1 transfer switch at the top of the drawing). The feedback for the
signal is the sum of the two flow meters for a given elevation (shown in purple on
Figures 6 and 8). The air flow setpoint is based on the outgoing signal labeled
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RSFC™ BURNERS LOW NOX FIRING SYSTEM
2/8 on Sheet 7 (read previous section for more information about that signal),
processed one final time in order to cross check the value to the sensor
capability. The cross check is described in the next paragraph.
When the following conditions are all true:
The elevation under consideration has no burners in service –AND–
Boiler operation is at or below 30% MCR
the logic takes the computed elevation air flow rate setpoint from Sheet 7 and
compares it to the minimum transmitter capability threshold value. Whichever
number is greater passes through and becomes the setpoint for the PI block. By
being defined in this manner the setpoint a given elevation requires will never be
below the transmitter range. Therefore the transmitter may be used in a true PI
block feedback implementation.
If the two bulleted conditions on the previous page are not both true, then the
setpoint to the PI block is simply the computed air flow rate setpoint that comes
directly from Sheet 7.
By defining the logic in this fashion, in conjunction with the minimum position
override for the tertiary dampers, the Unit airflow minimum of 30% may always be
achieved even with the air flow measurement capable range constraint.
There are four other potential damper positions possible based on logic, and as
follows:
•
The burner tertiary dampers are driven to a minimum percentage open
position when the “Set Burner XY Tertiary Air Damper to Minimum
Position” signal is true. A full discussion on the conditions that make up
that signal is given in the Sheet 5 discussion.
•
Selection of an appropriate “Minimum position” damper value will be
made during tuning of the Unit. The damper position must allow
sufficient airflow through the Unit elevation to drive enough flow where it
can be properly registered by the corresponding level’s flow transmitters.
•
The burner tertiary dampers are driven to a “Purge Position” (a fixed
percentage open) 5 minutes after a MFT has been tripped, but prior to
“Purge Complete” being delivered by the BMS. These fixed positions are
set to allow for sufficient airflow to fully Purge the Unit and help clear the
Master Fuel Trip latch.
•
When an MFT occurs, for five minutes from the instance of the trip the
tertiary (outer) air dampers are all fixed at the position they resided in
immediately preceding the trip. This is to drive compliance with NFPA
code; devices that help drive air flow to the Unit are to remain at their pretrip output conditions during this 5 minute period.
•
In the event of a MFT event where the System fans are compromised, a
post-purge fan trip is initiated. Here natural draft through the Unit is
promoted by setting all tertiary air dampers to their full open positions.
They remain that way until the post-purge fan trip has been cleared within
the BMS logic.
Sheet 9 – EB0-007991-1D9336 – Header Air Damper (K10) Control
The K10 header dampers in the future state implementation (with new Alstom
RSFC burners) no longer modulate to control air flow rate to the Unit. That
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
25
RSFC™ BURNERS LOW NOX FIRING SYSTEM
function is now controlled via the RSFC outer (tertiary) air dampers. As a result,
the K10 header damper control is highly simplified.
The new scheme is as follows:
The K10 dampers are set to a wide open position (100% open) for the majority of
the time. The only time the K10 dampers are not full open is as follows:
•
If all burners on a given elevation are not in service, and the Unit is above
30% of MCR then the associated K10 dampers are not full open, but
rather are set to some minimum position (15% for initial commissioning.
Note that the final percentage open value may be adjusted during tuning.)
When airflow is required to any burner the K10 dampers must be full open. If
airflow must be routed through an elevation to help achieve the minimum Unit
airflow then they must also be wide open.
Sheet 10 – EB0-007991-1D9337 – RSFC Burner Inner Damper Control
This sheet provides the control direction to the inner RSFC dampers as shown in
green on Figure 7. Recall that these dampers are being used to help set the
airflow distribution within a single RSFC burner. As mentioned in Table 2, the
control of these devices is based on an open loop schedule for operation. There
is no closed loop control with feedback from a sensor helping drive these
component’s movements.
The control for these devices is as follows:
•
If the burner is firing oil, the inner (primary) air damper position is set to a
fixed position based on a schedule tied to the total oil flow rate to the
burner. Oil flow to the burner at one rate will set one damper percentage
open, while a different oil flow rate will result in another output value.
•
If the burner is firing gas, the inner (primary) air damper position is set to
a fixed position based on a schedule tied to the total gas flow rate to the
burner. Gas flow to the burner at one rate will set one damper
percentage open, while a different gas flow rate will result in another
output value.
•
Immediately after a MFT trip the primary air dampers will remain frozen in
the position that they were sitting in just before the event took place.
They will stay at that percentage open value for five full minutes before
being released from that control mode.
•
If none of the above conditions is true, the inner dampers will be set to
their full closed, 0.0% open positions.
Note that since a flow meter is present on each elevation that measures the total
oil flow rate, and a separate flow meter is present on each elevation that
measures the total gas flow rate, the rate going to an individual burner is simply
computed by dividing by the number of burners that are active and firing the fuel.
Other Considerations
Fuel Flow Demand
Typically Unit operation is driven by an overall Boiler Master control. The Boiler
Master tries to maintain the required steam pressure to support desired electrical
generating output. If the steam pressure is not high enough, the Boiler Master
directs additional fuel to be fired, thereby generating more steam and helping
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
26
RSFC™ BURNERS LOW NOX FIRING SYSTEM
achieve the necessary Unit output. Similarly if the header steam pressure is in
excess, less steam is required. To generate less steam, less fuel needs to be
combusted in the furnace. The system throttling occurs via the Boiler Master.
The logic defined in this document and the Reference 1 drawings presumes that
a Boiler Master implementation already exists within the DCS. The airflow rates
required are all based on supporting the amount of fuel routed to each elevation,
and subsequently to each burner register.
It is assumed the Boiler Master also helps distribute where fuel is being burned
within the Overall Unit. Based on component sizing and design considerations, to
achieve full Unit MCR all 24 burners must be active. Throughout the process
going from full cold, full off conditions to rated MCR at different points in time
more burners must be brought online. How the controller determines how much
fuel to fire at the different elevations is assumed to already be defined within the
DCS control logic.
Fuel/Air Cross-Limiting
Another key element that should be incorporated into the Control logic is fuel/air
cross-limiting constraints. It is important when going from Unit full off conditions
toward greater and greater load, that airflow control should lead the fuel ramp-up
process. Feedback data from the air system should be the basis for authorizing
increases in setpoints of fuel operation. To prevent any safety concerns there
should always be more air present than fuel to allow for full reactant combustion
during the start-up or ramp up process. When shutting down from high load
levels, fuel flow should always be reduced before air flows are lowered. Again it
is critical to maintain excess air over fuel.
Alstom expects that fuel/air cross-limiting has been, or will be, included in the
control logic design. Inclusion of cross-limiting is required to ensure safe boiler
operation.
The C30B-1636-002(A) drawing appears to incorporate cross-limiting and forms
the basis for the individual elevation air flow rate setpoint content. This type of
functionality should continue to be used.
Reference 5 (Case Studies)
The PowerPoint slides developed in Reference 5 help summarize the overall
control action for the Unit in a visual manner. Because there are 24 individual
burners spread over 4 elevations there are quite a large number of different
scenarios that might occur with regard to Unit Operation. The different cases
shown in that reference documentation may help provide additional
understanding of how the air flow control works. It is strongly recommended that
Reference 5 be reviewed and compared to this write-up and the logic drawings
themselves.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
27
PAMPA
AIR DAMPER
CONTROL METHODOLOGY
REV B
A. Fitting
10/16/2015
ALSTOM US
1
RSFC AIR DAMPER OVERVIEW
• Each RSFC burner (Qty 24 per Unit) has
two automated actuators
• 1) Outer (Tertiary Damper)
• This damper will be used to
control 70 – 75% of the total
burner air flow
• 2) Inner (Primary Damper)
• This damper is used to control 10
to 15% of the total burner
airflow at the oil and gas gun
zone within the burner.
• A more wide open primary
damper directs more
airflow to the central region
of the RSFC closest to the
fuel feed. A more closed
primary damper directs less
airflow to the central region
within the RSFC.
1.
2.
Outer (Tertiary)
Damper
Inner (Primary)
Damper
RSFC BURNER
Note: damper appearance here is
for diagrammatic purposes only –
actual physical damper design uses
linear actuation instead of butterfly
2
style dampers – See slide 3
RSFC AIR DAMPER – PHYSICAL CONFIGURATION
Outer and inner damper actuators
Axis of actuator movement
Damper drives give linear actuation
3
HEADER & INDIVIDUAL BURNER
DAMPER LAYOUT (Per Elevation)
One elevation of
burners
(representative)
FROM
FD FAN
K10 Damper
(Left Side)
This layout is
repeated four
(4) times to give
the full Unit
• There are four (4) elevations of six (6) burners
• Each elevation is fed by two header air feeds;
each header has a damper
• K10 Damper (Left Side)
• K10 Damper (Right Side)
FROM
FD FAN
K10 Damper
(Right Side)
4
AIRFLOW LOGIC (OUTER DAMPER) – QUICK SUMMARY
•
•
•
•
MFT – from MFT initiation until 5 minutes post-occurrence RSFC outer dampers are held in their last
previous position from just before the trip
MFT Post Purge Fan Trip – for instances when the fan operation has been compromised a post-purge
fan trip is conducted where all outer dampers are held 100% open
Purge – 5 minutes post-MFT until “purge complete” has been achieved…. RSFC outer dampers are
set open loop to fixed percentage open values to give desired overall unit purge airflow
Auto
• RSFC outer dampers are driven to a minimum percent open when:
• 1) Unit is at or above 30% MCR & the burner under consideration is not in service (no
fuel flowing)
• 2) Unit is below 30% MCR & At least 1 elevation has no burners active & the burner
under consideration is on an elevation that has at least one burner active & the specific
burner under review is not in service (no fuel is active)
• RSFC outer dampers modulate per the following:
• 1) If no fuel is being burned on a particular elevation (and unit is running at ≤ 30% MCR)
these dampers move to bring overall Unit air flow up to the minimum required Unit
airflow rate; note that the Unit air flow rate here is constrained and may never be less
than the minimum air flow transmitter output possible
• 2) If fuel is burning on an elevation or will be fired soon then the Boiler Master already
present within the DCS will help set the necessary airflow demand for individual
elevations; this construct will be incorporated with Alstom’s new equipment - the outer
damper drives actuate to give the desired flow rates
5
AIRFLOW LOGIC (OUTER DAMPER) – Sample Cases
Slides 7 through 13 give different operating
scenarios and describe the RSFC outer damper
control function
The descriptions on those pages are with regard
to the outer (tertiary) RSFC dampers
6
ELEV.
4
3
2
FIRING GAS
FIRING OIL
NO COMBUSTION
1
BRN.
6
5
4
3
2
1
OUTER (TERTIARY DAMPER)
ELEV.
4
I. PURGE CONDITION
3
2
1
BRN.
6
5
4
3
2
1
• All 24 RSFC outer dampers set to
fixed positions for purging – open
loop % open values
7
ELEV.
4
3
2
FIRING GAS
FIRING OIL
NO COMBUSTION
1
BRN.
6
5
4
3
2
1
OUTER (TERTIARY DAMPER)
ELEV.
4
3
2
1
BRN.
6
5
4
3
2
1
II. PURGE COMPLETE –
PRE/LOAD
• All 4 Elevations – no fuel firing
• Boiler load < 30%
• Total 30% airflow split evenly amongst 4
elevations; 7.5% of total flow to El. 1,2,3, &
4
• All RSFC outer dampers move together (1
through 6 to achieve 7.5% elevation flow
8
on each level)
ELEV.
4
3
2
FIRING GAS
FIRING OIL
NO COMBUSTION
1
BRN.
6
5
4
3
2
1
OUTER (TERTIARY DAMPER)
ELEV.
4
3
2
1
BRN.
6
5
4
3
2
1
III. FIRST BURNER FIRE
• 1 elevation – fuel firing; 3 no firing
• Boiler load < 30%
• El. 1  Airflow to sustain gas firing on 11 burner
will be set and provided; burners 12, 13, 14, 15,
16 will have outer dampers set to minimum
positions
• Elevations 2,3, and 4 will have balance airflow
needed to achieve total 30% airflow equally split
• All elevation 2, 3, and 4 burner RSFC outer air9
dampers move together to satisfy setpoint
ELEV.
4
3
2
FIRING GAS
FIRING OIL
NO COMBUSTION
1
BRN.
6
5
4
3
2
1
OUTER (TERTIARY DAMPER)
ELEV.
4
3
2
1
BRN.
6
5
4
3
2
1
IV. FIRST BURNERS FIRE
• 1 elevation – fuel firing; 3 no firing
• Boiler load < 30%
• El. 1  Airflow to sustain gas firing on 11 & 16
burner will be set and provided – closed loop
control; burners 12, 13, 14, and 15 will have
outer dampers set to minimum positions
• Elevations 2,3, and 4 will have balance airflow
needed to achieve total 30% airflow equally split
• All elevation 2, 3, and 4 burner outer dampers
10
move together to satisfy setpoint
ELEV.
4
FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN.
6
5
4
3
2
1
OUTER (TERTIARY DAMPER)
V. MULTIPLE ELEVATIONS
ELEV.
•
•
2 elevations – fuel firing; 2 no firing
Boiler load < 30%
4
•
El. 1  Airflow to sustain gas firing on 11 through 16 will
be provided; El. 2 airflow for 21 will be provided; 22
through 26 outer dampers will be set to minimum
positions
Elevations 3 and 4 will balance airflow through all 6 of
their respective registers to ensure total Unit 30%
minimum airflow is achieved
All elevation 3 and 4 RSFC outer dampers move together;
if the individual air flow setpoints for 3 or 4 fall below the
minimum transmitter capability the 3&4 flow setpoints
11
will be increased to the readable range
3
2
1
BRN.
6
5
4
3
2
1
•
•
ELEV.
4
FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN.
6
5
4
3
2
1
OUTER (TERTIARY DAMPER)
VI. MULTIPLE ELEVATIONS (Cont.)
•
2 elevations – fuel firing; 2 no firing
Boiler load > 30%
•
El. 1  Airflow to sustain gas firing on 11 through 16 will be
provided; El. 2 airflow for 21 through 26 will be provided
All burners receiving fuel will have their RSFC outer
dampers move together on an elevation basis (11 is at x%,
12 is at same percent, 15 is at same percent…etc.; 26 is at
y%, 25 is at y% also, same with 23…etc.)
All elev. 3 and 4 burners are at minimum positions (also see
K10 control – minimal airflow to top elevations)
ELEV. •
4
3
2
•
1
BRN.
6
5
4
3
2
1
Note: When less than 30% boiler load at
least one elevation must not have any fuel
being fired.
•
12
ELEV.
4
FIRING GAS
3
FIRING OIL
2
NO COMBUSTION
1
BRN.
6
5
4
3
2
OUTER (TERTIARY DAMPER)
1
VII. MULTIPLE FUELS
• 1 elevation – fuel firing; 3 no firing; 2 fuels
• Boiler load < 30%
ELEV.
4
3
2
1
BRN.
6
5
4
3
2
1
• El. 1 horizontally includes 2 burners, each firing
different fuel; controls compute overall elevation air
flow rate to support combustion (DCS elevation
master). 11 and 16 RSFC outer dampers move to the
same percentage open at all times in Auto.
• El. 2, 3, and 4 have airflow balance equally to give
30% minimum. Outer dampers 12, 13, 14, and 15
are all set to minimum percent open position.
13
HEADER K10 DAMPER CONTROL – SUMMARY
• Position of K10 dampers is based on
checking RSFC operating status for a
given elevation
• If all six RSFC burners are out of
service and boiler load > 30% then
both K10 damper drives are driven
to a minimum percentage open
position of approximately 10-15%
(final value will be field tuned during
commissioning)
• If any one RSFC burner is in service
then both K10 damper drives will be
100% open
• When boiler load is less than 30% all
K10 dampers are 100% open
• Control of the K10 devices is fully open
loop – no feedback PI computation is
used here
K10 HEADER DAMPERS
Per Elevation
14
BURNER AIRFLOW DISTRIBUTION LOGIC (INNER DAMPER)
• MFT – from MFT initiation until 5
minutes post-occurrence RSFC inner
dampers are driven closed
• Purge – 5 minutes post-MFT until “purge
complete” has been achieved RSFC inner
dampers continue to be directed closed
• Auto occurs at all other times
• In Auto if no fuel is being delivered
to the burner under consideration
then its corresponding RSFC inner
damper is maintained closed
• In Auto if fuel is being delivered to
the burner under consideration then
its RSFC inner damper moves to the
defined open loop % open position
based on the amount and type of
fuel being supplied to that burner
register
NATURAL
GAS
OIL
15
AIRFLOW DAMPER CONTROL SUMMARY
• Present control scheme uses K10 header dampers to control air flow to each
elevation of burners; air flow is equivalently provided to all 6 burners on a given
elevation
• New control scheme as defined by Alstom US assigns air flow control to each,
individual burner via the outer air damper actuator associated with each RSFC
assembly
• This scheme allows for more direct air flow control to individual burners
• Alstom RSFC outer dampers control the majority of the air flow, while RSFC
inner dampers control a smaller amount of air flow proportional to the fuel flow
• New control loop for K10 header dampers is simplified now that air flow control
is handled using actuators within the individual burners themselves
16
C
*
*
*
*
*
126
117 2X
2X 115
2X 116
128
118 2X
114 2X
1 [19]
16
C
S E C T IO N C -C
S E C T IO N B -B
S P R IN G D E T A IL
D RIV E SH A FT LO C A T IO N 2X
SEE NO TE 1
(I N S T R U C T I O N S F O R S P R I N G S E A L I N S T A L L A T I O N )
*
*
127
112 113 4X
108
111 2X
*
*
109
P /N 1 -2 4 2 9 6 -B A (C W )
FO R O TH ER PARTS
A N D D IM E N SIO N S
S E E P /N 1 -2 4 2 9 6 -A A
4X 110 /111
T O 1 2 3 /1 2 6
.1 9
.1 9
*
*
B I L L O F M A T E R I A L Q u a n t it ie s L is t e d a r e fo r 1 A s s e m b ly 1 - 2 4 2 9 6 - A A O R 1 - 2 4 2 9 6 - B A
N O . R E Q 'D
D E SC R IP T IO N
IT E M N O PA R T N O .
D R A W IN G N O .
101
M D 8-0 0 0 2 2 -1 6 5 4
8
M D 80 -1 C 0 0 2 2
W A S H E R - P L A I N T Y P E A .6 2 5 " (N )
N U T - H E X .6 2 5 - 1 1 U N C - 2 B
102
1 1 -2 0 0 8
8
M D 80 -1 C 0 0 0 3
----L I N E A R A C T U A T O R - S T R O K E 1 6 .6 "
103
V 0 0 -9 3 6 8
1
----1
LIN E A R A C T U A T O R
104
V 0 0 -9 3 6 9
R O D E N D C LE V IS
105
9 0 3 -2 0 1 1
2
B -9 0 3 -2 0 1 1
H E X JA M N U T
106
M D 8-0 0 0 85 -A A
2
M D 80 -1 C 0 0 85
S C R - C A P H E X S O C H D .3 1 2 X 2 .0 0 0 "
107
1 3 -4 1 3 6
8
M D 80 -1 C 0 0 0 9
----108
V 0 0 -1 6 1 3
2
C L E V E L A N D M O D S P E E D R E D U C E R P /N
M 1311AA-50 C
----A L U M I N U M K N U R L E D H A N D C R A N K W .M .
109
V 0 0 -1 5 5 1
2
B E R G . IN C - P /N C N 1 2 -1 0
110
9 0 3 -1 9 82 -2
2
B -9 0 3 -1 9 82
T E R T IA R Y SU PPO R T B R A C K E T
111
PR IM A R Y SU PPO R T B R A C K E T
9 0 3 -1 9 81 -2
2
B -9 0 3 -1 9 81
S C R E W - H E X H E A D C A P .3 1 2 5 - 1 8
112
1 3 -3 0 2 1
8
M D 80 -1 C 0 0 0 5
U N R C - 2 A x .7 5 L G
113
1 5 -1 0 0 1
8
M D 80 -1 C 0 0 2 2
W A S H E R - P L A I N T Y P E A .3 1 2 " (W )
M O D IF IE D PIP E C A P T H R E A D E D F IT T IN G
114
9 0 2 -1 4 2 2
2
A -9 0 2 -1 4 2 2
CLASS 150
F A B R IC A T E D W A SH E R
115
4
9 0 2 -1 4 2 3
A -9 0 2 -1 4 2 3
4
116
M D 8-0 0 0 3 2 -B F
M D 80 -1 C 0 0 3 2
W A S H E R - P LA IN T Y P E A W ID E 3 /8
117
V 0 0 -1 5 4 7
2
C O M P R E S S I O N S P R I N G (4 .5 6 L G )
4
P L U G S - S Q U A R E H E A D P I P E .1 2 5 - 2 7 ,
118
1 2 -6 0 0 0
M D 80 -1 C 0 1 0 5
SO LID
1
119
9 0 3 -6 3 0 0 -A A
B -9 0 3 -6 3 0 0
R SFC BU RN ER N AM EPLATE
120
9 0 2 -1 82 0 -1 1
2
B -9 0 2 -1 82 0
P IN 5 /8" W /C O T T E R P IN S
-------121
V 0 0 -1 5 5 2
4
H A I R P I N (1 .8 " D I A X 1 - 1 5 / 1 6 L G )
4
122
M D 8-0 0 2 0 0 -A N
M D 80 -1 C 0 2 0 0
SLO T T E D PA N H E A D T A PP IN G SC R E W T Y P E "A B "
B I L L O F M A T E R I A L Q u a n t itie s L is t e d a r e fo r 1 A s s e m b ly 1 - 2 4 2 9 6 - A A
IT E M N O PA R T N O .
N O . R E Q 'D
D R A W IN G N O .
D E SC R IP T IO N
1
123
1 -2 4 2 9 7 -A A
E B 0 -0 0 7 9 9 1 -1 E 9 2 6 0 R S F C B U R N E R & D A M P E R A S S E M B L Y
124
1 -2 4 3 0 4 -A A
1
E B 0 -0 0 7 9 9 1 -1 D 9 2 6 7 D A M P E R T U B E A S S E M B L Y
125
1 -2 4 3 2 0 -A A
1
E B 0 -0 0 7 9 9 1 -1 D 9 2 86 D A M P E R T U B E A S S E M B L Y
B I L L O F M A T E R I A L Q u a n t itie s L is t e d a r e fo r 1 A s s e m b ly 1 - 2 4 2 9 6 - B A
N O . R E Q 'D
IT E M N O PA R T N O .
D R AW IN G N O .
D E SC R IP T IO N
126
1 -2 4 2 9 7 -B A
1
E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 0 R S F C B U R N E R & D A M P E R A S S E M B L Y (C W )
127
1 -2 4 3 2 0 -B A
1
E B 0 - 0 0 7 9 9 1 - 1 D 9 2 8 6 D A M P E R T U B E A S S E M B L Y (C W )
1
128
1 -2 4 3 0 4 -B A
E B 0 - 0 0 7 9 9 1 - 1 D 9 2 6 7 D A M P E R T U B E A S S E M B L Y (C W )
* D EN O T ES IT EM S SH IPPED LO O SE
123
4X 101
4X 102
4X 101
125
112 113 4X
124
109
108
4X
G
107 4X
(5 '- 2 116 " [ 1 5 7 6 ] )
122
103
120
121
105
106
(7 '- 1 196 " [ 2 1 7 3 ] )
A
A1
3 " [7 6 ]
PA IN T LU G
YELLO W
5" [127]
B
B
---------
M A T 'L I T E M
------M A T 'L I T E M
-------
PA IN T N O T E S:
1 . S T A M P / S T E N C I L " A S S 'Y N O . 1 - 2 4 2 9 6 - A A " O R " A S S 'Y N O . 1 - 2 4 2 9 6 - B A " . I N C L U D E R O T A T I O N (C C W O R C W ) I N
S T A M P O N B A C K P L A T E A N D O N N A M E P L A T E (I T E M 1 1 9 ) .
2 . D O N O T P A IN T IN SID E O F H O LE S, A N Y S T A IN LE SS ST E E L C O M PO N E N T S, D A M PE R B E A R IN G H O U SIN G S, O R
H A N D W H E E L A N D G E A R D R IV E B O X E S.
3 . SH O P PR IM E A LL O T H E R SU R F A C E S O F M A IN B O D Y , E X C E PT A S SPE C IF IE D IN N O T E T W O , W IT H R E D O X ID E
P R I M E R (1 .7 ) . R E D O X I D E P R I M E R T O B E P E R A L S T O M S T D . D W G . C - 9 8 5 - 0 6 6 9 , I T E M N O . 9 .0 . R E F E R T O
D R A W IN G N O . B -9 85 -0 3 0 8 F O R C O A T IN G S P E C IF IC A T IO N S .
4 . P A I N T O U T S I D E O F B A C K P L A T E W I T H A L U M I N U M H E A T R E S I S T A N T P A I N T (1 .1 .3 ) P E R A L S T O M S T D . D W G .
C - 9 8 5 - 0 6 6 9 I T E M N O . 9 .0 . R E F E R T O D W G . N O . B - 9 8 5 - 0 3 0 8 F O R C O A T I N G S P E C I F I C A T I O N S .
63°
ITEM 108
34°
IT E M 1 0 8
Ø (3 '- 1 176 " [ 9 5 1 ] )
(5 '- 3 34 " [ 1 6 1 9 ] )
R E F E R E N C E D R A W IN G S:
1 . R S F C B U R N E R & D A M P E R A S S E M B L Y .....................E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 0
2 . R S F C B U R N E R & L I N K A G E A S S E M B L Y .....................E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 1
3 . R S F C B A C K P L A T E A N D S W I R L E R A S S S E M B L Y ..........E B 0 - 0 0 7 9 9 1 - 1 E 9 2 6 2
4 . R S F C B U R N E R G E N E R A L A R R A N G E M E N T - S H 1 ......E B 0 - 0 0 7 9 9 1 - 1 E 9 2 5 0
5 . R S F C B U R N E R G E N E R A L A R R A N G E M E N T - S H 4 ......E B 0 - 0 0 7 9 9 1 - 1 E 9 2 5 3
6 . R S F C B U R N E R A R R A N G E M E N T ................................E B 0 - 0 0 7 9 9 1 - 1 E 9 2 5 8
104
2 '- 7 78 " [ 8 1 0 ]
SE E D E T A IL 6
REF DW G 6
F O R IN ST A LLA T IO N
D E T A ILS
A
A1
P A IN T IT E M 2 1 0 Y E LLO W
A LL PLACES
PA IN T T U B E
YELLO W
(5 '- 3 43 " [ 1 6 1 9 ] )
V IE W A -A
P /N 1 -2 4 2 9 6 -A A (C C W A S S H O W N )
V IE W A 1 -A 1
P /N 1 -2 4 2 9 6 -B A (C W O P P O S IT E H A N D )
---------
IN ST R U C T IO N S FO R A C T U A T O R IN ST A LLA T IO N
1 . P R I O R T O R E M O V I N G T H E E I G H T (8 ) Y E L L O W S H I P P I N G T A B S F R O M T H E S H R O U D S , T H R E A D O N T H E JA M B
N U T A N D T H E N T H E C L E V I S (I T E M 'S 1 0 5 & 1 0 6 ) T O A L L O W 6 0 - 6 5 m m O F T H R E A D F R O M T H E D A M P E R S H A F T S
TO BE EXPO SED .
2 . I N S T A L L T H E D A M P E R T U B A S S E M B L I E S (I T E M 'S 1 2 4 & 1 2 5 ) . S E C U R E W I T H I T E M S 1 0 1 & 1 0 2 . E N S U R E T H E
W E LD M E N T IS H O R IZO N T A L - T H E U SE O F F LA T W A SH E R S IS PE R M IT T E D .
3 . R E M O V E T H E F O U R (4 ) 1 .5 " L O N G C A P - S C R E W S F R O M T H E B A C K O F E A C H A C T U A T O R A N D D I S C A R D . U S E T H E
F O U R (4 ) 2 ” L O N G C A P - S C R E W S F R O M T H E S M A L L B O X I N S I D E T H E S H I P P I N G C R A T E . H O L D T H E A C T U A T O R I N
P L A C E (1 8 k g .) A N D S E C U R E W I T H C A P - S C R E W S . E N S U R E T H E W E L D M E N T I S H O R I Z O N T A L - T H E U S E O F F L A T
W A SH E R S IS PE R M IT T E D .
4 . R E M O V E T H E S H I P P I N G T A B S (P A I N T E D Y E L L O W ) , R E T R A C T T H E S H R O U D U N T I L T H E C L E V I S A N D T H E D R I V E
PIN H O LE S A R E A LIG N E D . SE C U R E W IT H IT E M S 1 2 0 & 1 2 1 .
5 . T E S T E A C H D R I V E (E L E C T R I C A L L Y ) T O E N S U R E F U L L S T R O K E . E A C H D R I V E M A Y B E A D JU S T E D , I F R E Q U I R E D ,
F O R T R A V E L. C O N SU LT R O T O R K IN S T R U C T IO N M A N U A L.
6 . O N C E P R O P E R O P P E R A T I O N H A S B E E N C O N F I R M E D C I N C H E A C H JA M B N U T (I T E M 1 0 6 ) .
(1 '- 3 78 " [ 4 0 4 ] )
119
-----
I N S T R U C T I O N S F O R G E A R D R I V E A S S E M B L Y (S E E D E T A I L G ) :
1 . (O P T I O N A L ) F I L L A L L G E A R D R I V E S (I T E M 1 0 8 ) W I T H 8 0 - 9 0 W O I L P R I O R T O S H I P P I N G T H E B U R N E R S .
2 . F I T K E Y (P R O V I D E D W I T H O U T P U T S H A F T O N G E A R D R I V E S (I T E M 1 0 8 ) I N T O C O U P L I N G K E Y W A Y O N D I R E C T
C R A N K A S SE M B LIE S . T IG H T E N SE T SC R E W IN C O U PLIN G .
3 . P R E A S S E M B L E A N D A L I G N G E A R D R I V E A S S E M B L I E S (I T E M S 1 0 8 , 1 0 9 , 1 1 0 , 1 1 2 & 1 1 3 A N D 1 0 8 , 1 0 9 , 1 1 1 , 1 1 2 ,
& 1 1 3 ) PR IO R T O W E LD IN G SO T H A T F U LL ST R O K E O F LIN K A G E A N D C R A N K A SSE M B LIE S IS PE R M IT T E D .
P O S IT IO N G E A R D R IV E S A S S E M B LIE S A S S H O W N IN V IE W S A -A A N D A 1 -A 1 .
P /N /1 -2 4 2 9 6 -A A (C C W )
126
-------
IN ST R U C T IO N S F O R SPR IN G SE A L IN ST A LLA T IO N :
1 . C U T S P R I N G (I T E M 1 1 7 ) T O R E Q U I R E D L E N G T H A N D B E N D B O T H E N D S U P I N T O S P R I N G T O P R E V E N T
G O U G I N G T H E W A S H E R S (I T E M 1 1 6 ) A F T E R A S S E M B L Y .
2 . A S S E M B L E B E A R I N G H O U S I N G S P E R S E C T I O N C - C (A - 7 ) D O N O T O V E R T I G H T E N B E A R I N G H O U S I N G P I P E C A P
(I T E M 1 1 4 ) . W A S H E R S S H O U L D B E A B L E T O M O V E I N A S S E M B L Y A F T E R T I G H T E N I N G .
3 . T H R E A D JA M N U T (I T E M 1 0 6 ) A N D C L E V I S (I T E M 1 0 5 ) O N T E R T I A R Y D A M P E R S H A F T (I T E M 2 0 6 - R E F . D W G
1 ).
4 . P R IO R T O A T T A C H IN G IT E M 1 0 3 /1 0 4 , S T R O K E T E R T IA R Y /P R IM A R Y D A M P E R A S S E M B L Y O V E R IT S F U L L
D IS T A N C E O F T R A V E L B Y P U S H IN G /P U L LIN G IT E M 1 0 5 . D A M P E R A S S E M B L Y S H O U L D M O V E F R E E L Y W IT H O U T
B IN D IN G .
5 . A F T E R F IN A L A S S E M B L Y & P A IN T IN G , R E M O V E IT E M S 1 0 3 , 1 0 4 , 1 0 7 , 1 2 0 , 1 2 1 , 1 2 4 /1 2 7 , & 1 2 5 /1 2 8. B A G &
L A B E L O R T A G R E M A I N I N G L O O S E I T E M S W I T H T H E B U R N E R T A G N O . F R O M T H E B U R N E R N A M E P L A T E (I T E M
1 1 9 ).
6 . A F T E R F I N A L A S S E M B L Y E N S U R E 1 1 .7 5 " O .D . T U B E S L I D E S F R E E L Y A N D C O N C E N T R I C A L L Y , W I T H O U T
O BSTR U CTIO N , TH R U CEN TER O F BU R N E R .
107
D E T A IL G
S C A L E 1 :6
123
---
GEN ERAL N O TES:
1 . D I M E N S I O N I N G A N D T O L E R A N C I N G P E R A S M E Y 1 4 .5 M - 1 9 9 4
U N LE SS O T H E R W ISE SPE C IF IE D :
a . A LL D IM E N SIO N S A R E IN F E E T A N D IN C H E S.
b . T O L E R A N C E S O N L I N E A R D I M E N S I O N S ± .0 6 .
c . T O L E R A N C E S O N A N G U L A R D I M E N S I O N S ± 0 ° - 3 0 '.
2 . A L L W E L D I N G P E R A W S D .1 .1 , L A T E S T E D I T I O N .
U S E E -7 0 1 8 E L E C T R O D E U N L E S S O T H E R W IS E S P E C IF IE D .
3 . W H E R E N O T E D , E - 3 0 9 E L E C T R O D E S H A L L B E U S E D . I N A D D I T I O N T O C O M P L Y I N G W I T H A W S D 1 .1 : L A T E S T
E D IT IO N .
a . A LL W E LD S SH A LL B E Q U A LIF IE D IN A C C O R D A N C E W IT H A SM E B O ILE R & PR E SSU R E V E SSE L C O D E SE C T IO N IX
O R E Q U IV A LE N T ST A N D A R D .
b. W E LD E R Q U A LIF IC A T IO N A N D C E R T IF IC A T IO N SH A LL B E A V A ILA B LE F O R R E V IE W A T T H E SU PPLIE R S S H O P.
c. W E LD PR O C E D U R E S PE C IF IC A T IO N S A N D PR O C E D U R E Q U A LIF IC A T IO N R E C O R D S SH A LL B E A V A ILA B LE F O R
R E V IE W A N D A PPR O V A L B Y A LST O M PO W E R .
d . A LL W E LD S SH A LL B E G IV E N A V ISU A L IN SPE C T IO N A N D W ILL M E E T T H E A C C E PT A N C E R E Q U IR E M E N T S O F
A .W .S . D 1 .1 : L A T E S T E D I T I O N .
4X 102
110 2X
M A T 'L I T E M
-----------------
8 '- 6 176 " [ 2 6 0 2 ]
9 8 .1 3 [ 2 4 9 3 ] E N D O F S H A F T W / O C L E V I S
P A IN T IT E M 2 0 9
YE LLO W
BILL O F M AT ERIALS
IT EM N O PART N O .
NO . REQ
1
1
1 -2 4 2 6 8 -A A
2
1 -2 4 5 2 4 -A A
1
3
1 -2 4 2 6 9 -A A
1
4
1 5 -1 0 0 6
24
5
1 1 -2 1 0 4
12
6
M D 8 -0 0 0 4 4 -F G
12
7
G P -2 8 7 6 -A U
1
D R AW IN G N O .
E B 0 -0 0 7 9 9 1 -1 E 9 3 2 1
E B 0 -0 0 7 9 9 1 -1 E 9 3 2 6
E B 0 -0 0 7 9 9 1 -1 E 9 3 2 2
M D 8 0 -1 C 0 0 2 2
M D 8 0 -1 C 0 0 0 1
M D 8 0 -1 C 0 0 4 4
C -G P -2 8 7 6
Q U A N T I T I E S L I S T E D A R E F O R (1 ) A S S E M B L Y
D ESC RIPT IO N
RSFC G A S PIPE A SSEM BLY
RSFC O IL & H EI G U ID E PIPE ASSEM BLY
C O RE AIR ASSEM BLY
W A S H E R -P L A I N T Y P E A .6 2 5 " (w )
N U T -H E X .7 5 0 I N
B O L T -H E X .7 5 0 X 2 .0 0 0 I N
1 0" 1 5 0# PIPE FLAN G E G ASK ET
M A T 'L I T E M
---------------
1
3
2
Ø 7 .5 0
D IFFU SER
D E T A IL B 1
SCALE 1 / 3
Ø 9 .5 0 I .D .
C O RE AIR
Ø 1 0 .0 0 O .D .
C O RE AIR
Ø 1 1 .0 0 I .D .
G AS
V IE W C -C
SCALE 1 / 3
1 2 3 .8 7
5
4
6
1 2 3 .8 7
7
C
B1
S E C T IO N B -B
SCALE 1 / 6
.1 9
C
SEAL
E -7 0 1 8
(1 1 2 .1 5 )
1 1 .6 9
A
B
B
A
G EN ERAL N O TES:
1 . D I M E N S I O N I N G A N D T O L E R A N C I N G P E R A S M E Y 1 4 .5 - 1 9 9 4 U N L E S S O T H E R W I S E S P E C I F I E D
a . A LL D IM E N SIO N S A R E IN IN C H E S
b . T O L O R A N C E O N D I M E N S I O N S ± .0 6
c. T O LE R A N C E S O N A N G U LA R D IM E N SIO N S ± 0 º3 0 '
2 . A L L W E L D S P E R A W S D 1 .1 L A T E S T E D I T I O N . U S E E - 7 0 1 8 E L E C T R O D E U N L E S S O T H E R W I S E
SPE C IF IE D .
a . A LL W E LD S SH A LL B E Q U A LIF IE D IN A C C O R D A N C E W IT H A S M E B O ILE R & PR E SSU R E V E SSE L
C O D E SE C T IO N IX O R E Q U IV A LE N T ST A N D A R D .
b. W E LD E R Q U A LIF IC A T IO N A N D C E R T IF IC A T IO N SH A LL B E A V A ILA B LE F O R R E V IE W A T T H E
SU PPLIE R S SH O P.
c. W E LD PR O C E D U R E SP E C IF IC A T IO N S A N D P R O C E D U R E Q U A LIF IC A T IO N R E C O R D S SH A LL B E
A V A ILA B LE F O R R E V IE W A N D A P PR O V A L B Y A LST O M PO W E R .
d . A LL W E LD S SH A LL B E G IV E N A V ISU A L IN SPE C T IO N A N D W ILL M E E T T H E A C C E PT A N C E
R E Q U I R E M E N T S O F A .W .S . D 1 .1 1 9 9 8
3 . W H E R E N O T E D , E -3 0 9 A N D E -3 1 6 E LE C T R O D E S H A L L B E U S E D . IN A D D IT IO N T O C O M P L Y IN G
W I T H A W S D 1 .1 L A T E S T E D I T I O N.
1 4 .0 0
4" G AS IN LET
4" C O R E A IR IN LET
1 2 .0 0
45°
45°
V IE W A -A
P /N 1 -2 4 2 6 7 -A A
CCW
V IE W A - A
P /N 1 -2 4 2 6 7 -B A
CW
TAB 2
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
TABLE OF CONTENTS
DESCRIPTION
PAGE NUMBER
LIMELIGHT™ 3” Bluff Body GAS pipe Ignitor General Description .............................................................. 1
IGNITOR COMPONENT FUNCTIONAL ....................................................................................................... 2
Main Gas Connection ................................................................................................................................ 2
Spark/Flame Rod Connector and Wire Train Assembly............................................................................ 3
Spark/Flame Rod Assembly .................................................................................................................. 4
Bluff Body .................................................................................................................................................. 5
Gas Pipe Tip Assembly ............................................................................................................................. 6
IGNITOR WINDBOX PRESSURE TAPS...................................................................................................... 7
IGNITOR OPERATION - GENERAL............................................................................................................. 7
IGNITOR CONTROL CABINET .................................................................................................................... 8
Gas Ignitor Control Cabinet Indicating Lights and Pushbuttons ............................................................ 8
IGNITOR COMBUSTION AIR SYSTEM (supplied by Others) ...................................................................... 8
GAS PIPE TRAIN .......................................................................................................................................... 8
IGNITOR SYSTEM CARE - GENERAL ........................................................................................................ 9
Foreign Material ......................................................................................................................................... 9
Inspection ............................................................................................................................................... 9
Shop Service and Handling.................................................................................................................... 9
Risk of Electrical Component Damage .................................................................................................. 9
Gas Ignitor Control Cabinet Panel Arrangement ..................................................................................... 10
OPERATION ............................................................................................................................................... 10
INSTALLATION/COMMISSIONING CHECK LIST ..................................................................................... 11
Gas Header Trip Switch Set Points ......................................................................................................... 12
SUMMARY .................................................................................................................................................. 12
UNIT DATA / CUSTOMER INFORMATION ............................................................................................... 13
TROUBLESHOOTING GUIDE.................................................................................................................... 14
Starting ................................................................................................................................................. 14
TROUBLESHOOTING GUIDE (Cont.)........................................................................................................ 15
Combustion Air and Gas ...................................................................................................................... 15
TROUBLESHOOTING GUIDE (Cont.)........................................................................................................ 16
Detection .............................................................................................................................................. 16
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
i
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
LIST OF FIGURES
Figure 1: Gas Pipe Ignitor Side and Plan View ............................................................................................. 2
Figure 2: Gas Connection and Pressure Test Tap........................................................................................ 3
Figure 3: Dust Plug Termination at Air Inlet Assembly.................................................................................. 4
Figure 4: Connector and Wire Train Assembly Wiring at Dust Plug ............................................................. 5
Figure 5: Spark/Flame Rod Assembly Inserted into the Bluff Body .............................................................. 5
Figure 6: Bluff Body Construction.................................................................................................................. 6
Figure 7: Gas Pipe Tip Assembly .................................................................................................................. 7
Figure 8: Ignitor ........................................................................................................................................... 11
DRAWINGS
DRAWING NUMBER
3" Bluff Body Gas Pipe Ignitor ....................................................................................... EB0-007991-1D9314
Gas Ignitor Control Cabinet Schematic ......................................................................... EB0-007991-1D9315
Gas Ignitor Valve Train – De-Energize To Trip, High Capacity ..................................... EB0-007991-1D9362
Gas Ignitor Control Cabinet Schematic ......................................................................... EB0-007991-1D9363
LIMELIGHT™ Diagnostic Flame
Indicator Model 100 Rev 4 ...............................................................................................................5001 R1
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
ii
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
LIMELIGHT™ 3” BLUFF
BODY GAS PIPE IGNITOR
GENERAL DESCRIPTION
The LIMELIGHT™ 3” Gas Pipe ignitor is designed to serve as an ignition torch for
gas, oil or coal burners in industrial and utility boiler applications. The ignitor itself
consists of the ignitor gas nozzle, spark rod, flame rod, bluff body and dust
plug/gas inlet. These components are housed inside the ignitor housing which is
called the “Air Inlet Assembly”. The LIMELIGHT™ ignitor design provides
improved combustion airflow with minimum pipe obstruction and pressure drop.
The gas ignitor uses a Diagnostic Flame Indicator for proving flame. The ignitor
utilizes a ceramic insulated solid rod design for both spark rod and flame rod
sensor. These solid rods remove all wiring and associated connections from
inside the ignitor’s air inlet assembly. This ignitor and Alstom’s associated flame
proving devices were designed to meet all code requirements including the
National Fire Protection Association (NFPA) and Black Liquor Recovery Boiler
Advisory Committee (BLRBAC) guidelines.
Gas is admitted through the main gas pipe out to and into the bluff body. The
majority of the gas exits the gas nozzle tip. However, inside the bluff body a
machined orifice creates a slight backpressure to the gas flow.
This
backpressure forces a small percentage of the main gas to flow through weep
holes machined in the bluff body.
This weep hole gas exits the bluff body behind the bluff body diffuser ring and
enters a recirculation zone created by the flow of combustion air around the bluff
body. Combustion air is admitted through the air inlet on the existing ignitor guide
pipe and is forced around the bluff body and out into the boiler. The sudden
increase in flow area on the downstream side of the bluff body creates a
recirculation zone for the combustion air. This recirculation zone provides mixing
for the gas and air and allows the pilot flame front to stabilize just downstream of
the bluff body. As long as the gas and air flows are properly maintained after
ignition, the recirculation zone creates a self stabilizing flame of weep gas that
exits the air inlet assembly around the main gas tip. The gas tip is setback 2”
from the existing ignitor guide pipe end to properly shape the flame. Reference
Figure 1 and drawing EB0-007991-1D9314.
The weep gas then ignites the main gas flow as it leaves the gas pipe tip
assembly. The burning weep gas inside the air inlet assembly creates an ionized
gas pocket that can be detected by Alstom’s LIMELIGHT™ Diagnostic Flame
Indicator (DFI).
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
1
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Figure 1: Gas Pipe Ignitor Side and Plan View
IGNITOR COMPONENT
FUNCTIONAL
The stainless steel ignitor was designed for quick and easy maintenance by
incorporating modularized construction reducing the need for spare parts. The
major components are described below.
Main Gas Connection
The main gas connection utilizes a 1” pipe coupling (reference Figure 2) to allow
for removal of the ignitor from the air inlet assembly. Gas pressure at the ignitor
is measured using the ¼” gas static pressure tap located downstream of the gas
inlet to the ignitor. When properly instrumented, this tap and its resulting
pressure reading when gas is supplied will indicate the Btu rating of the ignitor.
There is a second static pressure tap (combustion/cooling air pressure tap)
located on the air inlet assembly. Refer to Figure 2 and drawing EB0-0079911D9314.
This tap is used to measure the combustion air pressure and its resulting flow
when the ignitor is being commissioned. These two taps, gas pressure and
combustion air pressure, are the test measurement locations needed to insure
the proper commissioning of the ignitor.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
2
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Figure 2: Gas Connection and Pressure Test Tap
Spark/Flame Rod Connector and Wire Train Assembly
The Spark/Flame Rod Connector and Wire Train assemblies are factory
assembled and are supplied with 10 feet of flex conduit and 30 feet of ground and
signal wire. There are two assemblies required per ignitor, one for spark and one
for the flame rod.
The loose field wires are terminated inside the respective local junction box for
the ignitor on the designated terminal strips. The wiring train’s connector housing
is attached to either the spark or the flame rod assembly at the ignitor dust plug
by securing the swivel adapter to the connector housing. Refer to Figure 3.
Grounding connections are pre-connected at the assembly’s connector as shown
in Figure 4.
The design of the system allows for the spark or flame rods to be
interchangeable, therefore it does not matter which connector is secured to the
spark or flame rod.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
3
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Figure 3: Dust Plug Termination at Air Inlet Assembly
NOTE:
Flexible conduit and flexible electrical connections are provided
at the ignitor to permit expansion and movement. The existing
flexible gas hose connects to the ignitor using a 1” pipe union.
When piping and wiring are run to the ignitor, care should be
taken to keep torque forces to a minimum so that components
are not stressed at the ignitor. Field piping and wiring should be
arranged to provide maintenance and operator accessibility.
Spark/Flame Rod Assembly
The spark/flame rod assembly comes as a factory assembled component and is
made to specific “E” dimensions for each ignitor contract. The rod assembly
screws into the dust plug and is supported and protected by Double Rod Standoff
Clips. The clips are permanently aligned and welded to the gas piping that is
down stream of the dust plug.
If replacement of the spark/flame rod assembly is required, the solid rod must be
unthreaded and pulled out of the ignitor from the bluff body side. Then the swivel
adapter is unscrewed from the dust plug, which allows removal of the ceramics
and protective sheath. The replacement parts are then inserted through the dust
plug and rod standoff clips and aligned into the bluff body.
CAUTION:
Care must be taken to re-install the spacer between the dust
plug and the threaded swivel adapter. If the spacer is not reinstalled, it is possible that the ceramics inside the
assembly will be broken when the adapter is tightened.
The spark/flame rod assembly’s sheath will lightly press-fit inside the bluff body
with approximately 1” of ceramic protruding from the downstream face of the bluff
body. The spark or flame rod should extend approximately 6” from the
downstream face of the bluff body.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
4
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Figure 4: Connector and Wire Train Assembly Wiring at Dust Plug
Bluff Body
The bluff body (Figures 5 and 6) is a machined component designed to produce
minimum pressure drop to the combustion air system while providing superior
fuel and air mixing. The outside of the body has four alignment fins that align the
ignitor inside the air inlet assembly. Two bore holes are drilled towards the
outside of the bluff body. These holes guide and allow for proper positioning of
the spark and flame rods. In the center of the body on the upstream side, a
reduced bore in the bluff body provides the inlet connection and mechanical stop
for the gas supply piping.
Figure 5: Spark/Flame Rod Assembly Inserted into the Bluff Body
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
5
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
NOTE:
The ceramics used can be damaged or broken if mishandled or
dropped. Care should be taken when replacing or removing
these devices to minimize any mechanical or impact damage.
The ceramics are great insulators and with the proper care
should provide excellent dielectric properties for many years.
However, as with any electronics, care should be taken to avoid
water from being sprayed into the ignitor assembly or wiring train
as the potential for developing an unwanted system ground
exists. This is especially true in boiler maintenance operations
where water washing is performed. Prior to any water washing, if
practical, the ignitor along with its air inlet assembly and
spark/flame rod wiring train should be removed from the furnace
and away from the aqueous environment. This method will
protect the spark and flame rods as an assembly. If this is not
possible, protection from the wash water should be made by
covering the removed air inlet assembly and ignitor with plastic.
There is a removable orifice, accessible from the downstream side of the bluff
body that provides for a small amount of gas to exit the bluff body through the
weep holes that discharge behind the diffuser plate. The downstream side of the
bluff body is threaded to allow for insertion and replacement of the gas pipe tip,
as well as access to the orifice.
Figure 6: Bluff Body Construction
Gas Pipe Tip Assembly
The gas pipe tip is available as a replacement part and can be replaced by
unthreading the tip from the bluff body, taking care to first remove any tack welds.
Refer to Figure 7. After commissioning, or upon replacement of the gas pipe tip,
it must be tack welded at the junction of the tip and bluff body. The gas pipe tip is
310 stainless steel, and when fully threaded into the bluff body should extend
8.00” from the face.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
6
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
The replacement tips should be installed into the bluff body as far as the threaded
hole allows. Prior to re-installing a gas tip, make sure that all of the gas weep
holes and center orifice are free and clear of debris. The attachment of an ignitor
flame diffuser assembly is used for horn ignitor applications.
Figure 7: Gas Pipe Tip Assembly
IGNITOR WINDBOX
PRESSURE TAPS
The ignitor assembly has two ¼” pressure taps. Gas pressure at the ignitor is
measured using the ¼” gas static pressure tap located at the gas inlet to the
ignitor. When properly instrumented, this tap and its resulting pressure reading
will indicate the Btu rating of the ignitor when gas is supplied. A combustion/
cooling air pressure tap is located on the air inlet assembly which measures the
combustion air pressure and its resulting flow rate.
IGNITOR OPERATION GENERAL
The LIMELIGHT™ three inch ignitor system is a permanently mounted fixed
arrangement where the individual ignitor components such as the flame rod,
spark rod, and gas assembly are mounted on an ignitor front plate. The spark
rod and flame rod components are secured on locating pipes with Camlock style
quick disconnects and can be removed while the unit is on line. During normal
operation the individual ignitor components should be locked in the ignitor front
plate locating pipes. Should maintenance or cleaning be required, the DFI flame
rod and spark rod can be removed by way of these quick disconnect fittings.
With the ignitor components installed on the ignitor windbox front plate, the gas
pipe connections are typically left installed to allow for the use of the ignitor at any
time.
The combustion air fan should typically be left running to keep the ignitor ready
for operation.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
7
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
IGNITOR CONTROL CABINET
Reference drawings EB0-007991-1D935 and EB0-007991-1D9363.
An ignitor control cabinet is installed at each corner to serve an individual ignitor.
The cabinet is installed conveniently near the ignitor installation, but in a cooler
location away from the furnace wall casing.
The cabinet houses the components required to operate and monitor the ignitor,
such as the DFI circuits, a spark transformer power supply, and all the necessary
electrical components and connection points for tying into the burner
management system for control room operation of the ignitor system. The DFI
System proof of flame is also housed in the cabinet.
Note:
This system was designed to be De-Energize-to-Trip
A window located on the front of the gas ignitor control cabinet allows the DFI
module to be viewed without opening the cabinet door.
The ignitor control cabinet contains the necessary electrical equipment to operate
and control the ignitor. This includes the following:
•
Spark Transformer
•
DFI System LIMELIGHT™ Diagnostic Flame Indicator Model DFI-100-40001
•
Indicating Light
•
Main Terminal Board
Gas Ignitor Control Cabinet Indicating Lights and Pushbuttons
The following Indicating Lights and pushbuttons are located on the front of the
ignitor control Cabinet:
•
RED “FLAME PROVEN” Indicating Light is located on the front of the gas
ignitor control cabinet. This light will illuminate if the DFI flame module
indicates flame plus gas pressure or flow is proven. This light provides visual
indication of the status of the ignitor.
IGNITOR COMBUSTION AIR
SYSTEM (SUPPLIED BY
OTHERS)
Combustion air to the ignitors is typically supplied by a scanner cooling/ignitor
combustion air fan.
The dampers should typically be set to achieve a 3” w.g. pressure drop across
the ignitor. This differential pressure between the ignitor windbox and furnace is
required to produce a stable ignitor flame.
GAS PIPE TRAIN
Reference drawing EB0-007991-1D9362.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
8
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Each of the ignitors has been supplied with an ignitor gas pipe train rated at 13
million Btu’s/hr and consists of a 1-1/2” 100 mesh strainer, two (2) 1-1/2”
pneumatically operated block valves, One (1) 3/4" pneumatically operated vent
valve and a 1-1/2” manual globe valve.
•
The strainer removes any final contaminants that might be in the gas before
the gas passes through the block valve into the ignitor.
•
Two 1-1/2" block valves provide positive isolation of gas from the ignitor when
the ignitor is not in service.
•
A 3/4" vent valve located between the block valves is open when the block
valves are closed, and will close when the block valves open.
•
A 1-1/2” manual globe valve is located in the gas pipe to provide final gas
pressure adjustment at an individual ignitor.
IGNITOR SYSTEM CARE GENERAL
Foreign Material
After the initial installation of the fuel piping is completed, all piping should be
blown out using steam or compressed air to remove mill scale and other foreign
material. This should be done again if future maintenance requires extensive
supply piping replacement or repair.
During initial operation the ignitor air inlet assembly and nozzle tip should be
inspected for furnace slagging when the opportunity presents.
Inspection
After the ignitor is removed from the furnace, always, inspect the burner openings
and remove any slag that may be present.
Shop Service and Handling
If the ignitor is removed from the boiler, it is recommended that the assembly be
placed in a protective rack. This rack system will protect the ignitor ceramics and
other components from potential damage.
If maintenance is performed on the ignitor, care must be given to ensure that the
ceramics are not damaged along with the ceramic sleeves. It is recommended
that all maintenance be performed using the maintenance rack.
If the ignitor is removed for the boiler, check the cleanliness of the flame rod, and
spark rod tip. Clean the flame rod or spark rod using a wire brush. Be careful to
not damage the ceramics or ceramic insulator sleeves.
Risk of Electrical Component Damage
When re-inserting the ignitor components, care must be taken to ensure that the
flame rod and spark rod are not damaged by the re-insertion process. If the
electrical connections were removed or are loose, they should be firmly tightened
to insure good electrical contact is made.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
9
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Gas Ignitor Control Cabinet Panel Arrangement
An ignitor control cabinet panel arrangement has been supplied that contains the
spark rod transformer, the DFI module and the wiring bus for the spark rod and
DFI connections and BMS interface.
The ignitor control cabinet panel is installed inside an existing ignitor control
cabinet conveniently near the ignitor installation, but in a cooler location away
from the furnace wall casing.
The panel supports the components required to operate and monitor the ignitor,
the ignitor has a DFI circuit, a spark transformer, and all the necessary electrical
components and connection points for tying into the burner management system
for control room operation of the ignitor system.
Note:
This system was designed to be De-Energize-to-Trip.
OPERATION
The ignitor is a fixed mount ignitor system that can be removed from the ignitor
air inlet assembly for cleaning and maintenance. The ignitor is locked in the
ignitor air inlet assembly using a 3” quick disconnect D-Coupler.
CAUTION:
If Ignitor is removed from boiler for maintenance while boiler
is in operation, care should be observed as the boiler
furnace pressure could go positive. A plug should be put in
the guide pipe assembly while the ignitor is removed this
will prevent short circuiting of the combustion air from the
guide pipe and prevent any furnace gases from escaping
should the furnace go positive.
With the ignitor installed in the windbox, the gas is typically left connected to allow
for the use of the ignitor at any time. The ignitor combustion air fan is left running
to keep the ignitor ready for operation and to keep it cool and clean during idle
periods.
To start the ignitor the boiler should have a purge complete permissive
established and the Ignitor gas supply header system lined up for service through
the Burner Management System. Ignitor operation is controlled from the existing
BMS.
Permissives for firing the ignitor require that the ignitor have a “no flame” signal
from the DFI electronics. There also should be “no furnace MFT” or no master
fuel trip.
When an Ignitor “Start” is initiated typically a ten second trial timer is started and
the ignitor gas shut-off valve is opened, the HEI spark exciter is energized begins
a ten second trial time. The spark ignites fuel air mixture. Flame is detected by
the flame rod, which then sends a “flame signal” to the local control cabinet.
The “flame detected” signal issued from the DFI. The “Ignitor Proven” signal is
sent to the Burner Management System and is then typically used as a start
permit for the adjacent gas gun.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
10
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
The ignitor will trip on loss of flame proven, loss of power to the local ignitor
cabinet, or an MFT is initiated. The existing ignitor valve train is a “de-energized
to trip”.
Figure 8: Ignitor
INSTALLATION/COMMISSIONING
CHECK LIST
1. Verify “A” dimension is matching the existing 3” furnace guide pipe
Centerline of air inlet assembly to end of guide tube in furnace (Figure 8).
2. Remove shipping tape and foam block before installing the flame rod.
3. Install tab for Ignitor Engagement switch, if required.
4. Make sure the gas line is sized to maintain sufficient pressure,
remove in-line orifice if reusing original valve trains (as required).
5. Clean strainer and solenoid valve, if required.
6. Install a new test gauge on the gas line, Ignitor Firing pressure – 0 to 15
PSIG.
7. Install a new test gauge on the Combustion air inlet – 0 to 10 “WG.
8. Position the ignitor in a secure location where sparking of the spark rod can
safely be observed. Charge the 10,000 VAC ignition transformer. Verify that
sparks occur from the spark rod disk to the side of the gas pipe.
WARNING:
DO NOT TOUCH THE IGNITOR WHILE THE TRANSFORMER
IS CHARGED.
9. Verify that the combustion air pressures for the ignitor are set properly.
10. Start the ignitor. Set the gas pressure as required for proper BTU rating for
the ignitor. Refer to the ignitor manual for the required flows and pressures.
11. Verify the ignitor start and stop control is functioning properly.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
11
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
Gas Header Trip Switch Set Points
Pressure switch settings for the high and low trip points are based upon the
nominal header pressure that produces the desired flow at the gas ignitors or gas
nozzles, as applicable. The primary purpose of the trip switches is to trip the gas
header for either of the following reasons:
•
High pressure: to prevent over firing of the gas ignitor/burner which may
result in damage to the components of same or excessive fuel velocities
which may cause the flame to become unstable and result in a loss of flame.
•
Low pressure: to prevent under firing of the gas ignitor/burner which may
cause the flame to become unstable and result in a loss of flame.
Typically, the trip set points are determined as follows:
•
High pressure trip is set at a pressure that results in a flow of approximately
125% of rated capacity.
•
Low pressure trip is set at a pressure that results in a flow of approximately
75% of rated capacity.
As an example the following is offered:
•
Rated capacity is achieved at a nominal pressure of 20 PSIG.
•
High pressure trip set point is at 31.25 PSIG (156% of nominal pressure
resulting in 125% of rated flow).
•
Low pressure trip set point is at 11.25 PSIG (56% nominal pressure resulting
in 75% of rated flow).
For calculative purposes, use the following:
•
High pressure set point = nominal pressure((1.25) ).
•
Low pressure set point = nominal pressure((0.75) ).
2
2
SUMMARY
1. Adjust ignitor firing pressures according to the ignitor firing charts.
2. Adjust combustion air pressures according to the ignitor firing charts.
3. Fill in the start-up settings chart for future reference.
4. Review the ignitor operation with operators and maintenance staff.
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
12
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
UNIT DATA / CUSTOMER
INFORMATION
Customer:
Date:
Station:
Tech Service Eng:
Unit #:
Ignitor Location:
Original Contract #:
CANBUS Address:
Services Contract #:
CANBUS Used: (yes/no)
Heat Input (MMBTU/hr):
Software Revision:
Ignitor Serial #:
DFI Serial #:
Table 2: DFI / Ignitor Operational Data
Test Data
Ignitor #
Ignitor #
Ignitor #
Ignitor #
Ignitor #
Ignitor #
Ignitor #
Ignitor #
DCV Trip Setpoint (F02)
ACV Trip Setpoint (F03)
AVG DCV Reading (F15)
AVG ACV Reading (F16)
Ignitor Combustion Air
Pressure (" wc)
Ignitor Inlet Gas Pressure
(psig)
Test Data
DCV Trip Setpoint (F02)
ACV Trip Setpoint (F03)
AVG DCV Reading (F15)
AVG ACV Reading (F16)
Ignitor Combustion Air
Pressure (" wc)
Ignitor Inlet Gas Pressure
(psig)
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
13
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
TROUBLESHOOTING GUIDE
Starting
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
14
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
TROUBLESHOOTING GUIDE (CONT.)
Combustion Air and Gas
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
15
LIMELIGHT™ 3” Bluff Body Gas Pipe Ignitor
TROUBLESHOOTING GUIDE (CONT.)
Detection
COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
16
P A R T S L IS T
4
5
15
14
11
12
12
12
2
3
5
6
7 X 1 0 .0 0
1 4 .5 0
6
4
15
14
V IE W B -B
1 / 4 " N P T C O M B U S T IO N A IR
P R E S S U R E T A P L O C A T IO N .
PART NUM BER
9 9 6 0 2 9 -C
9 9 6 0 9 8 -F
9 9 6 1 0 4 -0 1
9 9 -6 0 0 8 B
0 5 -0 5 5 4 -0 1
0 5 -0 5 5 4 -0 3
9 9 6 0 1 5 -0 1
9 9 6 0 0 1 -0 9 C
9 9 6 0 0 1 -1 0 C
9 9 6 0 1 7 -0 1
9 9 6 0 1 8 -0 1
9 9 6 0 0 1 -1 3 J
996034
E P S D -0 3 2 1
9 9 6 0 3 3 -0 0
9 9 -6 0 2 2
QTY
1
1
1
2
1
1
1
1
1
1
8
1
2
2
1
1
D R A W IN G
C -9 9 -6 0 2 9
C -9 9 -6 0 9 8
C -9 9 -6 1 0 4
C -9 9 -6 0 0 8
D -0 5 -0 5 5 4
D -0 5 -0 5 5 4
B -9 9 -6 0 1 5
G -9 9 -6 0 0 1
G -9 9 -6 0 0 1
C -9 9 -6 0 1 7
C -9 9 -6 0 1 8
G -9 9 -6 0 0 1
A -9 9 -6 0 3 4
D -E P S D -0 3 2 1
C -9 9 -6 0 3 3
C -9 9 -6 0 2 2
D E S C R IP T IO N
G A S IN L E T A S S E M B L Y
R E P L A C E A B L E O R IF IC E B L U F F B O D Y A S S Y .
R E M O V A B L E G A S P I P E T IP
S P A R K /F L A M E R O D A S S E M B L Y
W IR E T R A IN A S S E M B L Y - D F I
W IR E T R A IN A S S E M B L Y - S S P K
1 .2 5 O .D . G A S P IP E O F F S E T B E N D
Q U IC K D IS C O N N E C T C O U P L IN G P L U G 1 .0 0 N P T
Q U IC K D IS C O N N E C T C O U P L IN G S O C K E T 1 .0 0 N P T
D O U B L E R O D L O N G S T A N D O F F C L IP
D O U B L E R O D S H O R T S T A N D O F F C L IP
1 .5 0 " N P T D O U B L E B R A ID E D F L E X G A S H O S E 6 0 " L G
SPACER W ASH ER
CO N N ECTO R ASSEM BLY
D UST PLUG ASSEM BLY
3 .0 0 K A M L O C K D -C O U P L E R M O D IF IC A T IO N
S C A L E 1 :5
(1 0 .0 0 )
(9 1 .5 8 )
17
A
IT E M
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
(9 3 .9 9 )
(4 .5 0 )
B
B
( 2 .0 0 )
6
5
7
1
.0 6
A
T A C K G A S P IP E T IP
(1 P L A C E ) A F T E R
C O M M IS S IO N I N G IS C O M P L E T E
10
16
1 /4 " N P T G A S P R E S S U R E T A P L O C A T IO N
S E E IN S T A L L A T IO N N O T E # 8
9
P /N 9 9 6 0 0 1 P 9 3 .9 F C J
13
15
IN S T A L L A T IO N N O T E S :
14
5
6
4
G RO UN D SET SCREW
1 . M E A S U R E G U ID E P IP E T O E N S U R E G A S P IP E T IP IS S E T B A C K 2 " A S S H O W N
2 . I N S E R T N E W IG N IT O R IN T E R N A L S
3 . I G N IT O R O R IE N T A T IO N IN K A M L O K D -D O U P L E R IS N O T C R IT IC A L
4 . A T T A C H D F I A N D S P A R K R O D W IR E C O N N E C T O R S A T B A C K O F IG N IT O R
5 . D F I A N D S O L ID S P A R K R O D W IR E T R A IN A S S E M B L IE S A R E IN T E R C H A N G E A B L E
6 . H IG H V O L T A G E C O N D U C O R F R O M S O L I D S P A R K R O D S H O U L D B E T E R M IN A T E D A T H IG H V O L T A G E O U T P U T O F
IG N IT IO N T R A N S F O R M E R . G R O U N W IR E R E T U R N S H O U L D B E T E R M IN A T E D A T C A B IN E T G R O U N D B U S B A R
7 . G R O U N D W IR E R E T U R N F R O M D F I F L A M E R O D S H O U L D B E T E R M IN A T E D D IR E C T L Y T O C A B IN E T G R O U N D B U S B A R .
8 . R E M O V E 1 /4 " P IP E P L U G IN G A S IN L E T E L B O W A N D A T T A C H D IG IT A L G A U G E T O P R E S S U R E T A P F O R C O M M IS S IO N IN G
9 . I N S E R T D U S T P L U G C A P A F T E R R E M O V IN G G A S IN L E T A S S E M B L Y .
T H IS D R A W IN G D O E S N O T C O N T A IN A L L IN F O R M A T IO N N E C E S S A R Y F O R
M F G . T H IS P A R T . R E F E R T O P /N C O M M E N T S & P R O D U C T S T R U C T U R E
F O R C O M P L E T E M A T E R IA L ID E N T IF IC A T IO N A N D P R O C E S S IN G .
GEN ERAL N OTES:
1 0 . N A T U R A L G A S IG N IT O R C A P A C I T Y 1 2 ,0 0 0 S C F H @ 2 .5 P S I @ G A S IN L E T P R E S S U R E T A P
1 1 . (2 4 ) T O T A L IG N IT O R S O N C O N T R A C T . (" A " D IM = 9 3 .9 9 " )
R E F E R E N C E D R A W IN G S :
S E C T IO N A -A
V IE W R O T A T E D
IT E M S R E M O V E D F O R C L A R IT Y
SCALE 1 : 1
1 . 3 .0 0 D R B L U F F B O D Y G A S F R O N T IG N IT O R A R R A N G E M E N T & D E T A IL S : G -9 9 -6 0 0 1 (P R O P R IE T A R Y )
A L L D IM E N S IO N S A R E IN IN C H E S
T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
X .X X
IG N IT IO N /D F I
GROUND
± .0 6
AN G ULAR:
± 0°30'
S U R F A C E T E X T U R E : 1 0 0 0 M IC R O IN C H E S
R O U G H N E S S A V E R A G E -R a
T H IS D R A W IN G IS IN A C C O R D A N C E W IT H
A S M E Y 1 4 .5 M -1 9 9 4
M TL
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
R
C
L
J
6
25
15
2
U PD A T ED Q U A N T IT Y FO R IT EM 9 , A N D
A D D ED IT EM 15
C
R
L
J
6
29
15
R EM O V ED IT EM 12 , A N D D ELET ED
W ELD SY M BO LS PER EN G IN EER IN G
BOM
( 6[125.3812 .7 m m ])
2
IT E M
1
2
3
4
5
6
7
8
9
10
11
13
14
15
PART NUM BER
V 0 0 -9 7 8 9
V 0 0 -9 8 0 4
V 0 0 -8 7 8 4
7 6 -Y S T R -0 3
V 0 0 -2 5 8 9
E P S -9
E B 0 -0 0 7 9 9 1 -9 3 6 2 -7
M D 8 -0 0 1 5 5 -H K
7 6 -G M V L -0 2
M D 8 -0 0 1 5 5 -H D
M D 8 -0 0 1 5 5 -E B
1 2 -2 0 0 3
M D 8 -0 0 1 1 7 -B E
V 0 0 -9 8 3 5
QTY
2
1
1
1
2
2
1
5
1
1
3
1
1
1
M A T E R IA L
D E S C R IP T IO N
1 -1 /2 " B A L L V L V . W /S O L E N O ID & A C T U A T . 0
3 /4 " B A L L V L V . W /S O L E N O ID & A C T U A T O R 0
0
3 /4 " B A L L V A L V E
0
1 1 /2 " Y S T R A IN E R
0
1 -1 /2 " X 3 /4 " H E X R E D U C IN G B U S H IN G
0
T E E , 1 -1 /2 " X 1 -1 /2 " X 1 -1 /2 "
E B 0 -0 0 7 9 9 1 -1 D 9 3 6 2 N IP P L E -L G .7 5 X 1 4 .0 0 S C H 8 0 N P T
151
151
M D 8 0 -1 C 0 1 5 5
N IP P L E -L G 1 .5 0 X 6 .0 0 S C H 8 0 N P T
0
G L O B E V A L V E 1 -1 /2 "
151
M D 8 0 -1 C 0 1 5 5
N IP P L E -L G 1 .5 0 X 3 .0 0 S C H 8 0 N P T
151
M D 8 0 -1 C 0 1 5 5
N IP P L E -L G .7 5 X 2 .0 0 S C H 8 0 N P T
M D 8 0 -1 C 0 1 0 2
C A P -P IP E .7 5 C L 1 5 0 N P T
213
M D 8 0 -1 C 0 1 1 7
P L U G - H E X H D .7 5 N P T
210
0
1 -1 /2 " B A L L V A L V E
D R A W IN G
-
M A T E R IA L S P E C IF IC A T IO N C H A R T
F O R IN D E X T O M A T E R IA L S P E C IF IC A T IO N R E F E R T O
S T A N D A R D N O . 1 7 -6 4 , IN D E X N O . 1 4 .2
IT E M
151
SPEC. NU M BER
S A -1 0 6
C O M P O S IT IO N
GRADE
P U R C H A S IN G
IN S T R U C T IO N S
C A R B O N S T E E L P -1 ,
G r. N o . 1
210
S A -1 0 5
C A R B O N S T E E L .3 5 C A R B O N P -1
G r. N o . 2
213
A -1 9 7
M A L L E A B L E IR O N
B
P1A12
NONE
NONE
NONE
NONE
13
11
3
11
2
GENERAL NOTES:
1 . V A L V E T R A IN A S S E M B L Y T O B E P R O T E C T E D F R O M W E A T H E R D U R IN G S T O R A G E A N D
P R IO R T O IN S T A L L A T IO N .
2 . L IG H T L Y A P P L Y P IP E JO IN T C O M P O U N D (P E R M A T E X N O . 5 1 -D ) T O A L L P IP E J O IN T S A T
ASSEM BLY. D O N O T U SE TEFLO N TAPE.
3 . N A T U R A L G A S S P E C IF IC A T IO N S = .0 4 2 lb /ft, H IG H H E A T V A L U E = 1 0 0 0 B T U /ft.
4 . G L O B E V A L V E (IT E M N O . 9 ) T O B E A D J U S T E D T O O B T A IN T H E G A S P R E S S U R E R E Q U IR E D
A T T H E IG N IT O R IN L E T .
5 . P L U G A L L H O L E S W IT H P L A S T IC C A P S P R IO R T O S H IP M E N T .
6 . A L L U N IT S IN IN C H E S .
7 . IN L E T A N D O U T L E T C O N N E C T IO N S A R E T H R E A D E D .
3 /4 " V E N T
11
2
( 2[514.325.2 m m ])
7
1
( 1[218.37 1.2 m m ])
15
1
5
5
8
FLO W
6
10
8
8
4
8
6
14
P /N : E B 0 -0 0 7 9 9 1 -9 3 6 2
2
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9
T H IS D R A W IN G D O E S N O T C O N T A IN A L L IN F O R M A T IO N N E C E S S A R Y F O R
M F G . T H IS P A R T . R E F E R T O P /N C O M M E N T S & P R O D U C T S T R U C T U R E
F O R C O M P L E T E M A T E R IA L ID E N T IF IC A T I O N A N D P R O C E S S IN G .
BILL O F M A TE R IA L
16.0 0
.75
14 .50
16.0 0
Ø .50 (T Y P )
4
3
1
8
9
4 .70
10 11
2.30
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2
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FLAME
REL
Q TY .
PART NO.
1
1
V 00-2643
N EM A 4 EN C LO S U R E 20" H X 16" W X 6" D
2
1
V 00-2644
EN C LO S U R E B A C K P A N E L
3
1
75-W K IT -01
W IN D O W K IT - N EM A 4
4
1
V 00-2645
M O U N T IN G FO O T K IT - 4 FEE T /K IT
5
2
V 00-6610
R ELA Y, 2 FO R M C , 24 V D C C O IL
6
3
V 00-6611
R ELA Y, S O C KE T , D IN R A IL M O U N T
7
1
E P S -6
N A M E P LA T E - "A LS T O M P O W ER IN C ."
8
1
V 00-2652
W IR IN G D U C T 1" W X 2" H (3' LEN G T H )
9
4
V 00-2650
EN D S T O P
10
18
V 00-2647-IN
M O U N T IN G R A IL - P R 30 (P E R IN C H , 18" R EQ 'D .)
11
2
V 00-2648
R A IL O FFS ET B R A C KE T - T S 0706
12
1
D FI-100-41105
13
14
V 00-2646
14
2
75-C B 10-01
C IR C U IT B R EA K ER - 1 P O LE
15
1
V 00-2665
M E T A L O X ID E V A R IS T O R - 135V
16
2
V 00-2649
EN D S E C T IO N
17
2
V 00-9725
EN D S E C T IO N (FO R FU S ED T ER M IN A L B LO C K)
18
1
V 00-2929
M A R KIN G T A G S - B LA N K
19
1
V 00-2662
C O P P E R B US S B A R
20
1
V 00-2666
LU G - B U R N D Y S IN G LE H O LE G R O U N D LU G
21
1
V 00-10032
IG N IT O R T R A N S FO R M E R 220V / 50H Z 10,000 V A C
22
1
V 00-2656
N A M E P LA T E - "W A R N IN G H IG H V O LT A G E "
23
1
V 00-10033
R ELA Y, 10A 240V A C C O IL
D E S C R IP TIO N
6.70
F A UL T
1
ITE M
2
3
4
13
5
C B -0 2 A
15
C B -0 2 B
N
N
16
V DC2A
3A
4A
20.00
17
21.50
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6A
20 .0 0
7A
8A
18
DOOR
9A
10A
11A
12A
6
W A R N IN G
H IG H V O LT A G E
23
22
6
5
21
LIM E LIG H T D IA G N O S T IC FLA M E IN D IC A T O R
T ER M IN A L B LO C K M 4/6
9
10
7
19
F R O N T V IE W
A S S E M B L Y P /N E B 0 -0 0 7 9 9 1 -9 3 6 3
6.75
20
F R O N T V IE W - D O O R R E M O V E D
F R O N T V IE W - D O O R C U T O U T S
3.75
NO TES:
1.0 6
1. IN S T A LL A S T A N D A R D 5.88" D IN R A IL (W IT H O FFS E T ) O N B A C K P A N EL O F T H E C A B IN ET IN
T H E V ER T IC A L P O S IT IO N . M O U N T T H E D FI O N T H E D IN R A IL A N D IN S T A LL E N D S T O P S
A B O V E A N D B E LO W T H E D FI T O K EE P IT S E C U R E.
2. Q U A N T IT IE S S H O W N A R E FO R O N E C O N T R O L C A B IN E T .
3. P R O T EC T C A B IN ET FR O M W EA T H ER D U R IN G S T O R A G E .
4. A LL U N IT S A R E IN IN C HE S .
5. R EFE R T O S C H EM A T IC D R A W IN G FO R W IR IN G D E T A ILS A N D IN S T R U C T IO N S .
6. A LL IN T ER N A L W IR IN G A S S H O W N O N R EF D R A W IN G 2 T O B E C O M P LE T ED B Y S H O P V EN D O R .
7. LO C A T E EQ U IP M EN T O N B A C K P A N EL A P P R O X IM A T ELY A S S H O W N .
8. V EN D O R T O S U P P LY A P P R O P R IA T E M O U N T IN G H A R D W A R E.
3.50
5.88
R E F E R E N C E D R A W IN G S :
12.00
1. IG N IT O R C O N T R O L C A B IN E T W IR IN G S C H E M A T IC - - - - - - - - - - - - - - - - EB 0-007991-1D 9315
11.76
W A R N IN G
H IG H V O LT A G E
6.88
T H IS D W G . D O E S N O T C O N T A IN A LL IN FO R M A T IO N N E C ES S A R Y FO R M A N U FA C T U R IN G T H IS
P A R T . R E FER T O P /N C O M M E N T S & P R O D U C T S T R U C T U R E FO R C O M P LE T E M A T E R IA L
ID EN T IFIC A T IO N A N D P R O C E S S IN G .
2.25
1.50
A L L D IM E N S IO N S A R E IN IN C H E S
T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
.62
.88
3.88
1.50
X .X X X ±.0 1 5
X .X X ±.0 6
3.75
D R IL L E D H O L E S :
BACK PANEL LAYOUT
T H IS D R A W IN G IS IN A C C O R D A N C E W IT H
A S M E Y 1 4 .5 M -1 9 9 4
X .X X X
Ø 0-1 IN +.01 0/-.000
O V E R 1 IN +.020/-.000
Instruction Manual
LIMELIGHTTM Diagnostic Flame Indicator
Model DFI-100 Revision 4
abcd
© COPYRIGHT 2015 ALSTOM POWER INC.
DOCUMENT 5001 R2
REVISION: 0
5/1/15
i
LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
PROPRIETARY MARKS
CANbus
The CANbus network specification, written by Bosch, has been
standardized by ISO and SAE. The entire CAN specification is
standardized in ISO 11898-1 & ISO 11898-2 contains the CAN
physical layer specification.
NOTICE
This instruction manual has been prepared to serve as a guide in
operating and maintaining the equipment supplied by ALSTOM Power
Inc. It is not intended to cover all possible variations in equipment or
all specific problems that may arise.
It must be recognized that no amount of written instructions can
replace intelligent thinking and reasoning on the part of the operators,
especially when coping with unforeseen operating conditions. It is the
operator’s responsibility to become thoroughly familiar with the
equipment.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: E2B-000109
REVISION: 0
5/1/15
ii
LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
TABLE OF CONTENTS
DESCRIPTION
PAGE NUMBER
INTRODUCTION........................................................................................................................................... 1
OVERVIEW OF OPERATION....................................................................................................................... 1
FLAME DETECTION ................................................................................................................................ 1
Flame Rod ............................................................................................................................................ 1
Optical Detector Head .......................................................................................................................... 2
Flame Quality ....................................................................................................................................... 2
SPARK STATUS ....................................................................................................................................... 2
RELAY OUTPUTS .................................................................................................................................... 3
COMMUNICATIONS ................................................................................................................................. 3
RS485 ................................................................................................................................................... 3
CANbus ................................................................................................................................................ 4
4 to 20 mA Current Loop ...................................................................................................................... 4
FIRST OUT ............................................................................................................................................... 4
DIAGNOSTICS.......................................................................................................................................... 4
DISPLAY AND INTERFACE ......................................................................................................................... 5
FACEPLATE DISPLAYS ........................................................................................................................... 5
OLED Display ....................................................................................................................................... 6
FACEPLATE PUSHBUTTONS ................................................................................................................. 6
USER INTERFACE ................................................................................................................................... 6
Normal Mode ........................................................................................................................................ 6
Program Mode ...................................................................................................................................... 6
WIRING ....................................................................................................................................................... 14
EQUIPMENT SPECIFICATIONS ................................................................................................................ 18
PART NUMBERING / REVISIONS ............................................................................................................. 18
CUSTOMER SERVICE CONTACTS .......................................................................................................... 19
LIST OF FIGURES
Figure 1: DFI Display and Interface .............................................................................................................. 5
Figure 2: DFI Faceplate Pushbuttons ........................................................................................................... 6
Figure 3 - Ground Wiring............................................................................................................................. 15
Figure 4: Terminal Block Connections and Layout ..................................................................................... 16
Figure 5: Optical Head Wiring ..................................................................................................................... 17
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: E2B-000109
REVISION: 0
5/1/15
iii
Limelight™ Diagnostic Flame Indicator Model 100
INTRODUCTION
This manual provides information on the installation, operation and
troubleshooting of the ALSTOM Limelight Diagnostic Flame Indicator,
(henceforth referred to as the 'DFI'.) The Limelight DFI is an ignitor flame-sensing
device, which is able to discriminate between a “Flame” and a “No Flame”
condition for an ignitor. The electronic package is self-contained and is mounted
in the Ignitor Control Cabinet or a nearby junction box. The DFI offers the latest
“next generation” technology, including a number of added benefits and features
for ignitor reliability, diagnostics and ease of maintenance.
OVERVIEW OF OPERATION
FLAME DETECTION
Flame Rod
When configured to use a flame rod input, the DFI applies a 40V bias voltage to
a flame rod located within the ignitor. This flame rod is positioned so that the
ignitor flame impinges on the rod providing a current path through the flame to
ground. Ionized particles, present in all flames, cause a flame to conduct
electricity.
The DFI monitors flame rod current. Due to turbulence in the ignitor flame, and
natural flame flicker, the current signal is a complex time varying waveform.
Every 100mS the current signal is analyzed and the results are used to
determine the status of the flame. The measurements taken from the 100mS of
accumulated current data are as follows:
• Intensity:
This is the average value of the flame current during the
sample period. Its value can range from 0 to 100%. Earlier
revisions of the DFI referred to this value as “DC”.
• AC:
This is the difference between the minimum and maximum
flame current values found during the sample period. Its
value can range from 0 to 100%.
• Frequency: This is the frequency of the AC component of the flame
current signal. It is measured in Hz.
The AC value, and optionally Intensity and Frequency, are compared to
predetermined pull in and drop out values to determine the flame status.
If an excessive Intensity value is detected, a fault condition is indicated, and both
relays are de-energized. This check occurs even when the Intensity value is not
used for flame determination. An excessive Intensity value is indicative of carbon
bridging on the flame rod, or damage to the wire train allowing an alternate
current path to ground.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: E2B-000109
REVISION: 0
5/1/15
1
LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
Optical Detector Head
When the DFI is configured to use an optical detector input, an Exacta Flame
Scanner detector head is mounted on the ignitor.
The detector head converts light energy from the flame into a current signal. An
internal 1,000 ohm resistor in the DFI converts this current signal to a voltage,
and the resultant voltage is monitored by the DFI.
Due to turbulence in the ignitor flame, and natural flame flicker, this signal is a
complex time varying waveform. Every 100mS the signal is analyzed and the
results are used to determine the status of the flame. The measurements taken
from the 100mS of accumulated data are as follows:
• Intensity:
This is the average value of the voltage during the sample
period. Its value can range from 0 to 100%.
• AC:
This is the difference between the minimum and maximum
values found during the sample period. Its value is
measured in mV.
• Frequency: This is the frequency of the AC component of the flame
signal. It is measured in Hz.
Intensity, Frequency, and optionally AC, are compared to predetermined pull in
and drop out values to determine the flame status.
If the voltage measured across the 1000 ohm resistor exceeds 2.35V, or is less
than 0.125V, a fault condition is indicated, and both relays are de-energized.
Flame Quality
While the DFI is proving flame a flame quality value is continuously calculated.
Flame quality is a value that ranges from 0 to 100%. A flame quality value of 0%
occurs at the point where the DFI drops the flame relay, indicating loss of flame.
The algorithm used to calculate flame quality takes into account all of the
measured values and drop out values that are being used for flame
determination. For the flame quality value to have meaning it must be calibrated
during DFI commissioning.
SPARK STATUS
Spark status is a new feature added to the DFI with revision 4. This feature can
only be used when using a flame rod, and when using a spark transformer to
light the ignitor.
The spark status indication uses the flame rod as an antenna to receive the radio
frequency energy produced by the spark during ignitor light off.
This radio frequency signal is monitored by the DFI, and when it determines that
a spark is occurring the text “Sparking” appears on the DFI’s OLED display. This
aids troubleshooting in the event that an ignitor fails to light off. Additionally, this
feature can optionally be used to block flame proving while the spark is occurring.
Another feature of the spark status indication is the calculation of a spark health
value. This feature analyzes the radio frequency signature of the spark, and can
give an indication of a gradually weakening spark, so that maintenance can be
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
REVISION: 0
5/1/15
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
performed prior to a failure of the ignitor to light off. For the spark health value to
be meaningful it must be calibrated during DFI commissioning.
RELAY OUTPUTS
The DFI contains 2 output relays each having 2 sets of FORM C contacts. These
contacts are rated at 5A at a maximum of 250VAC / 30VDC when switching a
resistive load.
The main relay is a dedicated flame proving relay. It energizes on flame proven,
de-energizes on loss of flame. The main relay should be used to provide the
flame signal for the ignitor trip logic.
The auxiliary relay can be configured for any one of the following purposes:
• Flame:
The relay behaves the same as the main relay, energizing
on flame, de-energizing on loss of flame. When configured
as a flame relay the auxiliary relay should be used for
informational purposes only. It should not be used to supply
a flame proven signal to the ignitor trip logic.
• Ready:
The relay energizes when the DFI is operating normally, deenergizes on fault, or loss of DFI power.
• Spark:
The relay is used to control a spark transformer during
ignitor lightoff. Upon assertion of the “run” digital input the
relay will energize, and remain energized until a
configurable time period expires.
COMMUNICATIONS
RS485
The DFI has an RS-485 port for MODBUS RTU communication. The port is fixed
at 19200 baud, 8 bits, no parity. The DFI’s MODBUS slave address is a
configuration parameter.
The following variables are exposed via this port:
Register
1000
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
Description
Flame Proven
Fault
Spark Detected
Signal Strength Alarm
Unused
Intensity
AC
Frequency
Flame Quality
Spark Quality
First Out
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
Note:
The register addresses shown are zero based. You may have to
add an offset depending on the requirements of your MODBUS
master.
CANbus
A CANbus port is provided for communication with an Alstom Network Interface
Module. The CAN address is a configuration parameter. Please see the Alstom
IM200 instruction manual for additional detail.
4 to 20 mA Current Loop
The DFI provides one analog output via a 4 to 20 mA current loop. As is typical of
field devices, this output is loop powered. In other words, power for this output
must be provided by the reading device, or by an external power supply.
This output can be configured to provide the current value of any one of the
following variables:
• Intensity
• Frequency
• AC
• Flame Quality
The choice of variable to output, and full scale value are set with configuration
parameters.
FIRST OUT
The first out feature is a simple sequence of events recorder that records the first
event that occurs before loss of ignitor flame.
To use this feature, at a minimum a set of dry contacts that are closed when the
ignitor is in the “run” state must be wired across digital input DI 1.
The following digital inputs are optional when using this feature:
• DI 2 Wire a set of dry contacts that close with combustion air
pressure/flow.
• DI 3 Wire a set of dry contacts that close when ignitor trip valve is open.
• DI 4 Wire a set of dry contacts that close with fuel pressure/flow.
The recorder is armed when all used inputs are closed, and the DFI proves the
ignitor flame. The DFI will then record the first digital input that opens before the
loss of flame. If an input opens and then closes again before loss of flame the
event is ignored.
DIAGNOSTICS
The DFI performs extensive internal self tests both on system startup, and
periodically during normal operation. Should a self test fail, power is removed
from both relays forcing them to de-energize, and the system immediately
reboots. If the reboot does not correct the problem, the DFI will continuously
cycle between reboot and self test.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
REVISION: 0
5/1/15
4
LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
DISPLAY AND INTERFACE
Figure 1: DFI Display and Interface
FACEPLATE DISPLAYS
POWER LED
The power LED is lit when AC power is supplied to the
DFI.
FLAME LED
The flame LED is lit when the programmed flame proving
criteria is satisfied.
REL LED
The reliability LED is lit when flame quality is below a
predefined threshold.
FAULT LED
The fault LED is lit when a fault condition has been
detected by the DFI.
LED BAR
GRAPH
The LED bar graph is used to represent the current value
of one of the following variables:
Intensity
Frequency
ACV
Flame Quality
The selection of which variable to use is a configuration parameter. The default
selection is Flame Quality.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
REVISION: 0
5/1/15
5
LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
OLED Display
The OLED display, along with the 5 faceplate pushbuttons, allow the user to
monitor and configure the DFI. It should be noted that the DFI has a screen saver
that will cause the display to turn off after 20 minutes of inactivity. When the
screen saver is active pressing any of the keypad keys will turn off the screen
saver. On DFI-100s with V06 or newer firmware, a change of state of any of the
digital inputs, or a change in flame status will also turn off the screen saver.
FACEPLATE PUSHBUTTONS
Each pushbutton has an associated numerical value, i.e. 1 to 5, that allows the
user to enter an access code prior to changing the function codes. The numerical
designation and description of the pushbuttons are identified in Figure 2 below.
Figure 2: DFI Faceplate Pushbuttons
USER INTERFACE
Normal Mode
Upon power up the DFI display is in a “normal” informational mode. In this mode
several screens of information are available to the user. Pressing the up (Key 2)
or down (Key 4) arrow keys will cycle through the available displays.
Program Mode
To enter program mode at the local keypad depress Key 1 (Program On/Off).
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
REVISION: 0
5/1/15
6
LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
NOTE:
The DFI is equipped with an interlock that prevents simultaneous
editing of parameters from two locations. An attempt to enter
program mode, while parameters are being edited remotely with
the PC interface, displays a warning message and returns the
DFI to normal mode.
After pressing Key 1 the user is prompted for a password. The factory default
password is 11111. After successfully entering the password the following menu
is displayed:
• Edit Parameters
• Cal Analog Out
• Force Relays
• Save Norm Fact
• Save Spark Fact
• Next Page
If you wish to exit program mode and return to normal mode press Key 1.
Otherwise use the up and down arrow keys (Key 2 & Key 4) to scroll to the
desired selection. When the desired selection is highlighted press Key 5
(Enter/Store).
Edit Parameters
Selecting “Edit Parameters” causes the configuration parameters to be
displayed one at a time. Use the up and down arrow keys (Key 2 & Key 4) to
cycle between the available parameters. To change the value of a displayed
parameter press Key 5 (Enter/Store). This will highlight the value indicating
that it can be changed.
If the entire value is highlighted, use the up and down arrow keys (Key 2 &
Key 4) to cycle between the available values.
If a single digit is highlighted, use the up and down arrow keys (Key 2 & Key
4) to increment/decrement the value of that digit. Use Key 2 to change the
highlighted digit.
After editing the parameter use Key 5 to store your change, or Key 1 to
discard your change and return to the original value.
The DFI configuration parameters are as follows:
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
• Detector Type:
Selects either Flame Rod, or Optical input. It should
be noted that the minimum, maximum and default
values for some of the flame proving parameters are
dependent on the type of input selected.
• Ignitor Identifier:
Eight character alpha numeric identifier for ignitor.
This is only for documentation purposes, and has no
effect of flame proving.
REVISION: 0
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LIMELIGHT
• Intensity Pull In:
Flame Rod
0
100
0
• Intensity Drop Out:
• AC Pull In:
Min Value
Max Value
Default
• AC Drop Out:
Min Value
Max Value
Default
• Freq Pull In:
Min Value
Max Value
Default
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
Diagnostic Flame Indicator Model 100
When flame intensity rises above this value, the
intensity flame proving criteria is met.
Min Value
Max Value
Default
Min Value
Max Value
Default
TM
Optical Head
10
100
10
When flame intensity drops below this value, the
intensity flame proving criteria is no longer met.
Separate pull-in and drop-out values allow for
hysterisis preventing relay from chattering as value
approaches the pull-in or drop-out level. Drop out
value cannot differ from pull in by more than 15.
Flame Rod
0
100
0
Optical Head
10
100
10
When the AC component of the flame signal rises
above this value, the AC requirement for proving
flame is met.
Flame Rod
10
100
10
Optical Head
0
100
0
When the AC component of the flame signal drops
below this value, the AC requirement for proving
flame is not met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from
chattering as value approaches the pull-in or dropout level. Drop out value cannot differ from pull in by
more than 15.
Flame Rod
10
100
10
Optical Head
0
100
0
When flame flicker frequency rises above this value,
the frequency flame proving criteria is met..
Flame Rod
0
250
0
REVISION: 0
5/1/15
Optical Head
5
250
5
8
LIMELIGHT
• Freq Drop Out::
Flame Rod
0
250
0
• Freq Sensitivity:
10
100
10
• Pull In Time Delay:
Time delay, in seconds, from the time that all flame
proving criteria is met, and the flame relay closes.
Min Value
Max Value
Default
0
10
0
Time delay, in seconds, from the time that a flame
proving requirement is lost, and the flame relay
opens.
Min Value
Max Value
Default
• Intensity Gain:
0
2
2
Multiplier applied to the measured intensity value
when using a flame rod. This parameter is ignored
when using an optical head.
Min Value
Max Value
Default
• AC Gain:
1
10
9
Multiplier applied to the measured AC value when
using a flame rod. This parameter is ignored when
using an optical head.
Min Value
Max Value
Default
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
Optical Head
5
250
5
Minimum peak-to-peak value, in mV, that the signal
must change to be included in the flicker frequency
calculation.
Min Value
Max Value
Default
Delay:
Diagnostic Flame Indicator Model 100
When flame flicker frequency drops below this
value, the frequency flame proving criteria is no
longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering
as value approaches the pull-in or drop-out level.
Drop out value cannot differ from pull in by more
than 6.
Min Value
Max Value
Default
• Drop Out Time
TM
1
10
6
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LIMELIGHT
• Intensity Filter
Fact:
Diagnostic Flame Indicator Model 100
Smoothing filter applied to the measured intensity
value. A value of 0 equals no filter, a value of 12
equals the maximum filter.
Min Value
Max Value
Default
0
12
3
• AC Filter Factor:
Smoothing filter applied to the measured AC value.
A value of 0 equals no filter, a value of 12 equals the
maximum filter.
Min Value
Max Value
Default
0
12
3
• Freq Filter Factor:
Smoothing filter applied to the measured frequency
value. A value of 0 equals no filter, a value of 12
equals the maximum filter.
Min Value
Max Value
Default
0
12
3
• Quality Filter
Factor:
Smoothing filter applied to the calculated flame
quality value. A value of 0 equals no filter, a value of
12 equals the maximum filter.
Min Value
Max Value
Default
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
TM
0
12
3
• 4 to 20ma Source:
Selects the value that will be output on the 4-20mA
current loop. Available choices are: Intensity, ACV,
Quality, and Frequency. The default value is Quality.
• 4 to 20ma Full
Scale:
Value that will cause a full scale output on the 420mA current loop
• Aux (B) Relay
Configuration:
Defines the purpose of the auxiliary relay. Available
choices are: Flame, Ready, Spark, and None.
Default value is Flame.
• MODBUS Port
Address:
Sets the slave address of the MODBUS port.
• CANBUS Address:
Sets the address of the CANbus port
• CANBUS Baud
Rate::
Sets the baud rate of the CANbus port. Available
choices are 62.5K, 125K and 250K. Default is 125K.
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
• Enable Flame
Proving:
Defines additional criteria to enable flame proving.
Choices are as follows:
“Always”
Close the flame relay whenever the flame proven
criteria is met.
“Run Spark”
Used when the aux relay is controlling a spark
transformer. Only close the flame relay if the “run”
digital input is asserted, aux relay is de-energized (
No spark), and the flame proving criteria is met.
“Run”
Only close the flame relay if the “run” digital input
is asserted, and the flame proving criteria is met.
“No Spark”
Only close the flame relay if spark is not detected,
and the flame proving criteria is met.
The default value is “Always”.
• First Out
Enables the first out feature and defines which
inputs will be used. When the first out feature is
enabled, Din1, the “run” input is required. The other
3 digital inputs are optional. Choices are as follows:
“432”
Monitor all digital inputs for “first out”
“XXX”-
Monitor only the “run” input Din1. All other digital
inputs are ignored.
“Off”-
The first out feature is disabled.
“43X”-
Monitor “run”, Din3, and Din4. Din2 is ignored.
“4X2“
Monitor “run”, Din2, and Din4. Din3 is ignored.
“4XX“
Monitor “run”, and Din4. Din2 and Din3 are
ignored.
“X3X“
Monitor “run”, and Din3. Din2 and Din4 are
ignored.
“XX2“
Monitor “run”, and Din2. Din4 and Din4 are
ignored.
The default value is “Off”.
• Spark Trans On
Time
Defines the time, in seconds, that the auxiliary relay
will remain energized, after the assertion of the run
input, when using the auxiliary transformer to control
the spark transformer.
Min Value
Max Value
Default
• Signal Strength
Alarm Setpoint
0
10
8
When flame quality is less than this value a reliability
alarm occurs. Setting this parameter to zero
disables the reliability alarm.
Min Value
Max Value
Default
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CONTRACT: EB0-000665
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100
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
• Spark Source
Used by the spark health algorithm. Choices are
“Transformer” and “HEI”. If HEI is selected, the
spark health calculation is not performed. The
default value is “transformer”
• Spark Det Setpoint
Used by the spark detection algorithm. Do not
change unless instructed to do so by Alstom
• Spark Width
Threshold
Used by the spark detection algorithm. Do not
change unless instructed to do so by Alstom
• Spark Det Filt
Factor
Used by the spark detection algorithm. Do not
change unless instructed to do so by Alstom
• Intensity Norm
Factor
Normalization factors should be calculated
automatically using the “Save Norm Factor” menu
selection. Do not manually change this value unless
instructed to do so by Alstom.
• AC Norm Factor
Normalization factors should be calculated
automatically using the “Save Norm Factor” menu
selection. Do not manually change this value unless
instructed to do so by Alstom.
• Frequency Norm
Factor
Normalization factors should be calculated
automatically using the “Save Norm Factor” menu
selection. Do not manually change this value unless
instructed to do so by Alstom.
• Bar Graph Source
Defines the variable that will be output on the bar
graph display. Available choices are “Intensity”,
“ACV”, “Quality”, and “Frequency”. When using a
flame rod input the default value is “ACV”, and when
using an optical head the default value is “Quality”.
• Line Frequency
Rejection
When this feature is enabled the DFI will not prove
flame if the AC component of the input signal is a
sine wave with the same frequency as the power
line. Use of this feature will prevent false flame
proving from a line powered light source, or from line
frequency electrical noise. The default is to disable
this feature.
• Line Frequency
Selects the power line frequency used by the line
frequency rejection feature. Available choices are
50Hz and 60Hz. The default value is 60Hz.
Cal Analog Out
“Cal Analog Out” allows calibrating the 4-20 mA outputs. Selecting this item
will cause the 4ma calibration value to be forced on the 4 to 20 mA output,
and to be displayed on the screen.
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
Use the up and down arrow keys (Key 2 & Key 4) to adjust the calibration
value until the reading device reads 4mA.
When the 4mA calibration is complete press Key 3 . The 20mA calibration
value is forced on the selected output, and displayed on the screen. Use the
up and down arrow keys (Key 2 & Key 4) to adjust the calibration value.
When the calibration is complete press Key 1 (Program On/Off) to return to
the previous menu.
Force Relays
“Force Relays” allow the user to force a relay into the energized state. This
feature is used during commissioning to verify the relay field wiring. When a
relay is placed into the “forced” mode the other relay is de-energized.
After selecting “Force Relays” the following is displayed:
Press Key 5
(Enter/Store) to
Force Relay 1
Use the up and down arrow keys (Key 2 & Key 4) to change the relay to
“force”. Selecting Key 5 (Enter/Store) will energize the relay. When a relay
is “forced”, pressing any key causes that relay to de-energize, and returns to
the above display. A relay can be forced for a maximum of 20 minutes. After
force mode expires, the DFI returns to normal operation.
Save Norm Fact
“Save Norm Fact” is used to save normalization factors. The normalization
factor is used in the flame quality calculation. The normalization factor should
be saved when the ignitor is in operation.
After selecting “Save Norm Factor” the following message is displayed:
Norm Fact Saved
Press any key
to continue
Save Spark Fact
“Save Spark Fact” is used to calibrate the spark health algorithm. When
selected this routine uses data collected during the last successful ignitor
lightoff to perform this calibration. If the data is suspect or if the ignitor has
not been run since the last DFI reboot, an error message is displayed, and
calibration is not performed.
Next Page
“Next Page” is used to access page 2 of 2 of the parameters. Selecting it
with Key 5 (Enter/Store) will show the following menu:
Restore Default
Change Password
Previous Page
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
Use the up and down arrow keys (Key 2 & Key 4) to scroll to the desired
selection.
When the desired selection is highlighted press Key 5
(Enter/Store).
Restore Default
“Restore Default” is used to clear all of the settings on the DFI and return it to the
original factory state. Selecting Key 5 (Enter/Store) will clear the memory and
display the following message:
Def Vals Loaded
Press any key
to continue
Change Password
After selecting “Change Password” the user is prompted for a new password.
The password must be 5 characters in length, and can be any combination of
Keys 1 through 5. A second prompt requires the new password be entered a
second time for confirmation.
Previous Page
“Previous Page,” when selected, takes the user back to page one of the
configuration screen.
WIRING
NOTE:
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-000665
•
The DFI ground connection, terminal 17, must be
connected directly to cabinet ground.
•
Do not connect the flame rod wire train ground wire
directly to terminal 17.
•
For proper operation of the DFI the flame rod wire train
ground wire must be connected directly to cabinet
ground
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
Figure 3 - Ground Wiring
NOTE:
The Metal Oxide Varistor sometimes installed, between pins 17
and 18, on Revision 3 and older DFIs is not required on Revision
4 and newer DFIs (Part Number DFI-100-40000 and higher).
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
RS485 +
L1
N
Unused
Unused
Aux Relay C1
Aux Relay C2
Figure 4: Terminal Block Connections and Layout
Digital Input Connections
DI1
DI2
DI3
DI4
Ignitor Run
Combustion Air
Trip Valve
Fuel Flow/Pressure
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LIMELIGHTTM Diagnostic Flame Indicator Model 100
1
+15V (Red)
Figure 5: Optical Head Wiring
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
EQUIPMENT
SPECIFICATIONS
Power:
Ambient Temperature:
Flame Relay:
Auxilliary Relay:
Digital Inputs:
Analog Output:
Dimensions:
Mounting:
2A max @ 85-250 VAC, 50-60 Hz
-18 – 70º C (0 – 160º F)
2 Form C contacts, 5 AMP @ 250 VAC / 30VDC
2 Form C contacts, 5 AMP @ 250 VAC / 30VDC
4 - Dry contacts only
4-20 mA (loop powered)
4.38” Wide x 4.13” Tall x 2.38” Deep
Standard DIN 3 Rail
PART NUMBERING /
REVISIONS
The part number for the revision 4 DFI100 takes the format of
DFI-100-4xyzz
Where:
4 
x 
y 
zz 
Indicates the overall product major revision.
Indicates the internal processor board hardware revision.
Indicates the internal IO board hardware revision.
Indicates the firmware revision.
As an example a DFI with a part number of DFI-100-40001 is a revision 4 DFI
with a rev 0 processor board, a revision 0 IO board, and a firmware revision of
01.
All DFI-100s are backwards compatible with previous revisions, so a newer
revision DFI-100 can be used to replace an older one.
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LIMELIGHT
TM
Diagnostic Flame Indicator Model 100
CUSTOMER SERVICE
CONTACTS
For questions regarding the DFI-100 or to obtain replacements, repair service, or
for warranty issues please contact the appropriate Customer Service
Representative noted below.
IN USA:
Alstom Power Inc.
200 Great Pond Drive
Windsor, CT 06095
(866) 257-8664
E-Mail: windsorparts@power.alstom.com
IN CANADA:
Alstom Power Canada
1430 Blair Place
Ottawa, ON K1J 9N2
CANADA
(613) 747-5779
E-Mail: canadianaftermarketparts@power.alstom.com
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TAB 3
LIMELIGHT™ High Energy Ignitor Retractable (HEIR)
TABLE OF CONTENTS
DESCRIPTION
PAGE NUMBER
Scope of Supply ............................................................................................................................................ 1
Limelight ™ High Energy Ignitor Retractable (HEIR) ................................................................................. 1
Major Components ........................................................................................................................................ 1
Solenoid Valve ........................................................................................................................................... 1
Proximity Switches ..................................................................................................................................... 1
Stroke Limiting Ignitor Clamp .................................................................................................................... 2
Pneumatic Retract ..................................................................................................................................... 2
Features & Benefits ....................................................................................................................................... 2
Easy Connections ...................................................................................................................................... 3
Small Profile............................................................................................................................................... 3
Easy Mounting ........................................................................................................................................... 3
Pneumatic Actuator and Proximity Switch Operation .................................................................................... 4
HEIR Exciter .................................................................................................................................................. 5
Advanced Ignition Technology................................................................................................................... 5
Exciter Theory of Operation ....................................................................................................................... 6
Ignitor Connection Diagram ....................................................................................................................... 7
Equipment Specifications .............................................................................................................................. 7
Ignition Exciter ........................................................................................................................................... 7
Mechanical: ............................................................................................................................................ 7
Igniter Tip ................................................................................................................................................... 8
Mechanical:................................................................................................................................................ 8
FAQ (Frequently asked Questions) ............................................................................................................... 8
Retraction Needed? ................................................................................................................................... 8
What Type of Proximity Switch is Used? ................................................................................................... 8
What are the Specifications of the Pneumatic Tubing?............................................................................. 8
What Air Pressure is Required? ................................................................................................................ 8
How long will the Igniter Tips Last? ........................................................................................................... 8
How long will the Exciters Last? ................................................................................................................ 8
Exciter Trouble Shooting ............................................................................................................................... 9
Intermittent or No Spark ............................................................................................................................ 9
Weak Spark ............................................................................................................................................... 9
MAINTENANCE .......................................................................................................................................... 10
Exciter Module Replacement .................................................................................................................. 10
HEIR Tip Inserted Position - Location And Adjustment ........................................................................... 10
HEIR Tip Positioning – Field Installation Procedure ................................................................................ 12
Recommended Spare Parts List ................................................................................................................. 13
LIST OF FIGURES
Figure 1: Limelight™ High Energy Ignitor Retractable (HEIR) Side View ..................................................... 2
Figure 2: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View ................................................. 3
Figure 3: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View showing Ignitor Stroke
Limiting Clamp............................................................................................................................................... 4
Figure 4: Junction Box Wiring Diagram ........................................................................................................ 4
Figure 5: Wiring Schematic for Local Exciter Cabinet................................................................................... 5
Figure 6: Exciter ............................................................................................................................................ 6
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CONTRACT: E2B-000109
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Figure 7: HEI Block Diagram ......................................................................................................................... 7
Figure 8: Flex Ignitor Cable and Flex Spark Rod .......................................................................................... 7
Figure 9: HEI Spark Tip Locating Guide ..................................................................................................... 11
Figure 10: HEI Spark Tip Set-Up Requirements ......................................................................................... 12
DRAWINGS
DRAWING NUMBER
High Energy Ignitor Assembly with Retract ....................................................................EB0-007991-1E9327
HEI Exciter and Cabinet ........................................................................................................... C-EPSC-0133
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LIMELIGHT™ High Energy Ignitor Retractable (HEIR)
SCOPE OF SUPPLY
Limelight ™ High Energy Ignitor Retractable (HEIR)
The new spark ignitor includes Alstom’s state of the art high energy exciter that
discharges 12 Joules of energy to the spark tip at a rate of 4 times per second.
The exciter is supplied in a junction box that is configured to accept switched 120
VAC. The Spark rod is mounted to a pneumatic advance/retract mechanism
complete with solenoid operation and proximity switch feedback. The spark rod
assembly utilizes Alstom’s solid rod technology which eliminates wires in the
spark rod and incorporates ceramic insulators inside the rod assembly. Further
details of this supply are:
LIMELIGHT™ Retractable HEA Ignitor hardware supplied consisting of 32
assemblies 16 left hand and 16 right hand configurations. Each complete with
stainless steel mechanical retract assembly. HEIR Ignitors are located in each of
the eight corner windboxes at the AB elevation, CD elevation, EF elevation, and
the GH elevation. Each consisting of the following:
•
Heavy oil high energy exciter complete with NEMA 4X junction boxes, 12
joules, 4 sparks per second, solid state design.
•
High energy arc ignitor (HEA) tip complete with wand assembly and 20 feet
(6096mm) of electrical wiring.
•
Pneumatic Retract Assembly, 5” (127mm) stroke, 120 Vac solenoid, 2
proximity switches. (Cylinder is capable of 8" (203.2mm) retraction currently
set to 5"(127mm) travel)
•
Guide pipe assembly
MAJOR COMPONENTS
The figures on the following pages show the highlights, major parts and air
system requirements for the HEIR Actuator Assembly.
Solenoid Valve
Air is supplied to the actuator assembly at 75 PSIG (5.1 bar)at 1
SCFM(28L/min)for 3-5 sec electronically controlled solenoid valves direct the air
to the pneumatic cylinder. The exhaust ports on the solenoid valves are supplied
with mufflers and have dedicated variable speed control orifices. These orifices
can be adjusted to allow for smooth, positive advance and retract of the spark rod
system. This is needed to insure that mechanical damage to the system does not
occur due to abrupt cylinder actions. Reference Drawings EB0-007991-1E9327
and Figures 1, 2, and 3.
Proximity Switches
Proximity switches are mounted on the pneumatic cylinder and are wired to the
NEMA 4X junction box. Proximity switches provide feedback as to whether the
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
flex spark rod is advanced or retracted. Reference Drawing EB0-007991-1E9327
and Figures 1, 2, and 3.
Stroke Limiting Ignitor Clamp
The stroke limiting ignitor clamp attached to the cylinder rod positions the flexible
spark rod relative to the advance/retract mechanism. Changing the clamp
location on the flex spark rod determines the spark tip insertion position when
advanced. This assembly will utilize a 5” stroke for the flexible spark. Reference
Drawing EB0-007991-1E9327 and Figure 3.
Figure 1: Limelight™ High Energy Ignitor Retractable (HEIR) Side View
Pneumatic Retract
Retraction is only used to prevent damage to the igniter tip. The last inch of the
igniter tip can withstand 1000°C. The maximum temperature of the connector
end of the igniter tip is 649°C. Retraction is used if these temperature limits are
exceeded; in general, this only applies for direct ignition of a main fuel.
Reference Drawing EB0-007991-1E9327 and Figure 1
FEATURES &
BENEFITS
The design incorporates many features requested by field personnel. Consider
the following common performance advantages.
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Easy Connections
All electrical connections are in a single NEMA 4X junction box, complete with
wiring schematic on the inside of the enclosure cover. The solenoid ports are
1/4" NPT with quick connect terminations.
Figure 2: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View
Small Profile
The entire assembly is compact to minimize the retractor profile on the burner
front. From the end view, the entire assembly can fit within an 8" (203mm)
diameter. This compact design allows easy retrofits and is readily incorporated
into new burner designs.
Easy Mounting
Mounting options include either a 5" OD flange. The assembly includes an
adjustable clamp to set the igniter tip position in the furnace. These features
allow fast and easy mounting with minimum changes.
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Figure 3: Limelight™ High Energy Ignitor Retractable (HEIR) Bottom View showing Ignitor Stroke
Limiting Clamp
PNEUMATIC ACTUATOR AND
PROXIMITY SWITCH OPERATION
The double acting pneumatic cylinders use air pressure to move the spark rod in
both directions. A five port, four-way solenoid valve controls the cylinder. When
power is applied, the spark rod inserts. When power is removed, the rod retracts.
The proximity switches are positioned to confirm full insertion or retraction. Each
NEMA 4X junction box includes a schematic reference figure 4 , which is affixed
to the enclosure cover. This internal label provides a quick and easy reference to
simplify installation or maintenance. Also reference Drawing EB0-007991-1E9327
and Figures 1, 2, and 3.
Figure 4: Junction Box Wiring Diagram
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
HEIR EXCITER
Reference Drawing C-EPSC-0133 and Figures 5, 6 and 7.
Direct Ignition of No. 2 Fuel Oil
Special Ignition Fuels Are Not Needed.
Our Oil ignition system is an ideal solution when gas or diesel is not available.
Alternatively, in the case of marine application where gas is not permissible, High
Energy ignition is an ideal replacement for the carbon arc rod. Direct ignition of
the main fuel lowers costs and reduces complexity.
Direct spark ignition eliminates ignition fuel controls & valves.
Direct spark ignition eliminates the need for separate fuel storage.
Direct spark ignition increases reliability since there are fewer parts that last
longer.
The high-energy spark clears fouling and is capable of igniting bunker grade fuel
oil. It even fires under water.
This system provides reliable light off of Light oil in the following conditions:
Advanced Ignition Technology
Standard HEI systems are capable of providing light off of light oil in optimum
conditions. Critical factors include fuel temperature, quality of fuel atomization
and a low loss discharge path. Our high-energy ignition system has additional
enhancements, which our research has shown to provide significant
improvements to light off capability. The exciter is solid-state. The elimination of
tubes increases the flexibility to provide various output characteristics while
increasing life. The exciter provides approximately 300 watts output, which is not
practical for the old gas tube technology.
Figure 5: Wiring Schematic for Local Exciter Cabinet
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Figure 6: Exciter
Exciter Theory of Operation
The High Energy Ignition Exciter operates without gas discharge tubes. Energy
accumulates on storage capacitor CSTG, as the exciter draws power from the
input power line. The capacitor slowly accumulates a charge to a preset voltage
during the interval between sparks. The capacitor charging circuit is a power
factor converter, PFC, which forces line current to approximate a sine wave in
phase with the line voltage. The resultant high power factor (>0.95) minimizes
line current amplitude and line voltage distortion.
Additionally, the power factor converter provides galvanic isolation between the
line and the discharge circuit potentials.
When the capacitor has charged to a preset voltage, an electronic switch rapidly
discharges the capacitor through a pulse-forming network into the ignitor.
Although the discharge current amplitude can vary from several hundred to
several thousand amperes (depending on the application), the life of the
electronic switch is not affected by the accumulation of these pulses.
The pulse-forming network controls the amplitude and duration of the discharge
current pulse to provide characteristics, which enhance ignition and extend the
life of the storage capacitor and igniter. Where the exciter output is typically
2000V the pulse-forming network can provide a 5000V-trigger voltage as needed.
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Power Factor Converter
85 to 265 VRMS
50 to 60 Hertz
CSTG
Electronic Switch
with
Pulse Forming Network
To Spark
Ignitor Tip
Figure 7: HEI Block Diagram
Ignitor Connection Diagram
The flex spark rod is 99.875 inches (2536 mm) total length. The harness has a
supplied spark and ground wire length of 20 feet (6096mm). The flex conduit
from the connector is typically supplied at a length of 10 feet (3048mm). Wand
Assemblies are built to length as required.
Figure 8: Flex Ignitor Cable and Flex Spark Rod
EQUIPMENT SPECIFICATIONS
Ignition Exciter
Mechanical:
Enclosure NEMA 4X,
NEMA 4X, 7/8" (22mm) Entrance Hole for input power access
Box dimensions:
10" X 8" X 6" [254mm X 203.2mm X 152.4
mm]
Net Weight:
26 Lb. [12 kg]
Input Power:
85-265 Vac, 50-60 Hz, 5A @ 100V
Stored Energy:
12 Joules Minimum
Spark Rate:
4 Sparks per Second minimum
Duty Cycle:
(2 minutes ON, 5 minutes OFF) X 4, followed by 60 minutes OFF
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Temperature:
Operating -25°C to 75°C
Igniter Tip
Mechanical:
Net Weight:
Shipping Weight:
Temperature:
Angle:
Length:
0.35 Lb. [.23 kg]
0.75 Lb. [.34 kg]
1200°F MAX [649°C]
Straight is standard, angles available up to 90° maximum
7.3 inches (185.42mm)
CAUTION:
Do not operate open circuit.
FAQ (FREQUENTLY ASKED
QUESTIONS)
Retraction Needed?
Retraction is only used to prevent damage to the igniter tip. The last inch of the
igniter tip can withstand 1000°C. The maximum temperature of the connector
end of the igniter tip is 649°C. Retraction is used if these temperature limits are
exceeded; in general, this only applies for direct ignition of a main fuel. On a
Recovery Boiler, retraction is required to prevent chemical attack on the spark tip
while firing black liquor.
What Type of Proximity Switch is Used?
A reed type. magnetic positioning switch is used it has L.E.D.display, which
illuminates when engaged and power has been applied. Switching current is
100mA max. Switching voltage is 10 to 120VAC, 10 to 30VDC. Function normally
open. Enclosure type IP68.
What are the Specifications of the Pneumatic Tubing?
The tubing material is high temperature polyamide rated to 250psi and 194°F
(90°C).
What Air Pressure is Required?
The solenoid control valve pressure rating is 14.5-145 PSIG (1-10 BAR). It has a
flow capacity of 79 SCFM (2237l/min). The cylinder and tubing is rated 250 P.S.I
(17.2 bar). Maximum.
How long will the Igniter Tips Last?
Oil Igniter Tips (P/N 1G-5900-2), and are expected to last 250,000 to 350,000
sparks. As igniter tips wear, the spark energy increases (spark size and intensity)
until complete failure. Actual life will depend on the temperature, environment
and duty-cycle.
How long will the Exciters Last?
The exciter is warranted for one year. The most likely component to wear out is
the energy storage capacitor. The expected capacitor life is approximately five
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CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
million output pulses. The exciters are designed to allow replacement of
capacitor assemblies. The typical useful life of many of our exciters is
approximately ten years.
EXCITER TROUBLE SHOOTING
WARNING:
ALL POWER TO THE IGNITION EXCITER SHOULD BE
TURNED “OFF” AND PRECAUTIONS TAKEN TO MAKE
SURE IT IS NOT ACCIDENTALLY TURNED “ON” AT
LEAST FIVE (5) MINUTES PRIOR TO TOUCHING THE
EXCITER MODULE. THIS WILL ALLOW TIME FOR
THE STORED ENERGY IN THE CAPACITORS TO
DISSIPATE. FAILURE TO DO THIS WILL RESULT IN
SEVERE PERSONNEL HAZARD. DANGEROUS AND
POTENTIAL LETHAL VOLTAGES ARE PRESENT.
Intermittent or No Spark
Before proceeding, ensure that the system is connected properly.
Igniter tips wear out over time. A worn igniter tip is the most likely reason for the
system to stop sparking. Remove power and replace the igniter tip.
After replacing the igniter tip, if the system is still not operating properly, ensure power
has been applied to the exciter module. This can be confirmed by observing the AC power
applied to the input power terminals L1 and L2 with a voltmeter. Often, you can hear the
exciter module operating. If it is ticking (at approximately 5 Hz), then it is likely that the
problem is downstream of the module. If the module is not ticking, remove power and
replace the module, per the directions below.
If the exciter appears to be generating pulses, and the igniter tip does not spark, remove
power and replace system components in the following order:
•
Igniter Tip
•
Rod
•
Harness
•
Exciter module
Weak Spark
Before proceeding, ensure that the system is connected properly.
Worn igniter tips generate a larger spark than a new tip because the air-gap
(distance between the center electrode and the shell) is larger.
As the igniter tip wears, the electrode material erodes. In effect the system
becomes more powerful as it ages. Eventually, the air-gap becomes too large for
the pulse to bridge the gap.
New igniter tips still have enough spark energy to ignite diesel or No. 2 oil, although
the spark may appear “weaker”.
 COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
9
LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
If the spark is exceptionally weak, even with a worn igniter tip (with air-gap of
approximately 2mm or 0.040” between the center electrode and shell), replace the
exciter module.
MAINTENANCE
Exciter Module Replacement
WARNING:
ALL POWER TO THE IGNITION EXCITER SHOULD
BE TURNED “OFF” AND PRECAUTIONS TAKEN TO MAKE
SURE IT IS NOT ACCIDENTALLY TURNED “ON” AT LEAST
FIVE (5) MINUTES PRIOR TO TOUCHING THE
EXCITER MODULE. THIS WILL ALLOW TIME FOR THE
STORED ENERGY IN THE CAPACITORS TO
DISSIPATE. FAILURE TO DO THIS WILL RESULT IN
SEVERE PERSONNEL HAZARD. DANGEROUS AND
POTENTIAL LETHAL VOLTAGES ARE PRESENT.
CAUTION:
In the unlikely event that the charge on the capacitor
has not dissipated the capacitor may be charged
with high voltage. Confirm the removal of all charge
with a DC VOLTMETER before proceeding. Measure the
DC voltage between the output terminals and case
ground to confirm that all charge is dissipated.
After confirmation that no voltage is present on the terminal connections, the
modular assembly can be removed for replacement. Remove all electrical connections
by unscrewing the terminal lugs and removing the wires from the input and output
terminal blocks.
WARNING:
THE INTERNAL EXCITER MODULE IS NOT
REPAIRABLE. IT MUST BE RETURNED TO THE
FACTORY TO BE REFURBISHED. FAILURE TO DO THIS
CAN RESULT IN SEVERE PERSONNEL HAZARD.
DANGEROUS AND POTENTIAL LETHAL VOLTAGES
ARE PRESENT.
HEIR Tip Inserted Position - Location And Adjustment
The attached illustrations outline the procedure for setting the ignitor tip in the
flame spray pattern of the oil gun during the outage. Correct placement of the
HEI tip is critical for the successful light-off of the oil gun. As shown the tip should
be inserted such that it is ½” to 1” (12.7mm to 25.4mm) within the oil spray
pattern. An external setting should be scribed on the external wand assembly to
ensure the correct placement of the HEI tip past the oil gun assembly.
 COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
10
LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Figure 9: HEI Spark Tip Locating Guide
 COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
11
LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
Figure 10: HEI Spark Tip Set-Up Requirements
HEIR Tip Positioning – Field Installation Procedure
The photograph below shows the suggested method of verification for tip
insertion in the advanced mode. With the oil gun fully advanced, loosen the
clamping device, advance and maintain the advanced position on the pneumatic
cylinder. Advance the spark tip to an approximate firing position. While inside
the furnace, install a welding rod that fits snug into the sprayer plate of the oil gun
tip. Align the spark tip to where it is advanced into the spray pattern between ½”
and 1” (12.7-25.4mm). Once the tip is in the proper position, tighten the clamping
device on the advance retract mechanism. With the cylinder retracted, measure
the position of the Spark Rod/HEI guide Pipe relative to the advance retract
mechanism and record for future use. In addition, it is suggested that the position
be scribed on the spark rod so that a quick review of the installation would reveal
that the proper location has been maintained.
 COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
11/6/15
12
LIMELIGHT™ HIGH ENERGY IGNITOR RETRACTABLE (HEIR)
RECOMMENDED SPARE PARTS LIST
Pampa Energy
Central Termica Units 29 & 30
Contract EB0-007991
Retractable HEI Ignitor (Short Stroke) Assembly Drawing EB0-007991-1E9327
Item
Quantity
Description
Part No.
2
5
Pneumatic Cylinder (8” Unit Air Assembly)
V00-7385
5
6
Solenoid Valve
V00-9756
6
6
Cylinder Position Sensor
V00-2715
15
3
Flexible Spark Rod
EPSD-0457-164-T
16
3
HEI Wire Train Assembly
EPSD-0305-3-20-20
26
6
Ignitor Tip
1G-5900-2
HEI Exciter and Cabinet Drawing C-EPSC-0133
-
3
 COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
High Energy Exciter
REVISION: 0
11/6/15
75-HEI-01
13
01
D
E
7
D
10
L
W
15
CHANG E NO TE # 7 FRO M REF DW G TO
C H EN T R O N IC S M AN U AL
PORT 2
C O N N EC T IT EM # 9 FR O M PO RT 2 T O
FRO N T O F C YLIN D ER. SEE N O T E # 1 0.
PO RT 4
C O N N EC T IT EM # 9 FRO M PO RT 4 T O
R EAR O F C YLIN D ER. SEE N O T E # 1 0.
6
IT EM
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
6
PO RT 2
C O N N EC T IT EM # 9 FRO M PO RT 2 T O
FR O N T O F C YLIN D ER. SEE N O T E # 1 0.
PO RT 4
C O N N EC T IT EM # 9 FRO M PO RT 4 T O
R EAR O F C YLIN D ER. SEE N O T E # 1 0.
31
3
27
27
30
1
D E T A IL A
6
P /N E B 0 -0 0 7 9 9 1 -9 2 3 2 -A
AS SH O W N
S C A L E 1 :2
6
D E T A IL B
P O S I T I O N S E N S O R S W I T C H E S (I T E M # 6 ) T O B E P R E S S E D
I N T O R E C E S S E D G R O O V E I N B O D Y O F C Y L I N D E R (I T E M # 2 ).
PO SIT IO N SEN SO R SW IT C H # 1 LO C AT ED AT R EAR O F
C Y LIN D ER. PO SIT IO N SEN SO R SW IT C H # 2 LO C A T ED A T RO D
EN D O R FRO N T O F C YLIN D ER.
IT EM
1
3
P /N E B 0 -0 0 7 9 9 1 -9 2 3 7 -B
O PPO SIT E H A N D
S C A L E 1 :2
IT EM
30
31
1 /4 " N P T F E M A L E C O N N E C T O R
8 0 -1 0 0 P S I G F I L T E R E D A I R .
SEE N O TE # 6
1 /4 " N P T F E M A L E C O N N E C T O R
8 0 -1 0 0 P S I G F I L T E R E D A I R .
SEE N O TE # 6
IT EM
276
289
295
297
540
551
(3 1 .1 0 )
(2 5 .2 5 )
18
P A R T S C O M M O N T O P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A A N D P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -B
PA RT N U M BER
QTY
D RA W IN G
D ESC R IPT IO N
1
8" U N IT A IR A SSEM BLY
V 0 0 -7 3 8 5
E P S C -0 1 5 6
2
C -E P S C -0 1 5 6
PAC K IN G R ET AIN ER ASSEM BLY
1
V 0 0 -9 7 5 6
SO LEN O ID V A LV E
V 0 0 -2 7 1 5
2
C YLIN D ER PO SIT IO N SEN SO R
V 0 0 -8 0 3 0
2
M A L E C O N N , 1 /4 "O D X 1 /4 " M A L E N P T -S S
V 0 0 -8 0 3 1
2
M A L E E L B O W -1 /4 "O D X 3 /8 " M A L E N P T -S S
V 0 0 -8 0 3 5
2
T U B I N G .2 5 " O .D . X .0 3 5 " W A L L - S S
V 0 0 -8 0 3 2
2
1 /4 " N P T F L O W R E D U C E R - S S
V 0 0 -9 7 9 0
1
1 /2 " 9 0 D E G . E L B O W
1
V 0 0 -9 7 9 4
1 /2 " 9 0 D E G . E L B O W
2
LIQ U ID T IG H T ST RAIN RELIEF C O N N EC T O R
V 0 0 -8 0 3 4
1
E P S D -0 4 9 2
D -E P S D -0 4 9 2
ST RO K E LIM IT IN G IG N IT O R C LAM P
E P S D -0 4 5 7 -1 6 4 -T
1
FLEXIBLE SPA R K R O D A SSEM BLY
E P S D -0 3 0 5 -3 -2 0 -3 0
1
D -E P S D -0 3 0 5 -3
H EI W IRE T RA IN A SSEM BLY
M D 8 -0 0 0 4 4 -E C
4
M D 8 0 -1 C 0 0 4 4
B O L T -H E X .3 7 5 X 1 .2 5 0 I N
M D 8 -0 0 2 1 8 -A N
4
M D 8 0 -1 C 0 2 1 8
W A S H E R -P L A I N
T Y P E B .3 7 5 N
W A S H E R -L O C K R E G S P G .3 7 5 "
1 5 -2 0 0 2
2
M D 8 0 -1 C 0 0 2 6
1 1 -2 0 0 6
2
M D 8 0 -1 C 0 0 0 3
N U T -H E X .3 7 5 I N
1
W A S H E R -L O C K R E G S P G .5 0 0 "
1 5 -2 0 0 4
M D 8 0 -1 C 0 0 2 6
1 1 -2 0 0 7
1
M D 8 0 -1 C 0 0 0 3
N U T -H E X .5 0 0 I N
2
S C R -C A P H E X S O C H D # 1 0 X 1 .2 5 0 "
M D 8 -0 0 0 6 4 -C H
M D 8 0 -1 C 0 0 6 4
M D 8 -0 0 0 2 6 -A M
2
M D 8 0 -1 C 0 0 2 6
W A S H E R -L O C K R E G S P G # 1 0 .1 9 0 "
M D 8 -0 0 0 4 2 -A H
2
M D 8 0 -1 C 0 0 4 2
N U T -H E X M A C H S C R # 1 0 .1 9 0 I N
1 G -5 9 0 0 -2
1
B -9 0 2 -8 1 0 2
IG N IT O R T IP
PRO T EC T IVE T U BE 1 8" LO N G
V 0 0 -9 8 2 4
2
1
G P -1 3 2 7 6
1 /2 " F L E X I B L E C O N D U I T
1
1 G -1 1 9 2
1 /4 " F L E X . M E T A L H O S E X 3 '-0 " L G
P A R T S O N L Y F O R P / N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A
PART NUM BER
QTY
D RAW IN G
D ESC R IPT IO N
E P S E -0 0 3 2 -A
1
E -E P S E -0 0 3 2
FRAM E ASSEM BLY - 5 " & 8" ST RO K E
E P S D -0 3 9 3 -A
1
D -E P S D -0 3 9 3
JU N C T IO N BO X A SSEM BLY
P A R T S O N L Y F O R P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -B
PART NU M BER
QTY
D R AW IN G
D ESC RIPT IO N
1
FRAM E ASSEM BLY - 5" & 8" STRO KE
E P S E -0 0 3 2 -B
E -E P S E -0 0 3 2
1
E P S D -0 3 9 3 -B
D -E P S D -0 3 9 3
JU N C T IO N BO X A SSEM BLY
17
17
18
19
20
SPEC N O
A -3 2 5 A -5 6 3 F -4 3 6
A -5 1 0
A -3 0 7 A -5 6 3
A -3 0 7
A -5 6 3
A -1 9 3
M AT ERIAL SPEC IFIC A T IO N C H A RT
C O M PO SIT IO N
C A R BO N ST EEL BO LT S N U T S W A SH ER S
CARBO N STEEL
C A R BO N ST EEL BO LT S N U T S
CARBO N STEEL
CARBO N STEEL
1 8 C r-8 N i S T A I N L E S S
GRADE
T YPE 1 C
NONE
AA
A
A
B8
1
30
A
(4 .0 0 )
31
3
6
3
5
27
7
27
7
P / N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A
13
8
(8 .9 0 )
22
P /N E B 0 -0 0 7 9 9 1 -9 3 2 7 -B
O P P O S IT E H A N D
AS SH O W N
9
6
9
8
21
2
16
15
26
(1 .3 7 )
(7 .1 7 )
4
23
14
28
25
10 SEE NO TE # 11
10
12
24
11
29
S P A R K R O D "A " D I M E N S I O N = (1 6 4 .0 0 )
R E T R A C T E D P O S IT IO N
P / N E B 0 -0 0 7 9 9 1 -9 3 2 7 -A
S C A L E 1 :2
SO LEN O ID
TO BM S
4
TO BM S
1
5
TO BM S
2
TO BM S
P .S . # 1
1
2
RETRACTED
1 ) M A X IM U M T E M PE R A T U R E R A N G E - 3 2 F T O 1 6 7 F
P .S . # 2
TO BM S
1
7
2
ADVANCED
8
2) CO M PO N ENT PARAM ETERS:
A . A LL C O M PO N E N T S A R E W A T E R T IG H T .
B . S IN G L E , 4 W A Y S O L E N O ID : 1 /4 " N P T , P R E S S U R E P O R T 1 3 0 P S I . M A X . P R E S S U R E , C O I L R A T E = 0 .5 5 W A T T S , 2 4 V D C
C . P R O X IM IT Y S W IT C H - 1 0 -3 0 V D C
C O N T IN U O U S C A R R Y IN G C U R R E N T - 1 0 0 M A M A X .
D . A IR C Y LIN D E R - S IN G LE R O D E N D ST Y LE N F PA IN T E R C H A N G E A B LE ,
7 0 -1 2 5 P S I, O P E R A T IN G P R E S S U R E , 2 5 0 P S I M A X .
TO BM S
10
PR O X IM IT Y
SW ITCH
CONTACTS
ADVANCE
T O H E I E X C IT E R
C A B IN E T
N O TES:
SPA R K R O D PO SIT IO N
3 ) A L L D I M E N S I O N S A R E I N I N C H E S . (M I L L I M E T E R S S P E C I F I E D I N B R A C K E T S )
IN T E R IM
4 ) F IN A L LO C A T IO N O F SPA R K R O D T O B E D E T E R M IN E D IN F IE LD A T T IM E O F
IG N IT O R IN S T A L LA T IO N (S E E B U R N E R O R W IN D B O X F O R IN F O ).
RETRACT
SW . # 1
1, 2
O PEN
OPEN
CLO SED
5 ) W I R I N G D I A G R A M I N D I C A T E S L I M I T S W I T C H E S W I T H T H E R E T R A C T A S S 'Y I N
T H E F U LLY R E T R A C T E D PO SIT IO N .
SW . # 2
1, 2
CLO SED
OPEN
O PEN
6 ) F LE X IB LE H O SE T O B E PR E SE T A T 5 0 % O F T O T A L B O ILE R V E R T IC A L &
H O R IZO N T A L O R C U B IC A L E X P A N SIO N . SE E R SF C B U R N E R A R R A N G E M E N T
S H E E T 1 . E B 0 -0 0 7 9 9 1 -1 E 9 2 5 0 F O R E X P A N S IO N .
R E F E R E N C E D R A W IN G S :
C - E P S C - 0 1 3 3 ..........H E I E X C I T E R A N D C A B I N E T
01
7 ) F O R H E A E N C L O S U R E A S S 'Y D E T A I L S , S E E C H E N T R O N I C S R A P I D F I R E H E I E X C I T E R
O PE R A T IO N S & M A IN T E N A N C E M A N U A L.
8) A N E PO X Y PA IN T SH O U LD B E A PPLIE D T O IT E M # 1 F O R W E A T H E R
PR O O F IN G PU R PO SE S. T H E P A IN T SH A LL B E IN T E R N A T IO N A L , IN T E R G A R D 3 4 5 O R E Q U IV .
9) N A M EPLA T ES, O PER AT O R PA N ELS & G A U G E FAC ES: ALL N A M E PLAT ES AN D EQ U IPM EN T
O PER AT O R PA N ELS AR E T O H A V E T H E IN FO RM AT IO N SH O W N IN T H E EN G LISH LA N G U AG E
W IT H SI M ET R IC U N IT S O F M EA SU R EM EN T . T A G S SH A LL BE C O N ST R U C T ED O F ST A IN LESS
ST EEL, LA M IN A T ED PH EN O LIC , O R PLA ST IC . T H E ST A IN LESS ST EEL T A G S SH ALL H A VE
ID EN T IFIC A T IO N C H A R A C T ER S ST A M PED O R EN G R A V ED T H ER EO N . FO R LA M IN A T ED
PH E N O LIC O R PLA ST IC , T A G S SH A LL H A V E BLA C K C H A R A C T ER S A N D T H E BA C K G RO U N D
C O L O R S H A L L B E W H I T E . F I G U R E H E I G H T S H A L L B E A M I N I M U M O F 3 /1 6 ". T A G S S H A L L B E
AT T AC H ED U SIN G RIV ET S, ST AIN LESS ST EEL M AC H IN E SC R EW S, O R ST AIN LESS ST EEL
W IRE. EN C LO SU RE T A G A T T A C H M EN T S SH A LL N O T D EG RA D E T H E EN C LO SU R E R A T IN G .
1 0 ) I T E M # 9 (T U B I N G ) S H A L L B E I N S T A L L E D I N S U C H A F A S H I O N T H A T T H E B E N D S F O L L O W T H E
C U R V A T U R E O F T H E A SSEM BLY A S M U C H A S PO SSIBLE T O M IN IM IZ E T H E EN V ELO PE O F T H E
EQ U IPM EN T .
1 1 ) S E T T I N G F O R F L O W R E D U C E R (I T E M # 1 0 ) C A N B E A D JU S T E D A S R E Q U I R E D I N F I E L D .
A LL D IM EN SIO N S A R E IN IN C H ES
T O LER A N C ES U N LESS O T H ER W ISE N O T ED
X .X X
± .0 6
ANG ULAR:
± 0°30'
SU RFAC E T EXT U RE: 1 000 M IC RO IN C H ES
R O U G H N E S S A V E R A G E -R a
T H IS D RAW IN G IS IN AC C O RD AN C E W IT H
A S M E Y 1 4 .5 M -1 9 9 4
MTL
0
0
MTL
0
0
PU RC H ASIN G IN ST RU C T IO N S
NONE
NONE
NONE
NONE
NONE
NONE
B
4
MTL
0
0
0
0
0
0
0
0
0
0
0
0
0
0
295
276
289
540
289
540
551
289
297
0
0
0
TAB 4
Exacta Flame Scanner System Upgrade
TABLE OF CONTENTS
DESCRIPTION
PAGE NUMBER
Exacta Flame Scanner System Upgrade ...................................................................................................... 1
Scope of Supply......................................................................................................................................... 1
DRAWINGS .................................................................................................................. DRAWING NUMBER
Exacta Flame Scanner Assembly – Gas ....................................................................... EB0-007991-1D9274
Exacta Flame Scanner Assembly – Oil ......................................................................... EB0-007991-1D9300
Exacta Flame Scanner Analyzer Cabinet Arrangement ................................................ EB0-007991-1D9317
Exacta Flame Scanner Analyzer Cabinet Schematic .................................................... EB0-007991-1D9318
Exacta Flame Scanner Cabinet Extensions Connection Diagram ................................ EB0-007991-1D9319
LIMELIGHT™ Exacta Flame Scanner System
For Tangential and Wall Fired Applications ............................................................................ 5002 RSFC
LIMELIGHT™ Exacta Flame
Scanner PC Interface Users Manual .................................................................................................... 2009
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
10/6/15
i
Exacta Flame Scanner System Upgrade
EXACTA FLAME SCANNER
SYSTEM UPGRADE
An Exacta Flame Scanner System upgrade has been supplied. This Flame
scanner system has been developed as a low cost installation option while
continuing to focus on the critical electronic technology of flame failure protection.
Scope of Supply
The base offer scope of supply listed below represents a flame scanner system
that utilizes an electronic module system that provides the signal generation (to
the plant’s Burner Management System (BMS) for flame presence.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
10/6/15
1
1
R
06
L
09
C
15
J
E X T E N S IV E C H A N G E T O D R A W IN G P E R
E N G IN E E R IN G , S E E R E V 1 F O R R E C O R D C H A N G E S
1
IT E M
1
2
3
4
PART NUM BER
E S H -7 0 0 -U V -L S -W
E F -C A -2 5
E P S B -0 0 8 6
E P S C -0 2 2 9
QTY
1
1
1
1
P A R T S L IS T
D R A W IN G
D E S C R IP T IO N
D -E P S D -0 6 3 8 U V L IN E O F S IG H T W ID E A N G L E
C -E P S C -0 0 6 1 P IG T A I L , 2 5 F T
B -E P S B -0 0 8 6 E X A C T A M O U N T I N G A D A P T E R & O -R IN G A S S Y - M O D IF IE D
C -E P S C -0 2 2 9 C O O L IN G A IR M A N IF O L D A S S E M B L Y
1
1
(.6 9 ) W R E N C H T IG H T
IN S T A L L A T IO N N O T E S :
1 . V E R IF Y F L A S H IN G L E D W H E N C O N N E C T E D T O P IG T A IL A N D F S A M O D U L E S A R E P O W E R E D U P .
R E F E R E N C E D R A W IN G S :
1 . D -E P S D -0 3 7 1 ...................... E X A C T A F IE L D W IR IN G D IA G R A M
1
4
3
1
2
T H IS D R A W IN G D O E S N O T C O N T A IN A L L IN F O R M A T IO N N E C E S S A R Y F O R
M F G . T H IS P A R T . R E F E R T O P /N C O M M E N T S & P R O D U C T S T R U C T U R E
F O R C O M P L E T E M A T E R IA L ID E N T IF IC A T IO N A N D P R O C E S S IN G .
P /N : E B 0 -0 0 7 9 9 1 -9 2 7 4
A L L D IM E N S IO N S A R E I N IN C H E S
T O L E R A N C E S U N L E S S O T H E R W IS E N O T E D
X .X X
± .0 6
AN G ULAR:
± 0°30'
S U R F A C E T E X T U R E : 1 0 0 0 M IC R O IN C H E S
R O U G H N E S S A V E R A G E -R a
T H IS D R A W IN G IS IN A C C O R D A N C E W IT H
A S M E Y 1 4 .5 M -1 9 9 4
M A T E R IA L
0
0
0
0
1
R
06
L
09
C
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A S M E Y 1 4 .5 M -1 9 9 4
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0
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Instruction Manual
LIMELIGHTTM Exacta Flame Scanner System
For
Tangential and Wall Fired Applications
© COPYRIGHT 2015 ALSTOM POWER INC.
DOCUMENT 5002 RSFC
REVISION: 0
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Exacta Flame Scanner System
PROPRIETARY MARKS
CANbus
The CANbus network specification, written by Bosch, has been standardized
by ISO and SAE. The entire CAN specification as standardized in ISO 118981 & ISO 11898-2 contains the CAN physical layer specification.
MODBUS Protocol
The MODBUS Protocol was originally developed by Modicon. In 1979
Schneider bought Modicon. In 2004 Modbus-IDA acquired MODBUS
Protocol transferring the entire “right, title and interest” in the protocol
copyright.
CERTIFICATIONS
CE Mark
This product conforms to:
IEC 6030-1 – Automatic electrical controls for household and similar use.
Canadian Standards Association (CSA)
This product conforms to:
CAN / CSA – C22.2 No. 199-M89 – Combustion Safety Controls and SolidState Igniters for Gas and Oil Burning Equipment.
NOTICE
This instruction manual has been prepared to serve as a guide in operating
and maintaining the equipment supplied by Alstom Power Inc. It is not
intended to cover all possible variations in equipment or all specific problems
that may arise.
It must be recognized that no amount of written instructions can replace
intelligent thinking and reasoning on the part of the operators, especially when
coping with unforeseen operating conditions. It is the operator’s responsibility
to become thoroughly familiar with the equipment.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
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Exacta Flame Scanner System
TABLE OF CONTENTS
DESCRIPTION
PAGE NUMBER
INTRODUCTION........................................................................................................................................... 1
Acronyms and Uncommon Words............................................................................................................. 2
Benefits of the Flame Scanner System ..................................................................................................... 3
Features of the Flame Scanner System .................................................................................................... 3
EQUIPMENT DESCRIPTION ....................................................................................................................... 4
Scanner Head ............................................................................................................................................ 4
UVH Head Jumper Setting ........................................................................................................................ 5
Mechanical Components (Fiber Optic (FO)) ............................................................................................. 6
Mechanical Components (Line of Sight (LOS)) ......................................................................................... 6
Flame Signal Analyzer (FSA) Overview .................................................................................................... 6
Modes of Operation ............................................................................................................................... 7
Inputs ..................................................................................................................................................... 7
Outputs .................................................................................................................................................. 8
Communication .......................................................................................................................................... 9
Read/Write Registers ............................................................................................................................. 9
Read Only Registers .............................................................................................................................. 9
INSTALLATION ........................................................................................................................................... 11
Scanner Head Installation Requirements ................................................................................................ 11
Temperature Limits .............................................................................................................................. 11
Cooling and Purge Air .......................................................................................................................... 11
Line of Sight (LOS) Installations .............................................................................................................. 12
Selecting Location................................................................................................................................ 12
Adjusting for Optimal Signal .................................................................................................................... 12
Fiber Optic Installations ........................................................................................................................... 12
Flame Signal Analyzer (FSA) Installation ................................................................................................ 13
Temperature Limits .............................................................................................................................. 13
Mounting .............................................................................................................................................. 13
Power Requirements ........................................................................................................................... 14
Wiring Instructions ............................................................................................................................... 14
OPERATION ............................................................................................................................................... 14
Programming ........................................................................................................................................... 15
Edit Parameters ................................................................................................................................... 16
Cal Analog Out..................................................................................................................................... 17
Force Relays ........................................................................................................................................ 18
Save Norm Fact ................................................................................................................................... 18
Change Password................................................................................................................................ 19
Restore Defaults .................................................................................................................................. 19
Parameters .............................................................................................................................................. 19
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Exacta Flame Scanner System
SYSTEM STARTUP .................................................................................................................................... 33
Initial Software Configuration .................................................................................................................. 33
Adjustment of Trip Points ........................................................................................................................ 33
MAINTENANCE .......................................................................................................................................... 33
Lens Cleaning, Fiber Optic (FO) Head .................................................................................................... 34
Disassembling the Lens Body ............................................................................................................. 34
Assembling the Lens Body .................................................................................................................. 34
Lens Cleaning, Line of Sight (LOS) Head ........................................................................................... 34
Inspecting the Fiber Optic Cable ......................................................................................................... 35
Replacing the Fiber optic Cable........................................................................................................... 35
CUSTOMER SERVICE CONTACTS .......................................................................................................... 36
RECOMMENDED SPARE PARTS (RSP) AND SPECIAL TOOLS LISTS ................................................. 37
GENERAL SPECIFICATIONS .................................................................................................................... 44
Scanner Head .......................................................................................................................................... 44
Flame Signal Analyzer............................................................................................................................. 44
APPENDIX I – FLAME SCANNER SYSTEM SELECTION SHEET ........................................................... 45
APPENDIX II – EXACTA FLAME SCANNER REMOTE HEAD ................................................................. 46
Mechanical Components ......................................................................................................................... 47
Exacta Remote Head Assembly Instructions .......................................................................................... 48
RECOMMENDED SPARE PARTS LIST .................................................................................................... 53
APPENDIX III – EXPLOSIVE ATMOSPHERE APPLICATION .................................................................. 55
Explosive Atmosphere Label Information ................................................................................................ 55
Intrinsic Safety Certification Standards ................................................................................................ 56
Entity Parameters ................................................................................................................................ 56
Approved Class Ratings ...................................................................................................................... 57
Special Conditions for Safe Use .......................................................................................................... 58
LIST OF TABLES
Table A: Head Selection for Fiber Optic Cable Applications ........................................................................ 6
Table B: Line of Sight Applications ............................................................................................................... 6
Table C: Exacta Flame Signal Analyzer ....................................................................................................... 6
Table D: Minimum, Maximum And Default Parameter Values ................................................................... 29
Table E: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range) LOS
– Standard Viewing Angle .............................................................................................................. 37
Table F: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range, UV – Ultraviolet,
UVH – Ultraviolet High-Gain) LOS – Wide Viewing Angle............................................................. 37
Table G: RSP List, Flame Scanner Assembly (VL - Visible Light, BR - Broad Range),
110” or 130” Fiber Optic Cable with Vortex Lens Body ................................................................. 39
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Table H: RSP List, Flame Scanner Assembly (UV – Ultraviolet or UVH – Ultraviolet High-Gain), 110” or
130” Fiber Optic Cable with Vortex Lens Body .............................................................................. 41
Table I: Accessory Parts ............................................................................................................................. 43
Table J: Special Tools ................................................................................................................................. 43
LIST OF FIGURES
Figure 1: Flame Scanner Head Assembly .................................................................................................... 4
Figure 2: Jumper Setting For Standard Gain ................................................................................................ 5
Figure 3: Jumper Setting For High Gain ....................................................................................................... 5
Figure 4: Spool Piece with Adjustable Length ............................................................................................ 13
Figure 5: Flame Signal Analyzer (FSA) ...................................................................................................... 15
Figure 6: Vortex Lens Body Assembly Details ............................................................................................ 34
Figure 7: Scanner Head (LOS) Parts .......................................................................................................... 38
Figure 8: Flame Scanner Assembly Parts (VL/BR) – 110” or 130” ............................................................. 40
Figure 9: Flame Scanner Assembly Parts (UV and UVH) – 110” or 130” ................................................. 42
Figure 10: Special Tools ............................................................................................................................. 43
Figure 11: Exacta Flame Scanner Remote Head Assembly ...................................................................... 46
Figure 12: Exacta Flame Scanner Remote Head Assembly for Ignitor Applications ................................. 46
Figure 13: Exacta Flame Scanner Remote Head Components.................................................................. 47
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (1 of 5) ...................................... 48
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (2 of 5) ...................................... 49
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (4 of 5) ...................................... 51
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (5 of 5) ...................................... 52
Figure 15: Recommended spare parts list .................................................................................................. 54
Figure 16: Sample ATEX label .................................................................................................................... 55
LIST OF DRAWINGS
Drawing 1: Exacta FSA Field Wiring Diagram, D-EPSD-0371 ................................................................... 59
Drawing 2: Exacta FSA Configuration, VL or BR FOC Variable Length, D-EPSD-0382 ............................ 60
Drawing 3: Exacta FSA, LOS VL or BR Standard Lens, D-EPSD-0384 .................................................... 61
Drawing 4: Exacta FSA, LOS VL/BR/UV-Wide Lens, D-EPSD-0397 ......................................................... 62
Drawing 5: Exacta FSA UV with Quartz FOC Variable Length, D-EPSD-0445 .......................................... 63
Drawing 6: Exacta Flame Scanner Remote Head Configuration, D-EPSD-0481....................................... 64
Drawing 7: Exacta Remote Head 3” Bluff Body Ignitor Installation, D-EPSD-0484.................................... 65
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LIMELIGHT™ Exacta Flame Scanner System
INTRODUCTION
This manual provides information on the installation, operation and required
TM
maintenance for the LIMELIGHT Exacta Flame Scanner. The Exacta Flame
Scanner System is a burner flame-sensing device designed for flame supervisory
applications as described in the National Fire Protection Association Codes. The
Flame Scanner has the important feature of being able to discriminate between a
flame and a no-flame condition for both the main and auxiliary support burners.
The Exacta Flame Scanner consists of a scanner head and a separate signalprocessing module. This configuration places minimal electronics in the heataffected areas of the burner front. The more sensitive signal conditioning
components are mounted away from the burner front.
Light from the flame is converted to an electrical signal in the scanner head. This
signal is then sent to the Flame Signal Analyzer (FSA) via a 2-0mA current loop.
Each FSA accepts the signal from two scanner heads. The signal from the head
is evaluated to determine flame intensity and flicker frequency. A third value, AC
amplitude, is also calculated, although this is only used for flame proving in a few
unusual applications.
There are two major configurations for Exacta Flame Scanner Heads, Line of
Sight (LOS), and Fiber Optic (FO). In general, FO heads are used for tilting
tangential applications, and LOS heads are used for wall-fired applications. In
some wall-fired applications it is necessary to use a FO scanner, due to
obstructions or excessive ambient temperature. Both of these configurations are
available with four different detector types: Ultraviolet (UV), Ultraviolet High-Gain
(UVH), Visible Light (VL), and Broad Range (BR). The detector type is chosen
based on the fuel(s) being fired.
The Flame Signal Analyzer (FSA) provides relay outputs and input signals to the
associated burner management system. The flame relays have adjustable trip
thresholds. The FSA is compatible with legacy flame scanner heads previously
supplied by the OEM boiler manufacturer. The Exacta Scanner System is
compatible with previously installed wiring, adapter cables and guide pipes. It
TM
can be provided as an in-kind component upgrade for SAFE SCAN and SAFE
TM
FLAME Scanners or as a new complete flame scanning system.
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LIMELIGHT™ Exacta Flame Scanner System
Acronyms and Uncommon Words
BMS
Burner Management System.
BR
Broad Range, an acronym used to describe the sensitivity range of the photo
detector, i.e. 400 nm to 1100 nm.
Fireball
This is a specific application-based philosophy. Flame scanner fireball
monitoring of boiler combustion is provided when discrimination of individual
burner flames is not practical.
FO
FO refers to the application of the conditioning electronics in concert with a
fiber optic cable assembly. Also, FO can refer to the optical fiber strands
used in the cable that transmits light energy from the burner flame to the
photo detector.
FOC
Fiber Optic Cable refers to the cable that transmits light energy from the
burner flame to the photo detector.
FSA
Flame Signal Analyzer, the flame scanner control module.
FSH
Flame Sensor Head, the hardware that monitors boiler flame.
ESA
Exacta Signal Analyzer, the flame scanner control module.
ESH
Exacta Sensor Head, the hardware that monitors boiler flame.
LOS
Line of Sight refers to the scanner head model that has an unobstructed view
of the burner flame. No fiber optic cable required.
nM
Nanometer, a unit of length equal to 10 meters.
NPT
National Pipe Thread, a US standard for tapered pipe threads.
OEM
Original Equipment Manufacture.
Scanner
Refers to the Exacta flame-monitoring device employed as a first line of
defense in a boiler explosion.
SCFM
Standard Cubic Feet per Minute, a unit of flow.
UV
Ultra Violet, an acronym used to describe the sensitivity range of the photo
detector, i.e. 210 nm to 380 nm.
UVH
High Gain version of the UV head with the ability to increase the sensitivity
by 20% for special applications.
VL
Visible Light, an acronym used to describe the sensitivity range of the photo
detector, i.e. 400 nm to 700 nm.
-W
Wide, used to describe hardware with extra wide-angle field of view.
RoHS
Restriction of Hazardous Substances RoHS Directive 2002/95/EC restricts
the use of six hazardous materials found in electrical and electronic products.
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LIMELIGHT™ Exacta Flame Scanner System
Benefits of the Flame Scanner System
Safe, reliable flame detection, easily interfaced to the plant safety system.
One flame scanner can monitor main and auxiliary fuels.
amount of equipment required.
This reduces the
Superior sensitivity and dynamic range enables operating at the lowest possible
boiler load.
Adjustable digital filters for optimum flexibility.
Flexible communication options simplify integration into existing plant systems.
Compatible with previously installed OEM equipment, which reduces the cost of
installation.
Features of the Flame Scanner System
State of the art burner flame proving device.
Variable length Adjustable Fiber Optic Cable Scanner.
Quick disconnect mechanical and electrical connectors for easy replacement
without wiring changes.
Built-in auctioneering supports redundant power supplies.
Flame proven relay outputs, for interfacing with Burner Management Systems
(BMS).
MODBUS communication port, and four 4-20mA outputs, allow easy monitoring
of the flame signal.
RoHS Compliant, lead-free components.
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LIMELIGHT™ Exacta Flame Scanner System
EQUIPMENT DESCRIPTION
Scanner Head
The Flame Scanner Head shown in Figure 1 contains the light detection PC
Board. The head displays a power/active light. The head will blink slowly when
powered and no flame is being detected. Blinking rate will increase as flame
intensity increases.
Figure 1: Flame Scanner Head Assembly
The Exacta Scanner Head assemblies are offered in various configurations
based on the intended application. The light wavelengths detected by the
various sensors are as follows:
UV
UVH
VL
BR
210 to 380 nM
210 to 380 nM
400 to 700 nM
400 to 1100 nM
The model number changes based on the type of sensor, and the light path.
Tilting tangential burners should use a fiber optic head. This allows the lens
body to tilt with the burners, ensuring a clear view of the flame.
Wall fired burners typically use a line of site head. Wide-angle lens heads are
used for opposed wall fired installations for improved discrimination between
near field, and far field flames. Wide-angle lenses can also be used to improve
low light intensity performance. UV and UVH LOS heads always use a wideangle lens.
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LIMELIGHT™ Exacta Flame Scanner System
UVH Head Jumper Setting
The UVH head has a jumper setting to switch between standard and high-gain
operation. When the jumper is set to standard gain it is in the location shown in
Figure 2.
Figure 2: Jumper Setting For Standard Gain
The high gain setting for the UVH head will increase the intensity of the flame
signal by about 20%. This increase is useful primarily for LOS heads where the
gas flame is far enough from the head or where the flame is partially obstructed
and intensity is reduced. To set the UVH head to high-gain operation, move the
jumper to the location shown in Figure 3.
Figure 3: Jumper Setting For High Gain
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LIMELIGHT™ Exacta Flame Scanner System
Table A: Head Selection for Fiber Optic Cable Applications
Part No
Description
Typical Application
ESH-700-UV-FO
Ultraviolet
Gas
ESH-700-UVH-FO
Ultraviolet
Gas
ESH-700-VL-FO
Visible Light
Coal / Oil
ESH-700-BR-FO
Broad Range
Gas Fireball
Table B: Line of Sight Applications
Part No
Description
Typical Application
Standard Lens
ESH-700-VL-LS
Visible Light
Coal / Oil
Wide Angle Lens
ESH-700-UV-LS-W
Ultraviolet
Gas / Oil
ESH-700-UVH-LS-W
Ultraviolet
Gas / Oil
ESH-700-VL-LS-W
Visible Light
Coal / Oil
Table C: Exacta Flame Signal Analyzer
Part No
Description
Typical Application
EPSD-0375
Digital Signal Analyzer
All Fuel Types
Mechanical Components (Fiber Optic (FO))
Refer to Alstom Drawing D-EPSD-0382 for FO scanner head mounting details.
Mechanical Components (Line of Sight (LOS))
Refer to Alstom Drawing D-EPSD-0384 for standard lens LOS scanner head
mounting details, and D-EPSD-0397 for wide-angle lens LOS scanner head
mounting details.
Flame Signal Analyzer (FSA) Overview
The Flame Signal Analyzer (FSA) accepts signal from up to two scanner heads.
Heads with different sensor types can be freely mixed. Due to the current loop
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LIMELIGHT™ Exacta Flame Scanner System
nature of the signal from the head and the high quality cable used, head to FSA
cable lengths up to 5000 feet are supported.
Modes of Operation
The FSA has four modes of operation. They are Single Fuel, Discriminate, Fuel
Switching, and Load Switching. Mode is set individually for each head, and can
be different for the two configurations.
In the Single Fuel mode, flame relay “A“ will close when the pull-in conditions of
parameter set “A” are met. Relay “B” and parameter set “B” are not used.
External inputs are not required for operation.
In the Discriminate mode, flame relay “A“ will close when the pull-in conditions
of parameter set “A” are met. Relay “B” will close when the pull-in conditions of
parameter set “B” are met. External inputs are not required for operation.
In the Fuel Switching mode flame relay “A” will close when the pull-in conditions
of parameter set “A” are met and the digital input indicating fuel “A” firing is pulled
low. Also, relay “B” will close when the pull-in conditions of parameter set “B” are
met and the fuel “B” digital input is low. If both inputs are high, flame proving is
disabled, so this mode can be used for installations where “blinding” is required.
In the Load Switching mode, when the “load profile” input is high parameter set
“A” controls the operation of relay ”A”. When the “load profile” input is low,
parameter set “B” controls the operation of relay “A”. In this mode, relay “B” is
disabled, and will remain open at all times.
Inputs
The FSA has four digital inputs. These inputs are intended to be driven by dry
contacts. The functions of the inputs are:
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
DIN 1
Digital input used to indicate firing of fuel “A” on head
1 when pulled low.
DIN 2
Digital input used to indicate firing of fuel “B” on head
1 when pulled low. Alternate function indicates load
profile “B” when pulled low.
DIN 3
Digital input used to indicate firing of fuel “A” on head
2 when pulled low.
DIN 4
Digital input used to indicate firing of fuel “B” on head
2 when pulled low. Alternate function indicates load
profile “B” when pulled low.
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LIMELIGHT™ Exacta Flame Scanner System
Outputs
The FSA has eight relay outputs and four 4-20mA current loop outputs. The 4-20
mA outputs are loop powered, 18 to 32 V. These outputs can be configured to
transmit any of the following values:
Head 1 Intensity
Head 1 Set A Frequency
Head 1 Set B Frequency
Head 1 Set A AC Amplitude
Head 1 Set B AC Amplitude
Head 1 Active Quality
Head 2 Intensity
Head 2 Set A Frequency
Head 2 Set B Frequency
Head 2 Set A AC Amplitude
Head 2 Set B AC Amplitude
Head 2 Active Quality
The eight relay outputs are FORM-C contacts rated at 2A, 250V. The functions
of these relays are:
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
Relay 1
Head 1, Flame Relay 1, see “Modes of Operation”.
Relay 2
Head 1, Flame Relay 2, see “Modes of Operation”.
Relay 3
Head 1, Pre-trip Relay, will de-energize when quality
drops below the pre-trip pull-in value specified in the
parameter set. In the DISCRIMINATE mode, the
user can select whether parameter set “A” quality,
parameter set “B” quality, or worst-case quality is
used.
Relay 4
Head 1, Fault Relay 4, as well as Flame Relays 1 and
2, will de-energize whenever a fault occurs that will
prevent the scanner from reliably proving flame on
Head 1.
Relay 5
Head 2, Flame Relay 1, see “Modes of Operation”.
Relay 6
Head 2, Flame Relay 2, see “Modes of Operation”.
Relay 7
Head 2, Pre-trip Relay, will de-energize when quality
drops below the pre-trip pull-in value specified in the
parameter set. When in DISCRIMINATE mode the
user can select whether parameter set “A” quality,
parameter set “B” quality, or worst-case quality is
used.
Relay 8
Head 2, Fault Relay 8, as well as Flame Relays 5
and 6, will de-energize whenever a fault occurs that
will prevent the scanner from reliably proving flame
on Head 2.
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LIMELIGHT™ Exacta Flame Scanner System
Communication
The Exacta flame scanner is equipped with two RS-485 ports. The first port is
intended for remote communication using Alstom's Exacta PC Configuration
software. The second RS-485 port is intended for communication with a remote
system using MODBUS RTU protocol. MODBUS slave address, Baud rate, and
parity are user configurable. Baud rates of 9600, 19200, 38400 and 57600 bps
are supported. The FSA uses base–0 addressing. Therefore the first MODBUS
register is 0. The data available via MODBUS, and its MODBUS register
assignment is as follows:
Read/Write Registers
Register
Description
501
Head 1 Fuel A input. When in fuel switching mode
writing 0xFF00 indicates firing fuel “A”. Writing
zero indicates fuel “A” not firing. Can also be
set/reset as a MODBUS digital value
502
Head 2 Fuel A input. When in fuel switching mode
writing 0xFF00 indicates firing fuel “A”. Writing
zero indicates fuel “A” not firing. Can also be
set/reset as a MODBUS digital value
503
Head 1 Fuel B input. When in fuel switching mode
writing 0xFF00 indicates firing fuel “B”. Writing
zero indicates fuel “B” not firing. This register is
also used to select load profile “B” in load switching
mode. Can also be set/reset as a MODBUS digital
value
504
Head 2 Fuel B input. When in fuel switching mode
writing 0xFF00 indicates firing fuel “B”. Writing
zero indicates fuel “B” not firing. This register is
also used to select load profile “B” in load switching
mode. Can also be set/reset as a MODBUS digital
value
Register
Description
1001
Head 1 Flame A status. 0xFF00 indicates flame
proven. Zero indicates flame not proven. Can
also be read as a MODBUS digital value.
1002
Head 2 Flame A status. 0xFF00 indicates flame
proven. Zero indicates flame not proven. Can
also be read as a MODBUS digital value.
1003
Head 1 Flame B status. 0xFF00 indicates flame
proven. Zero indicates flame not proven. Can
also be read as a MODBUS digital value.
Read Only Registers
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LIMELIGHT™ Exacta Flame Scanner System
© COPYRIGHT 2015 ALSTOM POWER INC.
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1004
Head 2 Flame B status. 0xFF00 indicates flame
proven. Zero indicates flame not proven. Can
also be read as a MODBUS digital value.
1005
Head 1 Marginal Flame. 0xFF00 indicates
marginal flame. Zero indicates we do not have
marginal condition. Can also be read as a
MODBUS digital value.
1006
Head 2 Marginal Flame. 0xFF00 indicates
marginal flame. Zero indicates we do not have
marginal condition. Can also be read as a
MODBUS digital value.
1007
Head 1 FAULT. 0xFF00 indicates a fault condition.
Zero indicates fault not present. Can also be read
as a MODBUS digital value.
1008
Head 1 FAULT. 0xFF00 indicates a fault condition.
Zero indicates fault not present. Can also be read
as a MODBUS digital value.
1009
Reserved for future use.
1010
Head 1 Intensity (%)
1011
Head 2 Intensity (%)
1012
Head 1 Active Frequency (Hz)
1013
Head 2 Active Frequency (Hz)
1014
Head 1 Active Quality
1015
Head 2 Active Quality
1016
Head 1 Active AC Amplitude (mV)
1017
Head 2 Active AC Amplitude (mV)
1018
Head 1 parameter set A frequency (Hz)
1019
Head 2 parameter set A frequency (Hz)
1020
Head 1 parameter set B frequency (Hz)
1021
Head 2 parameter set B frequency (Hz)
1022
Head 1 parameter set A AC amplitude (mV)
1023
Head 2 parameter set A AC amplitude (mV)
1024
Head 1 parameter set B AC amplitude (mV)
1025
Head 2 parameter set B AC amplitude (mV)
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1026
Head 1 parameter set A Quality
1027
Head 2 parameter set A Quality
1028
Head 1 parameter set B Quality
1029
Head 2 parameter set B Quality
The FSA also has a CANbus port. The port uses a proprietary data-encoding
scheme for use with an Alstom IM200 network interface module.
INSTALLATION
Scanner Head Installation Requirements
Temperature Limits
The scanner head should be installed in a location where the ambient
temperature is less than 185 deg F (85 deg C).
Cooling and Purge Air
The flame scanner heads require a maximum allowed cooling air temperature of
120 deg F (49 deg C) at the cooling air manifold. This can be accomplished with
a low-pressure blower system or with compressed air and an orifice. Refer to
“General Specifications”, “Scanner Head”.
CAUTION:
The scanner head must be supplied with cooling air
whenever there is fire in the furnace, or the boiler interior is
greater than 800 deg F (427 deg C).
Note:
Installing Shutoff Valves or Manual Adjustable Orifices in cooling
air feed lines is not recommended. If required for balancing the
air system, locking devices or removable handles should be
considered to eliminate air system tampering.
Each LOS Flame Scanner Head assembly requires 10 SCFM of cooling airflow.
Each FO Flame Scanner Head assembly requires 30 SCFM of cooling airflow. In
the FO scanner head, a secondary effect of the cooling air is to provide purge air
through the Fiber Optic Extension to the Lens Body. This prevents particles from
depositing onto the lens in the lens body assembly. If multiple flame scanners
are connected to a common cooling air supply, install the supplied cover plate
whenever a LOS scanner head, or a fiber optic assembly is removed. This
prevents a reduction in cooling airflow to the remaining scanners.
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Line of Sight (LOS) Installations
Selecting Location
The scanner head requires a clear view to the root of the flame. If an air
deflector plate surrounds the burner tip, aim the flame scanner at the edge of the
plate. If the furnace wall or other object prevents the scanner from sighting at the
edge of the deflector plate, a minimum 3” diameter hole in the plate may be
required. If a hole is required, place the hole as close to the edge of the plate as
possible.
Mounting Options
Refer to Alstom drawings D-EPSD-0384 and D-EPSD-0397 for possible LOS
scanner mounting arrangements.
Adjusting for Optimal Signal
Swivel mount
Loosen the three screws on the swivel mount. Rock the scanner head through
its range of motion to find the location where the “winker” LED is blinking the
fastest. Tighten the three screws on the swivel mount.
Sighting pipe
Loosen the three locking nuts on the adjusting screws. Move the three adjusting
screws until the scanner head “winker” LED is flashing at its fastest rate. Tighten
the three lock nuts.
Fiber Optic Installations
The guide pipe is normally fixed in the windbox front by means of a seal plate.
The cooling air manifold is screwed (2" NPT) onto the guide pipe and is threaded
to accept a flexible hose connection at its cooling air inlet with an opening for the
Flame Scanner Fiber Optic Extension. The furnace end of the guide pipe is tack
welded to the air nozzle tip, which normally is set two inches back from the end
of the nozzle.
Note:
In order to prevent a reduction in cooling airflow to other
scanners, the guide pipe opening must be closed with the cover
plate when the fiber optic extension is removed for maintenance.
The Flame Scanner Fiber Optic Extension Assembly passes through the cooling
air manifold and slides into a fully inserted position. It is strongly recommended
that the tilts be in a horizontal position (Zero Tilt) prior to installing the Flame
Scanner Fiber Optic Extension Assembly.
CAUTION:
Experience has shown that there is potential for the
assembly to get stuck, partially installed, if the tilt position
is not horizontal. Once stuck, removal may damage the
equipment.
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The installer should “feel” the lens body assembly contact the grip area at the
end of the guide on the guidepipe. This area is designed to center the lens body
assembly and prevent it from changing position when the tilts are stroked. Once
the lens body is in contact with the grip area, the scanner assembly should
require approximately ½” of compression to fully engage the Scanner Head with
the Air Cooling manifold, with the tilts at horizontal.
If there is insufficient compression, the Lens Body may slip out of the Guide at
the furnace end of the guide pipe when the tilts are moved up or down. This
would impact the sighting to the flame and consequently the operation of the
scanner. If there is excessive compression, the Fiber Optic Extension may be
difficult to insert. This could also shorten the life of the flex hose.
The amount of flex hose compression can be adjusted by removing the two
setscrews in the spool piece. The ribbed sleeve can then be slid in and out to
adjust the amount of compression. Refer to Figure 4.
Figure 4: Spool Piece with Adjustable Length
Flame Signal Analyzer (FSA) Installation
Temperature Limits
The FSA should be mounted in an area where the maximum ambient
temperature is less than 160 deg F (70 deg C).
Mounting
The FSA is designed to mount vertically to a standard 35mm DIN rail. End stops
are required to prevent slippage. The FSA should be mounted in an enclosure
that provides adequate physical and environmental protection.
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Power Requirements
The FSA requires 24VDC. The power supply should have a capacity of 12W per
FSA. This value contains an adequate safety factor. Redundant power supplies
are supported.
Wiring Instructions
Refer to Alstom drawing D-EPSD-0371 for field wiring details. The cable
connecting the FSA with the scanner heads has a maximum length of 5000 feet.
In most installations, a local junction box is mounted near the scanner head.
This junction box is used to transition from the scanner head pigtail to bulk cable.
OPERATION
The FSA has a local display and a 5-key keypad. Refer to Figure 5. There are
also two sets of five LED’s that indicate the status of the burners being monitored
by the two heads. The functions of the status LED’s are:
Flame A
Lights when the parameter set A flame
proving requirements are met.
Flame B
Lights when the parameter set B flame
proving requirements are met.
Marginal Flame
Lights when flame quality is less than
the marginal pull-in value.
Fault
Lights when a fault condition is
present. A fault condition forces a “No
Flame” signal.
Signal Strength
Duplicates the function of the “winker”
LED on the back of the Exacta scanner
head. The blink rate is a function of
flame intensity.
If a scanner head is disabled, all of its LED’s are turned off. During normal
operation five screens of information can be displayed on the local FSA display.
Use the up arrow (Key 2) and the down arrow (Key 4) to scroll through these
screens.
Screen 1 displays a summary of the current values from both heads.
Screen 2 and Screen 3 display detailed information for each head individually.
If a head is disabled, its detailed screen is skipped when scrolling through the
displays.
Screen 4 displays the status of the four digital inputs, and the three
communication ports.
Screen 5 displays the amount of time the FSA has been running.
The display is equipped with a screen saver. After 20 minutes of inactivity, the
display goes dark. Pressing any keypad key restores the display.
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Figure 5: Flame Signal Analyzer (FSA)
Programming
To enter program mode at the local keypad depress Key 1 (Program On/Off).
NOTE:
The FSA is equipped with an interlock that prevents
simultaneous editing of parameters from two locations. An
attempt to enter program mode, while parameters are being
edited remotely with the PC interface, displays a warning
message and returns the FSA to normal mode.
After pressing Key 1 the user is prompted for a password. The factory default
password is 11111. After successfully entering the password the following menu
is displayed:
Edit Parameters
Cal Analog Out
Force Relays
Save Norm Fact
Change Password
Restore Defaults
Use the up and down arrow keys (Key 2 & Key 4) to scroll to the desired
selection. When the desired selection is highlighted press Key 5 (Enter/Store).
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Edit Parameters
Selecting “Edit Parameters” causes the following menu to be displayed:
Communication Parameters
Head 1 Parameters
Head 1 Mode
Head 2 Parameters
Head 2 Mode
4-20ma Output Parameters
The display is truncated at 20 characters. To display the rest of the line, press
key 3 (Head select). Use the up and down arrow keys (Key 2 & Key 4) to scroll
to the desired selection. When the desired selection is highlighted press Key 5
(Enter/Store).
Communication Parameters
Selecting “Communication Parameters” causes the first communication
parameter to be displayed. Use the up and down arrow keys (Key 2 & Key 4) to
scroll through all of the communication parameters. Press Key 1 (Program
On/Off) to return to the “Edit Parameters” menu.
To change a parameter, press key 5 (Enter/Store) while that parameter is
displayed. The value of the parameter is highlighted. Use the up and down
arrow keys (Key 2 & Key 4) to change the value of the parameter. If only one
digit of the parameter is highlighted, the arrow keys act on that digit. In this case
Key 3 (Head Select) changes the digit that is highlighted.
After the parameter is changed to the desired value, press Key 5 (Enter / Store)
to save the new value. The display returns to the mode of scrolling between
values. To return to this mode without storing new value press Key 1 (Program
On / Off).
Head 1 Parameters, Head 2 Parameters
Selecting “Head 1 Parameters”, or “Head 2 Parameters” allows the user to view
/edit the parameters for that head that are common to both parameter sets. The
keys perform the same functions described under “Communication
Parameters” above.
Head 1 Mode, Head 2 Mode
Selecting “Head 1 Mode”, or “Head 2 Mode” displays the following menu:
Single Fuel
Discriminate
Fuel Switching
Load Switching
Use the up and down arrow keys (Key 2 & Key 4) to scroll to the desired
operating mode. When the desired selection is highlighted press Key 5
(Enter/Store). Press key 1 (Program On / Off) to return to the previous menu.
Single Fuel
Selecting “Single Fuel” displays the following menu:
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Basic Parameters
Expert Parameters
Marginal Relay Parameters
Use the up and down arrow keys (Key 2 & Key 4) to scroll to the desired
selection. When the desired selection is highlighted press Key 5 (Enter/Store).
Press key 1 (Program On / Off) to return to the previous menu.
Basic Parameters are those most likely changed in a typical installation. Expert
Parameters are modified only under unusual circumstances. Marginal Relay
Parameters define the operation of the marginal relay. The marginal relay warns
the operator that the flame quality is degrading, and a trip is imminent. After
making a selection, the parameters are edited or viewed as described under
“Communication Parameters” above.
Discriminate, Fuel Switching, Load Switching
Selecting “Discriminate”, “Fuel Switching”, or “Load Switching” causes the
following menu to be displayed:
Set A Basic Parameters
Set A Expert Parameters
Set B Basic Parameters
Set B Expert Parameters
Marginal Relay Parameters
The FSA has the ability to store two independent sets of parameters, Parameter
Set “A” and Parameter Set “B”. Two independent sets of parameters permit the
operator to detect two significantly different firing conditions. For example one
instance would be a change in fuel.
Another instance may be a change in firing equipment. In the first instance, set
“A” may be configured for #6 fuel oil guns, where set “B” parameters are tuned to
match natural gas firing. The two parameter sets extend the dynamic range of
the flame scanner. This improves the flame scanner’s ability to discriminate
between two different types of fuels or firing conditions.
4-20 mA Output Parameters
Selecting “4-20mA Output Parameters” allows viewing or editing the parameters
that define the operation of the 4 to 20 mA current loop outputs. The parameters
are edited or viewed as described under “Communication Parameters” above.
Cal Analog Out
“Cal Analog Out” allows calibrating the 4-20 mA outputs. Selecting this item
displays the following:
Cal Analog Out 1
Cal Analog Out 2
Cal Analog Out 3
Cal Analog Out 4
Select the Head to calibrate. The selected Head is forced to its current 4mA
calibration value. This value is also displayed on the screen. Use the up and
down arrow keys (Key 2 & Key 4) to adjust the calibration value.
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When the 4mA calibration is complete press Key 3 (Head Select). The 20mA
calibration value is forced on the selected output, and displayed on the screen.
Use the up and down arrow keys (Key 2 & Key 4) to adjust the calibration value.
When the calibration is complete press Key 1 (Program On/Off) to return to the
previous menu.
Force Relays
“Force Relays” allow the user to force a relay into the energized state. This
feature is used during commissioning to verify the relay field wiring. When a
relay is placed into the “forced” mode all other relays are de-energized. This
prevents using the force feature to create an unsafe condition. Since the fault
relay de-energizes on fault, a minimum of two relays have to be energized to
prove flame (Fault relay energized to indicate a non-fault condition, and a flame
relay energized).
CAUTION:
Entering into “Force Relays” mode during normal operation
will switch the scanner to a “No Flame” state, and can result
in a unit trip.
After selecting “Force Relays” the following is displayed:
Press Key 5
(Enter/Store) to
Force Relay 1
Use the up and down arrow keys (Key 2 & Key 4) to change the relay to “force”.
Selecting Key 5 (Enter/Store) will energize the relay. When a relay is “forced”,
pressing any key causes that relay to de-energize, and returns to the above
display. A relay can be forced for a maximum of 20 minutes. After force mode
expires, the FSA returns to normal operation.
Save Norm Fact
“Save Norm Fact” is used to save normalization factors. The normalization factor
is used in the flame quality calculation. A separate normalization factor is stored
for each parameter set. The normalization factor should be saved when the
burner has the brightest flame for the fuel being proven by a parameter set, i.e., if
parameter set “A” is proving coal, save the set “A” normalization factor at full load
firing coal.
After selecting “Save Norm Factor” the following menu is displayed.
Save Hd 1A Norm
Save Hd 1B Norm
Save Hd 2A Norm
Save Hd 2B Norm
Use the up and down arrow keys (Key 2 & Key 4) to scroll to the desired
selection. Press Key 5 (Enter/Store) to save the normalization factor for the
highlighted head and parameter set.
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Change Password
After selecting “Change Password” the user is prompted for a new password.
The password must be 5 characters in length, and can be any combination of
Keys 1 through 5. A second prompt requires the new password be entered a
second time for confirmation.
Restore Defaults
Selecting this item causes all parameters, including the password, to be reset to
factory default values.
Parameters
The FSA configuration parameters include:
Configuration Port Address
When multiple FSA’s have their configuration ports tied to a common bus, each
configuration port must have a unique address
MODBUS Port Address
FSA’s MODBUS slave address. Must be unique for every MODBUS device on
the network.
MODBUS Port Baud Rate
Communication speed of the MODBUS network. Set per the requirements of the
MODBUS master.
MODBUS Port Parity
Set per the requirements of the MODBUS master.
CANbus Port Address
Each device connected to a single IM200 must have a unique address.
CANbus Port Baud Rate
Set to match the IM200.
Head 1 Enable/Disable
Used to disable an input port if only one head will be connected to an FSA.
Head 1 Identifier
Two alphanumeric characters that identify the head’s location on the boiler.
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LIMELIGHT™ Exacta Flame Scanner System
Head 1 Mode
Sets the operating mode of the head. Possible values are Single Fuel,
Discriminate, Fuel Switching, and Load Switching.
Head 1 Marginal Source
Value that controls the marginal flame relay/alarm. Possible values are Worst
Quality, Parameter Set “A” Quality, Parameter Set "B” Quality.
Head 1 Marginal Pull-in
When value of marginal source falls below this value the marginal flame relay will
close.
Head 1 Marginal Drop-out
When value of marginal source rises above this value the marginal flame relay
will open. Separate pull-in and drop-out values allow for hysterisis preventing
relay from chattering as value approaches the pull-in or drop-out level.
Head 1 Set “A” Intensity Pull-in
When flame intensity rises above this value, the intensity flame proving criteria
for parameter set “A” is met.
Head 1 Set “A” Intensity Drop-out
When flame intensity drops below this value, the intensity flame proving criteria
for parameter set “A” is no longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering as value approaches the pullin or drop-out level.
Head 1 Set “A” Frequency Pull-in
When flame flicker frequency rises above this value, the frequency flame proving
criteria for parameter set “A” is met.
Head 1 Set “A” Frequency Drop-out
When flame flicker frequency drops below this value, the frequency flame proving
criteria for parameter set “A” is no longer met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from chattering as value approaches
the pull-in or drop-out level.
Head 1 Set “A” Frequency Sensitivity
Minimum peak-to-peak value, in mV, that the signal must change to be included
in the flicker frequency calculation.
Head 1 Set “A” Intensity Filter Factor
Smoothing filter applied to the flame intensity. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
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Head 1 Set “A” Intensity Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 1 Set “A” Frequency Filter Factor
Smoothing filter applied to the flicker frequency. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 1 Set “A” Frequency Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 1 Set “A” AC Pull-in
When the peak-to-peak amplitude of the AC component of the flame signal rises
above this value, the AC requirement for proving flame is met. This is an expert
value, normally not used in most installations. It is disabled by defaulting to a
value of zero.
Head 1 Set “A” AC Drop-Out
When the peak-to-peak amplitude of the AC component of the flame signal drops
below this value, the AC requirement for proving flame is not met. This is an
expert value, normally not used in most installations. It is disabled by defaulting
to a value of zero.
Head 1 Set “A” AC Filter Factor
Smoothing filter applied to the AC component. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 1 Set “A” AC Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 1 Set “A” Bandpass Cutoff
Sets the characteristics of the digital filter applied to the flame signal. This is an
expert parameter normally left at the default value for most installations.
Head 1 Set “A” Pull-in Time Delay
Time delay, in seconds, from the time that all flame proving criteria is met, and
the flame relay closes. This is an expert parameter normally left at the default
value for most installations.
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LIMELIGHT™ Exacta Flame Scanner System
Head 1 Set “A” Drop-out Time Delay
Time delay, in seconds, from the time that a flame proving requirement is lost,
and the flame relay opens. This is an expert parameter normally left at the
default value for most installations.
Head 1 Set “A” High Frequency Drop-out
When enabled, Head 1 Flame A relay de-energizes when frequency exceeds
Head 1 Set “B” frequency pull-in.
Head 1 Set “B” Intensity Pull-in
When flame intensity rises above this value, the intensity flame proving criteria
for parameter set “B” is met.
Head 1 Set “B” Intensity Drop-out
When flame intensity drops below this value, the intensity flame proving criteria
for parameter set “B” is no longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering as value approaches the pullin or drop-out level.
Head 1 Set “B” Frequency Pull-in
When flame flicker frequency rises above this value, the frequency flame proving
criteria for parameter set “B” is met.
Head 1 Set “B” Frequency Drop-out
When flame flicker frequency drops below this value, the frequency flame proving
criteria for parameter set “B” is no longer met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from chattering as value approaches
the pull-in or drop-out level.
Head 1 Set “B” Frequency Sensitivity
Minimum peak-to-peak value, in mV, that the signal must change to be included
in the flicker frequency calculation.
Head 1 Set “B” Intensity Filter Factor
Smoothing filter applied to the flame intensity. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 1 Set “B” Intensity Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
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Head 1 Set “B” Frequency Filter Factor
Smoothing filter applied to the flicker frequency. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 1 Set “B” Frequency Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 1 Set “B” AC Pull-in
When the peak-to-peak amplitude of the AC component of the flame signal rises
above this value, the AC requirement for proving flame is met. This is an expert
value normally not used in most installations. It is disabled by defaulting to a
value of zero.
Head 1 Set “B” AC Drop-out
When the peak-to-peak amplitude of the AC component of the flame signal drops
below this value, the AC requirement for proving flame is not met. This is an
expert value normally not used in most installations. It is disabled by defaulting
to a value of zero.
Head 1 Set “B” AC Filter Factor
Smoothing filter applied to the AC component. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 1 Set “B” AC Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 1 Set “B” Bandpass Cutoff
Sets the characteristics of the digital filter applied to the flame signal. This is an
expert parameter normally left at the default value for most installations.
Head 1 Set “B” Pull-in Time Delay
Time delay, in seconds, from the time that all flame proving criteria is met, and
the flame relay closes. This is an expert parameter normally left at the default
value for most installations.
Head 1 Set “B” Drop-out Time Delay
Time delay, in seconds, from the time that a flame proving requirement is lost,
and the flame relay opens. This is an expert parameter normally left at the
default value for most installations
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LIMELIGHT™ Exacta Flame Scanner System
Head 2 Enable/Disable
Used to disable an input port if only one head will be connected to an FSA.
Head 2 Identifier
Two alphanumeric characters that identify the head’s location on the boiler.
Head 2 Mode
Sets the operating mode of the head. Possible values are Single Fuel,
Discriminate, Fuel Switching, and Load Switching.
Head 2 Marginal Source
Value that controls the marginal flame relay/alarm. Possible values are Worst
Quality, Parameter Set “A” Quality, Parameter Set "B” Quality.
Head 2 Marginal Pull-in
When value of marginal source falls below this value the marginal flame relay will
close.
Head 2 Marginal Drop-out
When value of marginal source rises above this value the marginal flame relay
will open. Separate pull-in and drop-out values allow for hysterisis preventing
relay from chattering as value approaches the pull-in or drop-out level.
Head 2 Set “A” Intensity Pull-in
When flame intensity rises above this value, the intensity flame proving criteria
for parameter set “A” is met.
Head 2 Set “A” Intensity Drop-out
When flame intensity drops below this value, the intensity flame proving criteria
for parameter set “A” is no longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering as value approaches the pullin or drop-out level.
Head 2 Set “A” Frequency Pull-in
When flame flicker frequency rises above this value, the frequency flame proving
criteria for parameter set “A” is met.
Head 2 Set “A” Frequency Drop-out
When flame flicker frequency drops below this value, the frequency flame proving
criteria for parameter set “A” is no longer met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from chattering as value approaches
the pull-in or drop-out level.
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LIMELIGHT™ Exacta Flame Scanner System
Head 2 Set “A” Frequency Sensitivity
Minimum peak-to-peak value, in mV, that the signal must change to be included
in the flicker frequency calculation.
Head 2 Set “A” Intensity Filter Factor
Smoothing filter applied to the flame intensity. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 2 Set “A” Intensity Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 2 Set “A” Frequency Filter Factor
Smoothing filter applied to the flicker frequency. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 2 Set “A” Frequency Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 2 Set “A” AC Pull-in
When the peak-to-peak amplitude of the AC component of the flame signal rises
above this value, the AC requirement for proving flame is met. This is an expert
value normally not used in most installations. It is disabled by defaulting to a
value of zero.
Head 2 Set “A” AC Drop-out
When the peak-to-peak amplitude of the AC component of the flame signal drops
below this value, the AC requirement for proving flame is not met. This is an
expert value normally not used in most installations. It is disabled by defaulting
to a value of zero.
Head 2 Set “A” AC Filter Factor
Smoothing filter applied to the AC component. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 2 Set “A” AC Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
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LIMELIGHT™ Exacta Flame Scanner System
Head 2 Set “A” Bandpass Cutoff
Sets the characteristics of the digital filter applied to the flame signal. This is an
expert parameter normally left at the default value for most installations.
Head 2 Set “A” Pull-in Time Delay
Time delay, in seconds, from the time that all flame proving criteria is met, and
the flame relay closes. This is an expert parameter normally left at the default
value for most installations.
Head 2 Set “A” Drop-out Time Delay
Time delay, in seconds, from the time that a flame proving requirement is lost,
and the flame relay opens. This is an expert parameter normally left at the
default value for most installations.
Head 2 Set “A” High Frequency Drop-out
When enabled, Head 2 Flame A relay de-energizes when frequency exceeds
Head 1 Set “B” frequency pull-in.
Head 2 Set “B” Intensity Pull-in
When flame intensity rises above this value, the intensity flame proving criteria
for parameter set “B” is met.
Head 2 Set “B” Intensity Drop-out
When flame intensity drops below this value, the intensity flame proving criteria
for parameter set “B” is no longer met. Separate pull-in and drop-out values
allow for hysterisis preventing relay from chattering as value approaches the pullin or drop-out level.
Head 2 Set “B” Frequency Pull-in
When flame flicker frequency rises above this value, the frequency flame proving
criteria for parameter set “B” is met.
Head 2 Set “B” Frequency Drop-out
When flame flicker frequency drops below this value, the frequency flame proving
criteria for parameter set “B” is no longer met. Separate pull-in and drop-out
values allow for hysterisis preventing relay from chattering as value approaches
the pull-in or drop-out level.
Head 2 Set “B” Frequency Sensitivity
Minimum peak-to-peak value, in mV, that the signal must change to be included
in the flicker frequency calculation.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Head 2 Set “B” Intensity Filter Factor
Smoothing filter applied to the flame intensity. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 2 Set “B” Intensity Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 2 Set “B” Frequency Filter Factor
Smoothing filter applied to the flicker frequency. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 2 Set “B” Frequency Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 2 Set “B” AC Pull-in
When the peak-to-peak amplitude of the AC component of the flame signal rises
above this value, the AC requirement for proving flame is met. This is an expert
value normally not used in most installations. It is disabled by defaulting to a
value of zero.
Head 2 Set “B” AC Drop-out
When the peak-to-peak amplitude of the AC component of the flame signal drops
below this value, the AC requirement for proving flame is not met. This is an
expert value normally not used in most installations. It is disabled by defaulting
to a value of zero.
Head 2 Set “B” AC Filter Factor
Smoothing filter applied to the AC component. A value of 0 equals no filter, a
value of 3 equals the maximum filter. This is an expert parameter normally not
changed in most installations.
Head 2 Set “B” AC Normalization Factor
Used in the flame quality calculation. This is an expert parameter typically set
using the “save normalization factor” function.
Head 2 Set “B” Bandpass Cutoff
Sets the characteristics of the digital filter applied to the flame signal. This is an
expert parameter normally left at the default value for most installations.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Head 2 Set “B” Pull-in Time Delay
Time delay, in seconds, from the time that all flame proving criteria is met, and
the flame relay closes. This is an expert parameter normally left at the default
value for most installations.
Head 2 Set “B” Drop-out Time Delay
Time delay, in seconds, from the time that a flame proving requirement is lost,
and the flame relay opens. This is an expert parameter normally left at the
default value for most installations.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Table D: Minimum, Maximum And Default Parameter Values
Parameter
Minimum
Maximum
Default
Configuration Port Address
1
255
1
MODBUS Port Address
1
255
1
MODBUS Port Baud Rate
MODBUS Port Parity
CANbus Port Address
9600, 19200, 38400, 57600
19200
Odd, Even, None
None
10
255
10
CANbus Port Baud Rate
62.5K, 125K , 250K
125K
Head 1 Enable/Disable
Enable, Disable
Enable
Head 1 Identifier
Any 6 alphanumeric characters
A1
Head 1 Mode
Single Fuel, Discriminate, Fuel
Switching, Load Switching
Discriminat
e
Head 1 Marginal Source
Worst Quality, Quality “A”, Quality
“B”
Worst
Quality
Head 1 Marginal Pull-in
0
100
10
Head 1 Marginal Drop-out
0
100
15
Head 1 Set “A” Intensity Pull-in
5
100
25
Head 1 Set “A” Intensity Drop-out
5
100
25
Head 1 Set “A” Frequency Pull-in
5
250
20
Head 1 Set “A” Frequency Drop-out
5
250
20
Head 1 Set “A” Frequency Sensitivity
10
100
30
Head 1 Set “A” Intensity Filter Factor
0
3
1
Head 1 Set “A” Intensity Normalization
Factor
0
100
80
Head 1 Set “A” Frequency Filter Factor
0
3
1
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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As Set
29
LIMELIGHT™ Exacta Flame Scanner System
Parameter
Minimum
Maximum
Default
Head 1 Set “A” Frequency Normalization
Factor
0
250
75
Head 1 Set “A” AC Pull-in
0
1000
0
Head 1 Set “A” AC Drop-out
0
1000
0
Head 1 Set “A” AC Filter Factor
0
3
1
Head 1 Set “A” AC Normalization Factor
0
1000
100
Head 1 Set “A” Bandpass Cutoff
No Filter, 10Hz Hi
10 - 200Hz
Pass, 10 - 100Hz, 10
- 200Hz, 0 - 100Hz, 0
- 200Hz
Head 1 Set “A” Pull-in Time Delay
0
4
0
Head 1 Set “A” Drop-out Time Delay
0
4
2
Enable, Disable
Disable
Head 1 Set “B” Intensity Pull-in
5
100
25
Head 1 Set “B” Intensity Drop-out
5
100
25
Head 1 Set “B” Frequency Pull-in
5
250
20
Head 1 Set “B” Frequency Drop-out
5
250
20
Head 1 Set “B” Frequency Sensitivity
10
100
30
Head 1 Set “B” Intensity Filter Factor
0
3
1
Head 1 Set “B” Intensity Normalization
Factor
0
100
80
Head 1 Set “B” Frequency Filter Factor
0
3
1
Head 1 Set “B” Frequency Normalization
Factor
0
250
75
Head 1 Set “B” AC Pull-in
0
1000
0
Head 1 Set “B” AC Drop-out
0
1000
0
Head 1 Set “B” AC Filter Factor
0
3
1
Head 1 Set “A” High Frequency Drop-out
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
As Set
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Parameter
Minimum
Maximum
Default
Head 1 Set “B” AC Normalization Factor
0
1000
100
Head 1 Set “B” Bandpass Cutoff
No Filter, 10Hz Hi
10 - 200Hz
Pass, 10 - 100Hz, 10
- 200Hz, 0 - 100Hz, 0
- 200Hz
Head 1 Set “B” Pull-in Time Delay
0
4
0
Head 1 Set “B” Drop-out Time Delay
0
4
2
Head 2 Enable/Disable
Enable, Disable
Enable
Head 2 Identifier
Any 6 alphanumeric characters
A2
Head 2 Mode
Single Fuel, Discriminate, Fuel
Switching, Load Switching
Discriminat
e
Head 2 Marginal Source
Worst Quality, Quality “A”, Quality
“B”
Worst
Quality
Head 2 Marginal Pull-in
0
100
10
Head 2 Marginal Drop-out
0
100
15
Head 2 Set “A” Intensity Pull-in
5
100
25
Head 2 Set “A” Intensity Drop-out
5
100
25
Head 2 Set “A” Frequency Pull-in
5
250
20
Head 2 Set “A” Frequency Drop-out
5
250
20
Head 2 Set “A” Frequency Sensitivity
10
100
30
Head 2 Set “A” Intensity Filter Factor
0
3
1
Head 2 Set “A” Intensity Normalization
Factor
0
100
80
Head 2 Set “A” Frequency Filter Factor
0
3
1
Head 2 Set “A” Frequency Normalization
Factor
0
250
75
Head 2 Set “A” AC Pull-in
0
1000
0
Head 2 Set “A” AC Drop-out
0
1000
0
Head 2 Set “A” AC Filter Factor
0
3
1
Head 2 Set “A” AC Normalization Factor
0
1000
100
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
As Set
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Parameter
Head 2 Set “A” Bandpass Cutoff
Minimum
Maximum
Default
No Filter, 10Hz Hi Pass, 10 10 - 200Hz
100Hz, 10 - 200Hz, 0 - 100Hz, 0 200Hz
Head 2 Set “A” Pull-in Time Delay
0
4
0
Head 2 Set “A” Drop-out Time Delay
0
4
2
Head 2 Set “A” High Frequency Drop-out
Enable, Disable
Head 2 Set “B” Intensity Pull-in
5
100
25
Head 2 Set “B” Intensity Drop-out
5
100
25
Head 2 Set “B” Frequency Pull-in
5
250
20
Head 2 Set “B” Frequency Drop-out
5
250
20
Head 2 Set “B” Frequency Sensitivity
10
100
30
0
3
1
Head 2 Set “B” Intensity Filter Factor
0
3
1
Head 2 Set “B” Intensity Normalization
Factor
0
100
80
Head 2 Set “B” Frequency Normalization
Factor
0
250
75
Head 2 Set “B” AC Pull-in
0
1000
0
Head 2 Set “B” AC Drop-out
0
1000
0
Head 2 Set “B” AC Filter Factor
0
3
1
Head 2 Set “B” AC Normalization Factor
0
1000
100
Head 2 Set “B” Frequency Filter Factor
Head 2 Set “B” Bandpass Cutoff
Disable
No Filter, 10Hz Hi
10 - 200Hz
Pass, 10 - 100Hz, 10
- 200Hz, 0 - 100Hz, 0
- 200Hz
Head 2 Set “B” Pull-in Time Delay
0
4
0
Head 2 Set “B” Drop-out Time Delay
0
4
2
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
As Set
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
SYSTEM STARTUP
Initial Software Configuration
If the Flame Signal analyzer, (FSA), configuration ports are networked, each FSA
must be given a unique configuration port address. This address must initially be
set using the local keypad. After this address is set, all other parameters can be
configured locally, or remotely using the PC interface software.
If the MODBUS network is being used each FSA must be assigned a unique
MODBUS slave address. It is permitted for the MODBUS port to use the same
address as the configuration port. The MODBUS baud rate and parity must be
set to match the requirements of the MODBUS master.
When using an IM-200 network interface module for network communications,
each FSA must be given a unique CANbus address. The CANbus baud rate
must be set to match the configuration of the IM-200.
The FSA has a parameter for storing a 2-character identifier for each head. This
is usually set to a letter number combination that identifies the elevation and
location of the scanner head. This identifier is only used by the PC interface
software, and has no effect on scanner operation.
After the scanner has been properly installed and configured it is ready for
startup. For ‘line of sight’ applications it may be necessary to make alignment
adjustments to properly ‘sight’ the scanner. Adjustment screws have been
provided. Rotate the three (3) adjusting screws until the scanner head ‘winker’
diode flashes at its fastest rate.
Adjustment of Trip Points
Trip set points or parameters can be adjusted by trained technicians or by Alstom
Power Inc. Technical Service Personnel. In many cases, different Scanners will
have different trip points because of Fireball location and unit specific variations.
If major adjustments are needed, Alstom Power Inc. recommends that Alstom
Power Inc. perform the adjustments or review the proposed changes. Generally
it is difficult to adjust set points in such a way that safety might be compromised
because of built-in safety features, but there is no substitute for experience and
knowledge in achieving reliable performance.
MAINTENANCE
The frequency of periodic maintenance varies from application to application.
Generally, cleaning of the Lens assembly should be scheduled annually. The
fiber optic cables should be inspected if there is a reduction of intensity or
frequency or suspect fiber breakage.
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LIMELIGHT™ Exacta Flame Scanner System
Lens Cleaning, Fiber Optic (FO) Head
Disassembling the Lens Body
•
•
•
•
•
Verify removal of the scanner head assembly from the guidepipe without
impacting unit operations or plant safety.
Remove the Flame Scanner Head (It is not necessary to disconnect the
electrical connector).
Remove the Fiber Optic Extension from the Guide Pipe.
Disassemble the Vortex Lens Body Assembly by removing the socket
head cap screws between the Lens Body and Plug, shown in Figure 6.
Remove the lens assembly and clean or replace the lens. Various fuels
cause different types of deposits. Isopropyl alcohol is typically effective
in removing deposits.
Figure 6: Vortex Lens Body Assembly Details
Assembling the Lens Body
The Flame Scanner lens body Assembly, shown in Figure 6, is assembled in the
following manner:
•
•
•
•
Slide the spring over the Fiber Optic cable, then thread the Jam Nut
approximately 3/4 down the end of the Fiber Optic Cable, sliding the Star
Washer and Flat Washer on after.
Screw the Fiber Optic Cable into the focusing lens assembly; bottom out
the Fiber Optic Cable to the Focusing Lens.
Lock the cable to the focusing lens assembly with the jam nut and
optional lock washer. Care should be taken not to twist the Fiber Optic
Cable excessively during this assembly as the fibers could be damaged.
Assemble the Vortex Body Assembly to the Plug, Secure with three
Socket Head Cap Screws. Use anti-seize compound on threads at
assembly.
Lens Cleaning, Line of Sight (LOS) Head
•
•
•
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
Verify removal of the scanner head assembly from the guidepipe without
impacting unit operations or plant safety.
Remove the Flame Scanner Head. The lens will not be accessible at the
end of the scanner head.
Clean the lens. Various fuels cause different types of deposits.
Isopropyl alcohol is typically effective in removing deposits.
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LIMELIGHT™ Exacta Flame Scanner System
•
•
If the lens is scratched or pitted, it can be replaced by carefully prying out
the truarc ring. Always use a new o-ring and truarc ring when replacing
the lens.
Replace the scanner head onto the guide pipe.
Inspecting the Fiber Optic Cable
•
•
•
Remove the scanner head and fiber optic extension as described above.
Shine a flashlight into the focusing lens in the lens body.
Observe the light pattern at the scanner end of the fiber optic extension.
If there is a significant number of dark spots (representing 15% or more
of the fibers) the fiber optic cable should be replaced.
Replacing the Fiber optic Cable
•
•
•
•
•
•
•
•
•
•
•
•
•
•
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
Remove the scanner head and fiber optic extension as described above.
Disassemble the lens body as described above.
Rock the plastic light guide to one side to detach it from the spool piece.
Pull the fiber optic cable from the spool piece.
Loosen the two setscrews, and unscrew the plastic light guide from the
fiber optic cable.
Remove the spring from the fiber optic cable.
Place the spring on the end of the new fiber optic cable.
Screw the plastic light guide onto the new fiber optic cable. The light
guide should be threaded on until the end of the fiber optic cable is flush
with the recess in the light guide. Tighten the two setscrews.
Feed the opposite end of the new fiber optic cable into the spool piece
and out the flex hose. Leave any excess cable extending out of the
spool piece.
Reassemble the lens body.
Push the excess fiber optic cable into the spool piece.
Span the light guide onto the spool piece.
Reinstall the fiber optic extension into the guide pipe.
Reinstall the scanner head.
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LIMELIGHT™ Exacta Flame Scanner System
CUSTOMER SERVICE CONTACTS
For questions regarding the Flame Scanner or to obtain replacements, spare
parts (see Table E, F, and G below), repair service or for warranty issues for any
of the components described within this Manual, please contact the appropriate
Customer Service Representative noted below.
IN USA
Alstom Power Inc.
2000 Day Hill Road
Windsor, CT 06095
(866) 257-8664
E-Mail: windsorparts@power.alstom.com
IN CANADA:
Alstom Power Canada
1430 Blair Place
Ottawa, ON K1J 9N2
CANADA
(613) 747-5779
E-Mail: canadianaftermarketparts@power.alstom.com
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
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LIMELIGHT™ Exacta Flame Scanner System
RECOMMENDED SPARE PARTS (RSP) AND SPECIAL TOOLS LISTS
The following tables list spare parts which are recommended for both essential
spares and commissioning / start-up spares. Housing and the associated
electronics are sold in three configurations, Visible Light (VL), Broad Range (BR)
and Ultraviolet. The application of these parts may require a Fiber Optic Cable
(FOC) or Line of Sight (LOS) Lenses.
Table E: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range) LOS –
Standard Viewing Angle
Item
No. *
Description
Part No.
Qty
1A
1B
2
3
4
5
6S
7
8
Flame Scanner Head (VL)
Flame Scanner Head (BR)
Connector Assembly
Connector Gasket
Spring Pull Pin
Locking Pull Pin
Quartz Lens (Standard)
O-Ring Gasket
Lens Retaining Ring
ESH-700-VL-LS
ESH-700-BR-LS
C36-92130
EPSA-0003
V00-4211
V00-4212
EPSB-0071
V00-4218
V00-4214
1
1
1
1
1
1
1
1
1
Commissioning
Spares Per
Unit
1
1
0
0
0
0
0
0
0
1-4
5-16
17-24
25Above
1
1
0
0
0
0
0
0
0
2
2
1
1
1
1
1
1
1
2
2
2
2
1
1
2
1
1
3
3
4
4
2
2
4
2
2
* Refer to Figure 7.
Table F: RSP List, Scanner Head (VL - Visible Light, BR – Broad Range, UV –
Ultraviolet, UVH – Ultraviolet High-Gain) LOS – Wide Viewing Angle
Item
No. *
Description
Part No.
Qty
1C
1D
1E
Flame Scanner Head (VL)
Flame Scanner Head (BR)
Flame Scanner Head (UV)
Flame Scanner Head
(UVH)
Connector Assembly
Connector Gasket
Spring Pull Pin
Locking Pull Pin
Quartz Lens (Wide Angle)
O-Ring Gasket
Lens Retaining Ring
ESH-700-VL-LS-W
ESH-700-BR-LS-W
ESH-700-UV-LS-W
1F
2
3
4
5
6W
7
8
1-4
5-16
17-24
25Above
1
1
1
Commissioning
Spares Per
Unit
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
ESH-700-UVH-LS-W
1
1
1
2
2
3
C36-92130
EPSA-0003
V00-4211
V00-4212
EPSC-0107
V00-4218
V00-4214
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
2
2
1
1
1
1
1
4
4
2
2
2
2
2
* Refer to Figure 7.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Figure 7: Scanner Head (LOS) Parts
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
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LIMELIGHT™ Exacta Flame Scanner System
Table G: RSP List, Flame Scanner Assembly (VL - Visible Light, BR - Broad Range), 110”
or 130” Fiber Optic Cable with Vortex Lens Body
Item
No. *
1A
1B
2A
2B
3
4A
4B
5A
5B
5C
6A
6B
6C
7
8
9
10
11
12
13
14
15
16
17
Description
Part No.
Qty
Flame Scanner Head (VL)
Flame Scanner Head (BR)
Exacta Shaft & Cover
Assembly, 110” FOC
Exacta Shaft & Cover
Assembly 130” FOC
Light Guide
Fiber Optic Cable 110” Long
Fiber Optic Cable 130” Long
Vortex Body Assembly 3 Deg
(consists of items 6 through 12
below)
Vortex Body Assembly 9 Deg
(consists of items 6 through 12
below)
Vortex Body Assembly 18 Deg
(consists of items 6 through 12
below)
Lens Barrel 3 Deg
Lens Barrel 9 Deg
Lens Barrel 18 Deg
Vortex Body
NPT Adapter
Socket Head Cap Screw
Spring
Star Washer
Hex Nut
Washer
Connector Assembly
Connector Gasket
Spring Pull Pin
Locking Pull Pin
ESH-700-VL-FO
ESH-700-BR-FO
EPSD-0363-110
1
1
1
Commissioning
Spares Per
Unit
1
1
1
1-4
5-16
17-24
25Above
1
1
0
2
2
1
2
2
1
3
3
2
EPSD-0363-130
1
1
0
1
1
2
EPSB-0100
FS-FC-110
FS-FC-130
EPSD-0400
1
1
0
1
1
0
2
1
2
2
3
4
1
1
0
0
0
0
EPSD-0404
1
1
0
0
0
0
EPSD-0405
1
1
0
0
0
0
EPSD-0401
EPSD-0402
EPSD-0403
EPSD-0420
EPSC-0082
V00-4236
EPSB-0118
V00-4235
V00-4237
V00-5050
C36-92130
EPSA-0003
V00-4211
V00-4212
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
1
1
1
1
0
6
1
1
1
1
1
1
1
1
2
2
2
2
0
12
2
2
2
2
2
2
1
1
3
3
3
3
1
24
3
3
3
3
4
4
2
2
* Refer to Figure 8.
Note: Select 1A for Visible Light (VL) Applications
Select 1B for Broad Range (BR) Applications
Select 2A for 110” fiber optic cable designs
Select 2B for 130” fiber optic cable designs
When ordering a complete assembly as a spare it is important to have the length dimension (L=xx.xx).
Refer to drawing D-EPSD-0382 below when ordering a replacement fiber optic scanner assembly.
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Figure 8: Flame Scanner Assembly Parts (VL/BR) – 110” or 130”
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
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LIMELIGHT™ Exacta Flame Scanner System
Table H: RSP List, Flame Scanner Assembly (UV – Ultraviolet or UVH – Ultraviolet HighGain), 110” or 130” Fiber Optic Cable with Vortex Lens Body
Item
No. *
Description
Part No.
Qty
Commissioning
Spares Per Unit
1-4
5-16
17-24
25Above
1A
Flame Scanner Head (UV)
ESH-700-UV-FO
1
1
1
2
2
3
1B
Flame Scanner Head (UVH)
Exacta Shaft & Cover
Assembly, 110” FOC Quartz
Cable
Exacta Shaft & Cover
Assembly, 130” FOC Quartz
Cable
Light Guide
Fiber Optic Cable 110”
Fiber Optic Cable 130”
Vortex Body Assembly 12 Deg
(consists of items 6 through 12
below)
Vortex Body Assembly 9 Deg
(consists of items 6 through 12
below)
Vortex Body Assembly 6.5 Deg
(consists of items 6 through 12
below)
Vortex Body Assembly 3 Deg
(consists of items 6 through 12
below)
Lens Barrel 12 Deg
Lens Barrel 9 Deg
Lens Barrel 6.5 Deg
Lens Barrel 3 Deg
Vortex Body
NPT Adapter
Socket Head Cap Screw
Spring
Star Washer
Hex Nut
Washer
Connector Assembly
Connector Gasket
Spring Pull Pin
Locking Pull Pin
ESH-700-UVH-FO
1
1
1
2
2
3
EPSD-0363-110-Q
1
1
0
1
1
2
EPSD-0363-130-Q
1
1
0
1
1
2
EPSB-0100
EPSB-0110-110
EPSB-0110-130
1
1
1
0
1
1
1
0
0
2
1
1
2
2
2
3
4
4
EPSD-0415
1
1
0
0
0
0
EPSD-0416
1
1
0
0
0
0
EPSD-0417
1
1
0
0
0
0
EPSD-0418
1
1
0
0
0
0
EPSD-0406
EPSD-0407
EPSD-0413
EPSD-0414
EPSD-0420
EPSC-0082
V00-4236
EPSB-0118
V00-4235
V00-4237
V00-5050
C36-92130
EPSA-0003
V00-4211
V00-4212
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
1
1
1
1
1
0
6
1
1
1
1
1
1
1
1
2
2
2
2
2
0
12
2
2
2
2
2
2
1
1
3
3
3
3
3
1
24
3
3
3
3
4
4
2
2
2A
2B
3
4A
4B
5A
5B
5C
5D
6A
6B
6C
6D
7
8
9
10
11
12
13
14
15
16
17
* Refer to Figure 9.
Note: Select 1A for Ultraviolet (UV) Applications
Select 1B for Ultraviolet High-Gain (UVH) Applications
Select 2A for 110” quartz fiber optic cable designs
Select 2B for 130” quartz fiber optic cable designs
When ordering a complete assembly as a spare it is important to have the length dimension (L=xx.xx).
Refer to drawing D-EPSD-0445 below when ordering a replacement fiber optic scanner assembly.
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LIMELIGHT™ Exacta Flame Scanner System
Figure 9: Flame Scanner Assembly Parts (UV and UVH) – 110” or 130”
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LIMELIGHT™ Exacta Flame Scanner System
Table I: Accessory Parts
Item
No.
1
1A
1B
1C
Description
Part No.
Qty
Connector Adapter Cable
10 Ft
Connector Adapter Cable
25 Ft
Connector Adapter Cable
50 Ft
Connector Adapter Cable
100 Ft
EF-CA-10
1
Commissioning
Spares Per
Unit
1
1-4
5-16
17-24
25Above
1
2
2
3
EF-CA-25
1
1
1
2
2
3
EF-CA-50
1
1
1
2
2
3
EF-CA-100
1
1
1
2
2
2
1-4
5-16
17-24
25Above
1
1
2
2
Table J: Special Tools
Item
No.
1
Description
Part No.
Qty
External Retaining Ring
Set Tool
EPSB-0107-02
1
Commissioning
Spares Per
Unit
1
Refer to Figure 10.
Fiber optic cable assemblies require a 0.050 hex key to service the light guide.
Figure 10: Special Tools
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LIMELIGHT™ Exacta Flame Scanner System
GENERAL SPECIFICATIONS
Scanner Head
Temperature Rating
Sealing
Cooling Air
Requirements for
FO Heads
Cooling Air
Requirements for
LOS Head with
Compressed air systems
Power
Overall Dimensions
14 to 185 Degrees F (-10 to 85 Degrees C)
Wash down waterproof
30 SCFM. Pressure should be adequate to
overcome furnace or windbox pressure. Generally
5-6” WC above furnace or windbox pressure will
generate approximately 30 SCFM of flow. Cooling
Air temperature shall be a maximum of 120 deg F
(49 deg C).
10 SCFM. Use Alstom engineered orifice to
generate 10 SCFM of flow with supply pressure
range of 80 to 120 PSI.
Supplied by Flame Signal Analyzer
5.7” (145mm) L x 2.4” (61mm) W x 4.4” (112mm) H
Flame Signal Analyzer
Temperature
Rating
Power
Mounting
Overall
Dimensions
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14 to 160 Degrees F (-10 to 70 Degrees C)
21.5 - 26Volts DC(+/- 10% Maximum Ripple), 12W
35mm DIN Rail, vertical mount with end stops
6.18” (157mm) Lx 3.38 ”(86mm) W x 2.28” (58mm) H
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LIMELIGHT™ Exacta Flame Scanner System
APPENDIX I – FLAME SCANNER SYSTEM SELECTION SHEET
abcd Power Inc. - Boiler and Environmental Plant Services
Flame Scanner Selection / Specification Sheet
Customer:
Location:
Station:
Unit No.:
OEM:
Original Contract No.:
Plant Type:
Unit Type:
Plant Contact:
Title:
Tel:
PSS Contract No.:
Unit Rating:
No. Of Corners:
Main Fuel:
Aux/Support Fuels:
Main Fuel Elevations:
Aux/Support Fuel
Elevations:
Ignitor Type:
Ignitor Fuel:
Number of Elevations:
Scanner Application:
Scanner Model:
No. Of Scanner's:
Scanner Firmware Version No.:
Scanner Hardware Version No.:
NIM Model:
No. Of NIM Modules
NIM Firmware Version No.:
NIM Hardware Version No.:
PC Interface Software Version No.
Scanner Power Supply:
BMS Interface:
(Scanner Head Contacts, NIM
Contacts)
(MODBUS Connection,
DeviceNet Connection, 4-20mA)
DCS Interface:
Drawings
Critical Dimensions
Flame Scanner AssemblyFabrication:
Flame Scanner AssemblyCustomer:
Tilting
Guide Pipe Length:
Make-up Nipple Length (If
Retrofit):
Fiber Optic Length:
Flexible Metal Hose
Length:
Rigid Pipe Length:
Scanner Head Wiring:
Scanner / NIM Interconnection
Wiring Dwg:
Junction Box-Mechanical:
Junction Box-Electrical:
Line of Sight
Rigid Nipple Length:
Nipple Material:
IM Cabinet-Mechanical:
IM Cabinet-Electrical:
Selection By:
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LIMELIGHT™ Exacta Flame Scanner System
APPENDIX II – EXACTA FLAME SCANNER REMOTE HEAD
Figure 11: Exacta Flame Scanner Remote Head Assembly
Figure 12: Exacta Flame Scanner Remote Head Assembly for Ignitor Applications
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LIMELIGHT™ Exacta Flame Scanner System
The Exacta Scanner Head assembly is offered in a Remote Head configuration
that can be installed on 3” Bluff Body Oil or Gas Ignitors. The Remote Head
Assembly can be easily mounted on existing Bluff Body Ignitors by removing the
Ignitor Flame Rod and putting a Fiber Optic Cable Assembly in its place.
The Ignitor Flame Light is propagated through the Fiber Optic cable and in turn
converted to an electrical signal that is sent to the Flame Signal Analyzer (FSA)
via a 2-0mA current loop. This signal is in turn evaluated using the same
characteristics outlined in this manual (i.e. Flame Intensity, Flicker Frequency,
and in certain cases AC amplitude).
Mechanical Components
Figure 13: Exacta Flame Scanner Remote Head Components
Item
Description
1 EXACTA REMOTE HEAD ASSY
2 EXACTA CONNECTOR ADAPTER CABLE ASSEMBLY
3 1/2" FLEX CONDUIT
4 1/2" STRAIGHT CONDUIT CONNECTOR
5 PIPE IGNITOR ADAPTER FOR REMOTE HEAD
6 FIBER OPTIC CABLE
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LIMELIGHT™ Exacta Flame Scanner System
For the complete Exacta Flame Scanner Remote Head Components Identification, refer to Drawing No.
D-EPSD-0481. The drawing includes Assembly Part Numbers along with a complete list of the Product
structure options associated with this particular Exacta Assembly configuration.
For Installation Instructions, refer to Drawing No. D-EPSD-0484
Exacta Remote Head Assembly Instructions
1.) Disconnect wire trains and fuel supply. Remove Pipe Ignitor and unthread IFM rod at furnace
end. For Gas Ignitors, save IFM rod and ceramics as spare parts for spark rod and ceramics.
2.) Remove Spark/IFM Connector & Wire Train Assembly including Ceramic. Rod Sheath (IFM
guide tube) is left in place.
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (1 of 5)
3.) Insert Pipe Nipple & Kamlock Coupling threading Kamlock to a rotation angle that allows full
motion and access to Kamlock levers.
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LIMELIGHT™ Exacta Flame Scanner System
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (2 of 5)
4.) Remove 1/2" Flex Conduit (i.e FO Cable fits inside Conduit for Final Assy), and Insert Fiber Optic
Cable down IFM Guide Tube until Cable stops in Bluff Body.
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LIMELIGHT™ Exacta Flame Scanner System
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (3 of 5)
5.) Cut Flex Conduit to desired length so as to cover exposed length of FO Cable.
6.) Remove entire Remote Head Assembly from Bluff Body Ignitor, Re-assemble Modified/Cut Flex
Conduit & re-attach to Remote Head Assembly. Place Entire Assembly back into the Ignitor.
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LIMELIGHT™ Exacta Flame Scanner System
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (4 of 5)
7.) Once Remote Head Assembly is in place, prior to fully inserting the FOC Guide Sleeve into the
Kamlock tighten Set Screw (until fiber optic cable is secure, using caution to prevent collapsing of
jacket armor) to allow 0.5 to 0.75” FOC compression. Clamp FOC Guide Sleeve into Kamlock.
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LIMELIGHT™ Exacta Flame Scanner System
Figure 14: Exacta Flame Scanner Remote Head Assembly Instructions (5 of 5)
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LIMELIGHT™ Exacta Flame Scanner System
RECOMMENDED SPARE PARTS LIST
Item
No.
Description
Part No.
Qty Spares Per Unit
1-4
5-16
17-24
25Above
1
1
1
2
2
3
1
1
1
2
2
3
1
0
0
1
1
2
1
0
0
1
1
2
Commissioning
1A
Exacta Visible Light (VL) Remote Head Assy
EPSD-0467-VL
1B
Exacta Broad Range (BR) Remote Head Assy
EPSD-0467-BR
1C
Exacta Ultra-Violet (UV) Remote Head Assy
EPSD-0467-UV
1D
Exacta Ultra-Violet (UVH) Remote Head Assy
EPSD-0467-UVH
2A
110" Fiber Optic Cable
C10-94501
2B
130" Fiber Optic Cable
C10-94502
2C
30' Fiber Optic Cable
C10-94503
2D
110" Quartz for UV
EPSB-110 (Gas Only)
2E
120" Quartz for UV
EPSB-130 (Gas Only)
3A
Sealtite Conduit 94"
V00-5553-94
3B
Sealtite Conduit 112"
V00-5553-112
3C
Sealtite Conduit 342"
V00-5553-342
4A
Exacta Connector Pigtail – 10 FT Long
EF-CA-10
4B
Exacta Connector Pigtail – 25 FT Long
EF-CA-25
4C
Exacta Connector Pigtail – 50 FT Long
EF-CA-50
4D
Exacta Connector Pigtail – 100 FT Long
EF-CA-100
5
FOC Guide Sleeve
EPSC-0146
1
0
0
1
1
2
6
Screw Set #1/4 - 20 x .50 LG
V00-5555
1
0
0
1
1
2
7
Coupling 1/2 NPT Kamlock
V00-5551
1
0
0
1
1
2
8
1/2" Straight Conduit Connector
V00-5552
2
0
0
2
2
4
9A
1/2" PIPE NIPPLE x 4.00" LG (GAS)
MD8-00131-FD
9B
1/2" PIPE MODIFIED NIPPLE 4.00" LG (OIL)
EPSB-0140
1
0
0
1
1
2
10
Exacta Flame Signal Analyzer
EPSD-0375
1
1
0
1
1
2
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LIMELIGHT™ Exacta Flame Scanner System
Figure 15: Recommended spare parts list
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LIMELIGHT™ Exacta Flame Scanner System
APPENDIX III – EXPLOSIVE ATMOSPHERE APPLICATION
Explosive Atmosphere Label Information
Exacta scanner heads with the following label information (Figure 16) are
certified as intrinsically safe for use in an explosive atmosphere when
they are wired in accordance with drawing DEPSD- 0536 Exacta
Intrinsically Safe Terminal Barrier External Connection Diagram (for
ESH-700 model heads) using the Intrinsically Safe Terminal Barrier
Assembly (D-EPSD-0545) to isolate the scanner heads from the signal
analyzers.
Figure 16: Sample ATEX label
The Exacta Scanner Head (ESH-700) has been ATEX certified for use in
explosive gas and dust atmospheres. The following scanner models
share this rating information:
•
•
•
•
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ESH-700-BR-FO
ESH-700-BR-LS
ESH-700-BR-LS-W
ESH-700-UV-FO
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LIMELIGHT™ Exacta Flame Scanner System
•
•
•
•
•
•
ESH-700-UV-LS-W
ESH-700-VL-FO
ESH-700-VL-LS
ESH-700-VL-LS-W
ESH-700-UVH-FO
ESH-700-UVH-LS-W
Labels for the Exacta heads that are approved for explosive
environments contain the following information:
• Manufacturer Address:
ALSTOM Power, Inc. 200 Great Pond Drive, P.O. Box 500, Windsor,
CT, 06095
• Flame Scanner Model Number
• Input Voltage (Ui), Current (Ii), and Power (Pi)
• Explosion Protection Marking
o ATEX II 1 G Ex ia IIC T5 -10ºC ≤ Ta ≤ +85ºC
o ATEX II 2 D Ex iaD 21 T100ºC
• TÜV ATEX certificate number: XXXXX
• CE Mark
• CSA Mark
Intrinsic Safety Certification Standards
Exacta scanner heads that are ATEX approved as intrinsically safe have
examination certificates issued by TÜV and are compliant with the
following standards:
• IEC EN 60079-0 – Electrical apparatus for explosive gas
atmospheres (Ex ia)
• IEC EN 60079-11 – Equipment protection by intrinsic safety “i” (Ex
ia)
• IEC EN 61241-0 – Electrical apparatus for use in the presence of
combustible dust (Ex iaD)
• IEC EN 61241-11 – Equipment protection by intrinsic safety “iD” (Ex
iaD)
Entity Parameters
+15 V circuit:
Connector J1: Pin 1 to pin 4
Ui =
+22.0 V
Ii =
150 mA
0,057 μF
Ci =
negligible
Li =
-15V circuit:
Connector J1: Pin 2 to pin 4
Ui =
-22.0 V
Ii =
150 mA
0,138 μF
Ci =
negligible
Li =
Signal circuit:
Connector J1: Pin 3 to pin 4
Ui =
9.56 V
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LIMELIGHT™ Exacta Flame Scanner System
Ii =
Ci =
Li =
195 mA
negligible
negligible
Approved Class Ratings
a. Device Group
The Exacta scanner heads belong to Equipment Group II, which is
suitable for non-mining (above ground) applications.
b. Device Category / Atmosphere
The Exacta scanner heads are ATEX category 1 compliant for gas (G)
and category 2 for dust (D)
Zone
ATEX
Equipment
Category
Gas &
Vapors
Definition of Zone
Dust
1
0
20
2
1
21
3
2
22
Explosive atmospheres are present continuously, for long
periods or frequently.
Explosive atmospheres are likely to occur under normal
operation, occasionally.
Explosive atmospheres may occur under abnormal
operation and persist for a short period only
c. Protection Type
The scanner heads are rated for Explosion Protection (Ex) by means of
Intrinsic Safety (ia). Devices that are rated to be intrinsically safe do not
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LIMELIGHT™ Exacta Flame Scanner System
require an explosion-proof enclosure because they do not contain
enough energy to cause ignition.
d. Equipment Group
The scanner heads are suitable for use in a IIC (most hazardous)
equipment group.
Gas Group
Hazard Category
Ignition Energy
Ethane
IIA
>180μJoules
Ethylene
IIB
>60μJoules
Hydrogen
IIC
>20μJoules
e. Temperature Class and Ambient Temperature Range
The temperature class of the Exacta scanner head is depending on the
surrounding ambient temperature.
Temperature
Class
Maximum Surface
Temperature
Maximum Surface
Temperature (Dust)
Operating
Temperature Range
T5
100ºC
T95ºC
-10ºC to 85ºC
Special Conditions for Safe Use
•
•
•
The flame scanner head has to be mounted in a way, that sparking
from friction or impact will not occur.
The power has to be provided by IS barriers complying with the
defined input values.
The installation has to be done according to IEC 60079-14.
Notes on the Safe Use of the ATEX approved Flame Scanner Head
The Alstom Exacta Flame Scanner Head was designed in accordance with the
technical and safety regulations of the EU when it is used for its intended
purpose.
The installation, commissioning, and operation of these scanner heads must be
performed by authorized and qualified personnel who have read and understand
the manual and will follow the instructions and drawings provided.
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LIMELIGHT™ Exacta Flame Scanner System
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Drawing 1: Exacta FSA Field Wiring Diagram, D-EPSD-0371
59
LIMELIGHT™ Exacta Flame Scanner System
Drawing 2: Exacta FSA Configuration, VL or BR FOC Variable Length, D-EPSD-0382
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LIMELIGHT™ Exacta Flame Scanner System
Drawing 3: Exacta FSA, LOS VL or BR Standard Lens, D-EPSD-0384
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LIMELIGHT™ Exacta Flame Scanner System
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Drawing 4: Exacta FSA, LOS VL/BR/UV-Wide Lens, D-EPSD-0397
62
LIMELIGHT™ Exacta Flame Scanner System
Drawing 5: Exacta FSA UV with Quartz FOC Variable Length, D-EPSD-0445
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LIMELIGHT™ Exacta Flame Scanner System
Drawing 6: Exacta Flame Scanner Remote Head Configuration, D-EPSD-0481
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LIMELIGHT™ Exacta Flame Scanner System
Drawing 7: Exacta Remote Head 3” Bluff Body Ignitor Installation, D-EPSD-0484
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User Manual
Limelight™ Exacta Flame
Scanner PC Interface
POWER SERVICE
Table of Contents
EXACTA PC INTERFACE SOFTWARE ......................................................................................... 1
System Requirements.................................................................................................................. 1
Installation .................................................................................................................................... 1
BEFORE RUNNING THE SOFTWARE .......................................................................................... 2
Modifying the Config Port Address .............................................................................................. 2
RUNNING THE PROGRAM FOR THE FIRST TIME ...................................................................... 3
Initializing the Network ................................................................................................................. 5
BASIC OPERATION........................................................................................................................ 6
Head Status ................................................................................................................................. 6
Reading Parameters .................................................................................................................... 6
Writing Parameters ...................................................................................................................... 7
Applying Parameter Changes ...................................................................................................... 8
Saving Parameters to a File......................................................................................................... 8
Load FSA parameters................................................................................................................ 11
Calibrating 4-20ma Outputs ....................................................................................................... 12
Displaying Scanner Data ........................................................................................................... 13
Logging Scanner Data ............................................................................................................... 15
Event Triggered Data Logging ................................................................................................... 16
SIMULATION MODE..................................................................................................................... 20
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
© ALSTOM Power Inc. 2009
ii
Table of Figures
Figure 1: Password Dialog .............................................................................................................. 3
Figure 2: RS485 Wiring Diagram..................................................................................................... 3
Figure 3: Daisy-Chain of FSA's ....................................................................................................... 4
Figure 4: Windows Device Manager................................................................................................ 4
Figure 5: Tools Menu - Options ....................................................................................................... 5
Figure 6: Options Window ............................................................................................................... 5
Figure 7: PC Interface Showing Flame Proven ............................................................................... 6
Figure 8: Head "CH 1" Marginal Flame and "CH 2" Fault ............................................................... 6
Figure 9: Active Module List ............................................................................................................ 6
Figure 10: Configuration Tabs ......................................................................................................... 7
Figure 11: Text Box Input Field ....................................................................................................... 7
Figure 12: Pull-Down Input Field ..................................................................................................... 7
Figure 13: Modified Parameter not yet applied ............................................................................... 8
Figure 14: Globally applied parameter ............................................................................................ 8
Figure 15: Apply Buttons ................................................................................................................. 8
Figure 16: File Menu – Save One FSA ........................................................................................... 9
Figure 17: Save As Dialog Box........................................................................................................ 9
Figure 18: File Menu – Save All FSA’s.......................................................................................... 10
Figure 19: File Menu – Load FSA Params .................................................................................... 11
Figure 20: Open Configuration Dialog........................................................................................... 11
Figure 21: Tools Menu – Calibrate 4-20ma Outputs ..................................................................... 12
Figure 22: Calibration Window ...................................................................................................... 12
Figure 23: View Menu – Current Values ....................................................................................... 13
Figure 24: Current Values Display Screen .................................................................................... 13
Figure 25: Current Values Screen Showing Data ......................................................................... 14
Figure 26: File Menu – Log All Data .............................................................................................. 15
Figure 27: Save As Dialog Box...................................................................................................... 15
Figure 28: Data Logging in Progress............................................................................................. 16
Figure 29: File Menu – Event Triggered Log................................................................................. 16
Figure 30: Save As Dialog Box...................................................................................................... 17
Figure 31: Event Logging Data window......................................................................................... 17
Figure 32: Waiting for Trigger window........................................................................................... 18
Figure 33: Event Log Triggered Data window ............................................................................... 18
Figure 34: Logging Complete window ........................................................................................... 19
Figure 35: Tools Menu – Log Out.................................................................................................. 20
Figure 36: Tools Menu – Log In..................................................................................................... 20
Figure 37: Sim Control Window..................................................................................................... 20
Figure 38: Active Modules Showing Flame Proven....................................................................... 21
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
© ALSTOM Power Inc. 2009
iii
EXACTA PC INTERFACE SOFTWARE
The Exacta PC Interface software allows for remote configuration of the Flame Signal Analyzer.
The following sections should provide assistance in using the software and some minor
troubleshooting.
System Requirements
The Exacta PC Interface requires a PC with a minimum of a 500MHz processor, 128Mb of RAM,
10Mb of disk space for installation, and running Windows 2000 or Windows XP Professional.
Installation
To install the Exacta PC Interface software, navigate to the folder where the Exacta PC
Interface.msi installer file exists.
Steps:
1. Double-Click the installer icon. A window will appear for the setup wizard.
2. Click the “Next >” button to continue
3. The Installation Folder window allows the user to change the installation folder location
from the default “C:\Program Files\Alstom Power\Exacta PC Interface\” as well as to set
up users that can run the software
4. Click the “Next >” button to continue
5. The Confirm Installation screen is the last chance to go back and make changes before
the software is installed.
6. Click the “Next >” button to continue
7. A progress bar will appear showing the progress of the installation. A successful
installation will show the Installation Complete screen.
8. Press “Close” to finish
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
© ALSTOM Power Inc. 2009
1
Before Running the Software
Before the Exacta PC Interface software is able to communicate with the Flame Scanner
modules, the modules must be connected to the computer running the PC Interface software by
means of an RS485 connection and each Flame Scanner module must have a unique Config
Port Address.
The only parameter that the PC Interface software cannot configure remotely is the Config Port
Address. This parameter is the identifier for each Flame Scanner Module. Setting available
Flame Scanner Modules port addresses to be in sequence will speed up the Initialize Network
process.
Modifying the Config Port Address
1. Enter the configuration mode on the Flame Scanner Module
a. Press the “Program” (1) key
b. Enter the 5 character password using the number keys
2. Select the Edit Parameters option
3. Select Communication Parameters
4. Press the "Enter" key to allow modification to the address value
5. Use the arrow keys to change the value
6. Press the "Enter" key to set address at desired value
7. Press the "Program" button 3 times to exit from local configuration
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
© ALSTOM Power Inc. 2009
2
Running the Program for the first time
The Exacta PC Interface can be launched by either double-clicking the desktop icon Exacta PC
Interface or navigating to the Start menu folder Start > Programs > Alstom > Exacta PC Interface.
Each time the program is run, a dialog box opens asking for the password (Figure 1). Initially,
there are only two passwords. Entering no password or an incorrect password will run the
software in read-only mode where no values can be changed.
Figure 1: Password Dialog
•
•
“Exacta” – this password allows the user to change configurable values and upload them
to the flame signal analyzer.
“simulate” – this password starts the software in simulation mode where the software
operates as if two FSA’s are connected and there is flame signal that is read (see the
section on “Simulation Mode”).
There are some settings that need to be configured before you can start communicating with your
Flame Signal Analyzers.
First, ensure that you are properly connected to the configuration port on TB4 of the FSA
(reference drawing D-EPSD-0371 Exacta Flame Scanner Field Wiring Diagram) and that your
RS485 connection is wired appropriately (Figure 2).
Figure 2: RS485 Wiring Diagram
If you are wiring to multiple FSA’s, ensure that you have correctly wired your devices in a daisychain (Figure 3).
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3
Figure 3: Daisy-Chain of FSA's
Once devices are connected, the appropriate Windows COM port needs to be selected for
communications. This is done by first checking the Windows device manager to find what COM
port was assigned for the RS485 adapter (this should be the same port as the serial port if a
serial RS232 to RS485 adapter is used and a new number if a USB to RS485 adapter is used)
(Figure 4).
COM Port for
USB to RS485
Figure 4: Windows Device Manager
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4
Initializing the Network
Once the Flame Scanner Modules have been connected to the computer running the
configuration software. The software needs to be configured to use the appropriate port to
communicate with the devices. The communications port is set using the tools pull-down menu
(Figure 5).
Figure 5: Tools Menu - Options
When the options window opens, the appropriate communications (COM) port can be selected
from the drop-down of active COM ports. The port address search range should also be set to
reflect the port addresses of the attached Flame Scanner Modules. This is the port found in the
Windows device manager (Figure 6).
Figure 6: Options Window
Once the communications port and port address ranges have been set. The software should
automatically send a request through the communications port to identify the attached Flame
Scanner Modules that are within the selected range. The PC Interface software will store this
information, so the above steps will not need to be repeated each time the software is run.
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5
Basic Operation
Head Status
The PC Interface software is constantly polling the Flame Signal Analyzers to find and report their
status. The software will show conditions of flame proven, marginal flame, and a fault with
different colors in the Active Module List. Flame proven has a red background and labels to show
the head that is proving and flame A or B depending on if discrimination mode is set (Figure 7).
Figure 7: PC Interface Showing Flame Proven
Marginal flames are displayed as a yellow background on the head identifier and faults are
displayed as a purple background (Figure 8).
Figure 8: Head "CH 1" Marginal Flame and "CH 2" Fault
Reading Parameters
The result of a successful network initialization is a populated tree control on the left side of the
application. That area of the application controls what detailed information is seen for one device.
Clicking on a 'FSA-n' node results in two consecutive actions; reading all 'setting related'
information, for the device indicated, and then, using the read information, populating it as new
information appearing on the right side.
The information in the parameters section of the software is separated into eleven groups
represented with an individual tab. The user clicks on the tabs to see the parameter information.
Here is the above restated as a series of steps:
1. Determine the FSA node of interest
2. Click on that “FSA-n” in the Active Module list (Figure 9)
Figure 9: Active Module List
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3. Observe the data that has populated the twelve (12) tabs and the FSA status bar reads
"FSA-n Communication Parameters." (Figure 10)
Figure 10: Configuration Tabs
The tabs available are as following:
•
•
•
•
•
•
•
•
•
•
•
•
Communication
Head 1 Common
Head 2 Common
Head 1 Set A Basic
Head 1 Set B Basic
Head 2 Set A Basic
Head 2 Set B Basic
Head 1 Set A Expert
Head 1 Set B Expert
Head 2 Set A Expert
Head 2 Set B Expert
4-20ma
You can freely click the tabs to observe device settings for the FSA indicated.
Writing Parameters
There are two types of fields used for updating parameters values: pull-down menus (Figure 12),
and text boxes (Figure 11). The pull-down menus are for parameters that have limited or very
specific values. Text boxes are used for parameters that have a wide range of acceptable integer
inputs.
Figure 11: Text Box Input Field
Figure 12: Pull-Down Input Field
Many parameter values are related to other parameter values by a specific range. Changing the
driving of these values outside of the range will change the driven value to be equal. There are
also limits for changing the driven value. If values entered into a driven parameter are outside of
the range, the software will display a pop-up message indicating the problem with the value and
will change it to the extents of the range.
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Parameter values and the tabs that contain them that have been modified, but not applied are
marked with a “*” (Figure 13).
Figure 13: Modified Parameter not yet applied
NOTE: Many parameters have the ability to be changed globally on all detected Flame Scanner
modules. These parameters are identified by a check box in the left column (Figure 14). Not all
values may be modified in a global way. Foremost among these are the head identifiers.
Figure 14: Globally applied parameter
Applying Parameter Changes
When all desired parameters have been changed, the updates are applied to the Flame Scanner
Module by clicking one of the apply buttons (Figure 15).
Figure 15: Apply Buttons
Apply Global: The "Apply Global" button will remain grayed-out until a "Global Update" check box
is checked. When the "Apply Global" button is clicked, all parameters with the "Global Update"
check box checked will be updated on all detected Flame Scanner Modules. Any modified
parameters that do not have a "Global Update" check box or the box is unchecked will be
ignored.
Apply Local: The "Apply Local" button will remain grayed-out until a parameter is modified. When
this button is clicked, if any parameters are selected for a "Global Update", the software will
present a dialog allowing the update locally or stopping the update so that it may be performed
globally.
Reload: Like the "Apply Local" button, the "Reload" button will remain grayed-out until a
parameter is modified. This button will clear all modified parameters that haven't been applied
and will replace them with the values from the Flame Scanner Module.
Saving Parameters to a File
It is often desired to back up files and settings for computers and equipment and the Exacta PC
Interface allows for the backup of FSA settings. This can be done for individual FSA’s as well as
for all recognized FSA’s in the program.
Save a single FSA's parameters:
1. Select the desired FSA in the network tree view in the left pane.
2. From the top menu select “File” and then “Save One FSA” (Figure 16)
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Figure 16: File Menu – Save One FSA
A window will then pop up allowing the destination folder and filename to be selected (Figure 17).
Figure 17: Save As Dialog Box
Upon clicking “Save” the selected FSA’s configuration parameters will be written to a file.
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Save all FSA’s parameters
1. From the top menu bar select “File” and then “Save All FSA’s” (Figure 18)
Figure 18: File Menu – Save All FSA’s
A window will pop up as above to allow selection of the destination folder and filename. It should
be noted that a separate file is created for each FSA in the network, and that the FSA’s
configuration address will be appended to the selected filename.
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10
Load FSA parameters
Select the target FSA from the network tree in the left pane of the display. From the top menu
bar, select “File” and then “Load FSA Params” (Figure 19).
Figure 19: File Menu – Load FSA Params
A window will pop up to allow the file containing the parameters to be selected (Figure 20).
Figure 20: Open Configuration Dialog
Upon clicking Open the parameter values from the file will be loaded in to the parameter property
sheets in the configuration window. Once the parameter property sheets have their new values,
the “Apply Local” button can be used to upload the parameters to the selected FSA or the
“Reload” button can be used to discard the loaded values and return to the current values stored
in the FSA.
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11
Calibrating 4-20ma Outputs
The 4-20ma analog outputs from the FSA are already factory calibrated, however, slight
variances in hardware and installation may require calibration to display desired values in the
DCS. The PC Interface software has the ability to adjust the calibration values. The calibration
screen is initiated through the tools menu after selecting the appropriate FSA in the active module
list (Figure 21).
Figure 21: Tools Menu – Calibrate 4-20ma Outputs
When the calibration window opens, the appropriate channel can be selected from the drop-down
of analog output channels. The counts / output current can be adjusted up or down and there are
test buttons for verifying the calibration (Figure 22).
Figure 22: Calibration Window
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Displaying Scanner Data
From the top menu bar select “View”, and then select “Current Values” from the drop down list
(Figure 23).
Figure 23: View Menu – Current Values
This will cause the right side pane to display the following screen (Figure 24).
Figure 24: Current Values Display Screen
To display values to plot in the displayed graph, select the desired FSA from the network tree
displayed in the left side pane then select the checkbox next to the value(s) that you wish to
trend. The trend will be displayed in the color of the text next to the check box. You can also
show the pull in and drop out values for each value being trended. Pull in /drop out values are
shown as a dotted line the same color as the trend (Figure 25).
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Figure 25: Current Values Screen Showing Data
Each trace on the trend window has its own scale. The full-scale value is shown beside the trend
window in a color matching the trace. You can change the scale of a trace by simply clicking on
the full-scale value, and entering a new number. If you enter a non-numeric value, the software
will resume auto-ranging the trace scale.
Thirty minutes of trend data is available. Data collection begins when the FSA is selected.
Three levels of zoom are available on the trend screen. The zoom level is selected from the drop
down box below the trend screen. At the highest zoom level 10 minutes of data is displayed in the
trend window. The full 30 minutes of trend data is available at this resolution. The 10-minute trend
window can be shifted back in time using the scroll bar under the trend window. Medium zoom
will show 20 minutes of data in the trend window, and low zoom will display the entire 30-minute
data set in the trend window.
By default, the latest value is shown to the left of the check box for each measured variable. If the
Min or Max radio button is selected, the minimum or maximum value, in the collected data, will be
displayed in place of the latest value.
If the reset button is pressed, the minimum and maximum values are reset, and will be calculated
only with data from that point foreword.
Pressing the stop button will stop the acquisition of new data, freezing the trend data set at the
current point in time.
After stopping the store button will be enabled. Pressing the store button will save the 30-minute
trend data for all variables to a comma-delimited file.
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14
Logging Scanner Data
From the top menu bar, select “File” and then “Log All Data” (Figure 26).
Figure 26: File Menu – Log All Data
A pop up window will appear, allowing the destination file to be selected (Figure 27).
Figure 27: Save As Dialog Box
All measured variables from each FSA on the network will be saved. A separate comma delimited
file is created for each FSA. Upon clicking “Save” data logging will begin. The following window
will pop up to indicate that data logging is in progress (Figure 28).
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15
Figure 28: Data Logging in Progress
Logging will continue until the “Stop” button is clicked.
Event Triggered Data Logging
Data can be stored centered on a change of state of the flame / fault relays. Using this feature, 6
minutes of data before the event, and 6 minutes of data after the event is written to a file for each
scanner in the network.
To start this data logging, select “File” and then “Event Triggered Log” from the top menu bar
(Figure 29).
Figure 29: File Menu – Event Triggered Log
A pop up window will appear allowing the destination folder and filename to be selected (Figure
30).
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Figure 30: Save As Dialog Box
A separate file will be created for each FSA in the network. The configuration port address of the
FSA will be appended to the filename. Then, a pop up window will appear to allow the triggering
event to be defined (Figure 31).
Figure 31: Event Logging Data window
Select the desired trigger condition using the drop down boxes. Upon selecting start the software
will begin waiting for the trigger event, and the following message will appear (Figure 32).
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Figure 32: Waiting for Trigger window
When the triggering even occurs the following message will be displayed (Figure 33).
Figure 33: Event Log Triggered Data window
When data collection is complete the following message will be displayed (Figure 34).
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Figure 34: Logging Complete window
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19
Simulation Mode
The Exacta PC Interface software also includes a simulation mode that can run as if it was
connected to an Exacta Flame Scanner system that is seeing an actual flame. The simulation
mode can be accessed by typing the password “simulate” on software startup or if the program is
already running, selecting “Log Out” from the Tools pull-down (Figure 35), then selecting “Log In”
from the same menu and entering “simulate” as the password (Figure 36).
Figure 35: Tools Menu – Log Out
Figure 36: Tools Menu – Log In
Once you are logged in to simulation mode, the first noticeable difference from the configuration
mode is the addition of the Sim Control window (Figure 37).
Figure 37: Sim Control Window
The Sim Control window gives the user the choice of simulating flame signal from two different
fuels: coal and oil. Clicking a fuel button starts that particular fuel simulation. The fuel
simulations can be activated independently or combined.
When the fuels are selected, the software will not only show the flame data in the Current Values
screen, but will show “flame proven” status by highlighting red the scanner head that is proving
flame in the active module list just like when connected to scanners that are seeing flame (Figure
38).
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20
Figure 38: Active Modules Showing Flame Proven
The simulation mode of the Exacta PC Interface is a useful tool for learning the affect of set
points and flame proving with multiple fuels. All of the features of the PC Interface software are
available in the simulation mode, making it a valuable training tool.
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third parties without express authority is strictly forbidden.
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21
TAB 5
Vendor-Supplied Equipment
TABLE OF CONTENTS
DESCRIPTION
Chentronics
Rapid Fire High Energy Ignition Exciter............................................................................................ 10SEP09
Maxon
Series 8000 Pneumatic Shut-off Valves ............................................................................50111985-001/A01
Rosemont
3051 Pressure Transmitter Product Data Sheet ................................................................. 00813-0100-4001
Rotork
LA-2400 Liner Actuators........................................................................................................ PUB045-003-00
© COPYRIGHT 2015 ALSTOM POWER INC.
CONTRACT: EB0-007991
REVISION: 0
17/6/15
i
OPERATIONS & MAINTENANCE MANUAL
Chentronics Corporation
Rapid‐Fire
High Energy Ignition Exciter
ITEM
Part Number
REV
Exciter Internals with Standard Base Plate
07000102-1
A
Exciter Internals with Compact Base Plate
07600102-1
A
Exciter Internals with Standard Base Plate and Diagnostics
07000102D-1
A
Exciter Internals with Compact Base Plate and Diagnostics
07600102D-1
A
07002038
A
Chentronics Spark Diagnostic Module
THIS EQUIPMENT IS SUITABLE FOR NON‐HAZARDOUS LOCATIONS ONLY
UNLESS EXCITER IS PLACED IN A RATED EXPLOSION PROOF ENCLOSURE
CHENTRONICS
OPERATION & MAINTENANCE MANUAL
PO BOX 368, Norwich N.Y., U.S.A.
www.chentronics.com
TEL: +1.607.334.5531
FAX: +1.607.336-.7447
Page 1 of 23
10SEP09
EMAIL: info@chentronics.com
Table of Contents
TABLE OF CONTENTS .................................................................................................................................................................. 2
REVISIONS .......................................................................................................................................................................................... 3
SAFETY INFORMATION .......................................................................................................................................................................... 4
Area Certification....................................................................................................................................................................... 4
Replacement of Components ..................................................................................................................................................... 4
Disconnection of Equipment ...................................................................................................................................................... 4
Branch Circuit Installation ......................................................................................................................................................... 4
Equipment Duty Cycle ................................................................................................................................................................ 4
EXCITER DESCRIPTION OF OPERATION........................................................................................................................................ 5
EXCITER CONFIGURATION AND MODES OF OPERATION ................................................................................................................................. 6
Factory Default Mode: Immediate Excitation ........................................................................................................................... 6
External Control Mode A: Controlling with a Zero Voltage Contact: ......................................................................................... 6
External Control Mode B: Controlling with a 24VDC Supply. ..................................................................................................... 6
External Switch Control: ............................................................................................................................................................ 6
EXCITER OUTPUT INDICATORS ................................................................................................................................................................. 7
Main Power Indicator ................................................................................................................................................................ 7
Attempting to Fire Indicator ...................................................................................................................................................... 7
Spark Indicator (If equipped with Diagnostic Module ONLY) ..................................................................................................... 7
Fault Present Indicator (If equipped with Diagnostic Module ONLY) ......................................................................................... 7
Fault Last Run Indicator (If equipped with Diagnostic Module ONLY) ....................................................................................... 8
CONNECTIONS PN 07000102‐1 OR 07600102‐1 ................................................................................................................................... 9
CONNECTIONS FOR PN 07000102D‐1 OR PN 07600102D‐1 ................................................................................................................... 9
EQUIPMENT SPECIFICATIONS ................................................................................................................................................... 10
INPUT POWER CHARACTERISTICS ........................................................................................................................................................... 10
INSTALLATION INSTRUCTIONS .................................................................................................................................................. 11
SAFETY ............................................................................................................................................................................................ 11
MOUNTING ...................................................................................................................................................................................... 11
OUTPUT CONNECTIONS ....................................................................................................................................................................... 11
EXCITER QUICK CONNECTION TABLE ...................................................................................................................................................... 12
IGNITION CONNECTION DIAGRAM.......................................................................................................................................................... 13
SYSTEM MAINTENANCE ........................................................................................................................................................... 14
INSPECTION ...................................................................................................................................................................................... 14
CLEANING ........................................................................................................................................................................................ 15
REPAIR ............................................................................................................................................................................................ 16
SEMI‐CONDUCTOR IGNITER RESISTANCE MEASUREMENTS .......................................................................................................................... 17
DRAWINGS ............................................................................................................................................................................... 18
INTERNAL EXCITER, P/N 07000102D‐1, STANDARD BASE‐PLATE FOR SAFE AREA ENCLOSURE .......................................................................... 18
EXCITER WITH NEMA4 ENCLOSURE, PN 07000102D ............................................................................................................................. 19
INTERNAL EXCITER, P/N 07600102D‐1, STANDARD BASE‐PLATE FOR HAZARDOUS AREA ENCLOSURE ................................................................ 20
EXCITER WITH EEXD ENCLOSURE, PN 07600102D ................................................................................................................................. 21
DIAGNOSTIC MODULE QUICK CONNECTION TABLE .................................................................................................................................... 22
DIAGNOSTIC MODULE, P/N 07002038 ................................................................................................................................................ 23
CHENTRONICS
OPERATION & MAINTENANCE MANUAL
PO BOX 368, Norwich N.Y., U.S.A.
www.chentronics.com
TEL: +1.607.334.5531
FAX: +1.607.336-.7447
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10SEP09
EMAIL: info@chentronics.com
Revisions
REV
A
DESCRIPTION OF CHANGE
PAGE
First Published Version
CHENTRONICS
OPERATION & MAINTENANCE MANUAL
PO BOX 368, Norwich N.Y., U.S.A.
www.chentronics.com
TEL: +1.607.334.5531
FAX: +1.607.336-.7447
DATE
10SEP09
Page 3 of 23
10SEP09
EMAIL: info@chentronics.com
Safety Information
Area Certification
THIS EQUIPMENT IS SUITABLE FOR USE IN NON‐HAZARDOUS LOCATIONS ONLY UNLESS INSTALLED IN A
PROPERLY RATED EXPLOSION PROOF ENCLOSURE
Replacement of Components
WARNING – EXPLOSION HAZARD – DO NOT REPLACE IGNITER UNLESS POWER HAS BEEN SWITCHED
OFF.
AVERTISSEMENT – RISQUE D’EXPLOSION – COUPER LE COURANT AVANT DE REPLACEER L’ IGNITER
Disconnection of Equipment
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF.
AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE
COURANT
Branch Circuit Installation
WARNING – RAPIDFIRE EXCITER REQUIRES A CIRCUIT BREAKER ON POWER INPUT BRANCH. THE
EXCITER HAS AN ADDIONAL SAFETY FUSE RATED TO 10A IS INSTALLED.
Equipment Duty Cycle
WARNING – DO NOT OPERATE THE EXCITER OUTSIDE THE POWER ON / POWER OFF DUTY CYCLE.
THE MAXIMUM ALLOWABLE DUTY CYCLE AS FOUND ON THE EQUIPMENT MAIN NAMEPLATE IS:
2 MINUTES ON / 5 MINUTES OFF
CAN BE OPERATED A MAXIMUM OF 4 TIMES IN SUCCESSION (28 MIN).
ALLOW 60 MINUTES BEFORE REPEATING DUTY CYCLE.
NEVER REPEATEDLY APPLY AND REMOVE POWER OUTSIDE THIS DUTY CYCLE RANGE.
Diagnostic Indicator
The diagnostic feature IS NOT a safety feature, and WILL NOT PROVE SPARK OR FLAME. The
diagnostic is a convenience feature for early warning of igniter plug wear only. The diagnostic
feature is unable to determine if the pulse discharge occurs at the tip or inside the igniter shell.
CHENTRONICS
OPERATION & MAINTENANCE MANUAL
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TEL: +1.607.334.5531
FAX: +1.607.336-.7447
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10SEP09
EMAIL: info@chentronics.com
Exciter Description of Operation
The High Energy Ignition Exciter operates without gas discharge tubes. Energy accumulates on storage
capacitor CSTG, as the exciter draws power from the input power line. The capacitor slowly accumulates
charge to a preset voltage during the interval between sparks. The capacitor charging circuit is a power
factor converter, PFC, which forces line current to approximate a sine wave in phase with the line voltage.
The resultant high power factor (>0.95) minimizes line current amplitude and line voltage distortion.
Additionally, the power factor converter provides galvanic isolation between the line and the discharge
circuit potentials. It operates over a wide input voltage range (100 to 240Vac, 50‐60 Hz).
When the capacitor has charged to a preset voltage, an electronic switch rapidly discharges the capacitor
through a pulse‐forming network into the igniter. Although the discharge current amplitude can vary from
several hundred to several thousand amperes (depending on the application), the life of the electronic
switch is not affected by the accumulation of these pulses.
The pulse‐forming network controls the amplitude and duration of the discharge current pulse to provide
characteristics, which enhance ignition and extend the life of the storage capacitor and igniter. While the
exciter output is typically 2000V, the pulse‐forming network can provide a 5000V‐trigger voltage as
needed.
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OPERATION & MAINTENANCE MANUAL
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TEL: +1.607.334.5531
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Exciter Configuration and Modes of Operation
Factory Default Mode: Immediate Excitation
The RapidFire Exciter series factory default configuration has a jumper wire across the CLOSE TO
START terminals (terminals 3 and 4). With the CLOSE TO START terminals shorted with a jumper,
the RapidFire will energize and begin firing immediately when input power is applied. This allows
the user to control the exciter by turning the main power input on and off. If the enclosure has
been supplied with an external switch, then this jumper will be removed in the factory before
shipping.
External Control Mode A: Controlling with a Zero Voltage Contact:
By removing the jumper from the CLOSE TO START input (terminals 3 and 4) it is possible to
control the RapidFire using a Zero Voltage Contact across the CLOSE TO START input. This can be
done using either the contacts of a relay or a transistorized system. If a transistor system is used,
an NPN type must be used with terminal 3 being the ground reference. The ratings of the device
used to close pins 3 and 4 must be a min of 24VDC at 50mA.
External Control Mode B: Controlling with a 24VDC Supply.
By removing the jumper from the CLOSE TO START input (terminals 3 and 4) it is possible to
control the RapidFire using a 24VDC Supply across the +24V TO START input terminals 1 and 2.
24VDC can be applied in either polarity using a relay or transistorized system. Note that this
connection is made directly to the coil of a relay internal to the exciter with no other devices in
parallel or series with the coil. The load current of the coil is 20mA.
Only one external control scheme should be used at a time.
Do not use the +24V TO START and CLOSE TO START inputs at the same time.
External Switch Control:
If the RapidFire enclosure has been equipped with an external switch, then the exciter can be fired by
pressing the switch when the RapidFire has Mains power available. Note that the CLOSE TO START terminal
jumper must be removed to use the external switch; otherwise the exciter will begin to fire as soon as it
receives Mains power.
CHENTRONICS
OPERATION & MAINTENANCE MANUAL
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Exciter Output Indicators
Main Power Indicator
Whenever Mains power is supplied to the RapidFire, the green POWER light will come on,
indicating the unit has power and is ready to fire. Additionally, the exciter provides an external Zero
Voltage Contact signal on terminals 5 and 6 that can be used to send a “ready to fire” signal to
other equipment. This output labeled POWER IND (NO) is open when exciter does not have power
and short when exciter is powered up. If the RapidFire enclosure has been equipped with a lighted
switch, the switch will light up when Mains power is applied as an additional ready to fire indicator.
Attempting to Fire Indicator
Whenever the RapidFire is powered up and receives a run signal, the red FIRING light will come on
indicating the RapidFire is attempting to fire the igniter plug. The RapidFire can receive a run signal
in one of three ways:
1) The CLOSE TO START terminals are shorted by either a jumper or external Contact
2) The +24V TO START terminals are supplied with 24VDC
3) If equipped, the Fire button on the enclosure is pressed.
Spark Indicator (If equipped with Diagnostic Module ONLY)
When equipped with a Diagnostic Module, a Blue LED spark indicator is available. This indicator will
flash OFF whenever the RapidFire releases an energy pulse. If this indicator remains ON solid, it is
an indication that the igniter is worn and is ceasing to fire or there is a problem with the harness
leading to the igniter. Additionally, if the RapidFire enclosure is equipped with both a lighted switch
and a Diagnostic Module, the external lighted switch will flash OFF in the same manner.
Fault Present Indicator (If equipped with Diagnostic Module ONLY)
When equipped with a Diagnostic Module, a FAULT PRESENT indicator is provided on terminals 7
and 8 with a Zero Voltage Contact. This output is OPEN when a fault is present at ANY TIME (run
signal independent) and SHORT when the igniter is firing normally. Additionally there is a red
FAULT WHEN OFF light that mimics the condition of this output with the light OFF indicating a
FAULT. Note that the FAULT PRESENT and FAULT LAST RUN outputs share terminal number 8 as a
common terminal.
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Fault Last Run Indicator (If equipped with Diagnostic Module ONLY)
When equipped with a Diagnostic Module, a latching FAULT LAST RUN indicator is provided on
terminals 8 and 9 with a Zero Voltage Contact. This output is maintained OPEN when a fault is
detected at ANYTIME DURING AND AFTER A RUN (when a run signal is applied and after it is
removed). This output is reset when new run signal is applied to the exciter or by cycling the exciter
main power. Additionally there is a red FAULT LAST RUN WHEN OFF light that mimics the
condition of this output with the light OFF indicating a FAULT LAST RUN. Note that the FAULT
PRESENT and FAULT LAST RUN outputs share terminal number 8 as a common terminal.
IMPORTANT NOTE: THE DIAGNOSTIC OUTPUTS ARE MASKED TO AN “OK” STATE FOR 3 SECONDS
EVERY TIME A NEW RUN SIGNAL IS APPLIED. THIS DELAY IS REQUIRED BY THE EXCITER TO COLLECT
DATA ON SPARK CONDITION AND PROCESS THE RESULTS.
*WARNING*
The diagnostic feature IS NOT a safety feature, and WILL NOT PROVE SPARK OR FLAME. The
diagnostic is a convenience feature for early warning of igniter plug wear only. The diagnostic
feature is unable to determine if the pulse discharge occurs at the tip or inside the igniter shell.
CHENTRONICS
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Connections PN 07000102­1 or 07600102­1
Terminals 1‐6 available accepting up to size 16AWG (1.3mm diameter) wire. Note that the
terminal block can be removed from the top board with wires attached for ease of installation
into a replacment exciter if neccesary.
Connections for PN 07000102D­1 or PN 07600102D­1
Terminals 1‐9 available accepting up to size 16AWG (1.3mm diameter) wire. Note that the
terminal block can be removed from the top board with wires attached for ease of installation
into a replacment exciter if neccesary.
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Equipment Specifications
Mechanical:
Input Power:
Stored Energy:
Spark Rate:
Temperature:
Duty Cycle:
NEMA4 (IP56) enclosure
Box dimensions: 12" X 12" X 7" [305 X 305 X 178 mm]
Illuminated ON/OFF switch (rated NEMA4) available
Net Weight: 20 Lb. [9 kg]
85 ‐ 265 VAC / 50‐60 Hz / 5 Amps @ 100 V
12 Joules Minimum
20 Sparks per Second minimum
‐25C to 75C
2 MINUTES ON, 5 MINUTES OFF (28%), OPERATED A MAXIMUM OF 4
TIMES IN SUCCESSION (28 MIN). ALLOW 60 MINUTES BEFORE
REPEATING DUTY CYCLE.
Input Power Characteristics
SUPPLY
VRMS
NORMAL OPERATING CURRENT
ARMS
APEAK
APEAK
APEAK
NORMAL IN‐RUSH CURRENT
APEAK
APEAK
APEAK
OVER
BEFORE
AFTER
FIRST
SECOND
THIRD
FOURTH
SPARK
SPARK
SPARK
CYCLE
CYCLE
CYCLE
CYCLE
15
10
5
10
6.7
3.3
‐
7.5
15
‐
5.9
11.7
‐
4.6
9.1
‐
3.6
7.1
PERIOD
85
120
240
7.5
5
2.5
In‐rush current peaks can be less than operating peaks because In‐rush is completed before sparking begins.
In‐rush is defined as the initial peak current drawn by the input capacitor when power is first applied to the
exciter. A resistor that is in series with the capacitor during turn‐on and shorted out once the capacitors are
charged limits the current. Because the capacitor must be fully charged before the exciter is allowed to
operate, it is possible to limit the inrush current to less than the operating current. Limiting the current to a
lower value requires a longer time for the capacitors to charge and a longer time for the exciter to provide the
first spark. An interval of 0.5 seconds or less between “power on” and “first spark” is generally accepted.
As can be seen in the above table, in‐rush peaks for 120Vrms are less than the operating peaks. However, the
same in‐rush resistor at 240Vrms produces twice the in‐rush current peak (which is larger than the operating
current).
The input terminal can accept up to AWG #12 (4‐mm2) wire. Input power wiring should be as large as possible,
taking into consideration the normal operating current noted above.
The exciter has an internal 10AMP Fast Acting fuse with an interrupt capability of 10kA. The dimensions are
10mm X 38mm. The fuse is CE marked and complies with IEC 269‐2‐1.
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Installation Instructions
Safety
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF.
AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE
COURANT
WARNING! Dangerous and potentially LETHAL voltages are present. READ DIRECTIONS BEFORE
PROCEEDING. DO NOT OPEN THE EXCITER ENCLOSURE for FIVE (5) MINUTES after operating the
exciter. This time is required to "bleed off" any high voltage residual charge left on the energy storage
capacitor.
Please follow the order of installation shown in this manual:
1. Mount Exciter
2. Exciter Output Wiring
3. Rod Termination
4. Input Wiring
*WARNING*
The diagnostic feature IS NOT a safety feature, and WILL NOT PROVE SPARK OR FLAME. The
diagnostic is a convenience feature for early warning of igniter plug wear only. The diagnostic
feature is unable to determine if the pulse discharge occurs at the tip or inside the igniter shell.
Mounting
For mounting dimensions, refer to drawing “Exciter Installation”. The exciter should be mounted to a
firm structure. It will function properly in either a vertical or horizontal position. The exciter has two
7/8" [22 mm] OD hole located on the side, one for Input Power the other for signal and control wires.
It is suitable for use with a hub and conduit. If the optional input power cord is not provided, complete
the input power connection as follows. Be sure to provide weatherproof connections.
WARNING – RAPIDFIRE EXCITER REQUIRES CIRCUIT BREAKER ON POWER INPUT BRANCH. NO
INTERNAL CIRCUIT BREAKERS ARE PROVIDED IN THE EQUIPMENT.
Output Connections
Attach the igniter to the rod. Please note that an anti‐seize compound is coated on the male threads of
the igniter at the factory to aid in maintenance removal. Attach the OUTPUT HARNESS to the rod.
Attach the OUTPUT HARNESS to the exciter.
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Exciter Quick Connection Table
A hole positioned alongside the output connector for input power entrance. The Mains power input wires
should be AWG #14 minimum. Input power should be turned ‘OFF” at the source and
steps should be taken to ensure that it remains “OFF” before proceeding with the
input wiring. Be sure to provide weatherproof connections. Inside the exciter, connect the single‐
phase input power to the L1 (Line), N (L2 Neutral) and G (Ground) terminations.
INPUT TERM.
L1
L2
GND
TERMINAL DESCRIPTION
Input power (HOT) wire, should be a minimum of 14AWG (600V).
Input power (NEUTRAL) wire, should be a minimum of 14AWG (600V).
Input (GROUND) wire, should be a minimum of 14AWG (600V).
OUTPUT TERM.
HI
LO
TERMINAL DESCRIPTION
Output, Igniter center wire, should be a minimum of 16AWG (2400V).
Output, Igniter shell return, should be a minimum of 16AWG (2400V).
Return wire must connect directly from this output to harness/igniter shell,
NOT to enclosure chassis. (ground return is to be through harness and not
though the building ground).
+24V START TERM.
1‐2
TERMINAL DESCRIPTION
Input Start/Stop Control – Applying a 24VDC signal to these pins will
energize the exciter. Polarity is not important.
CLOSE TO START TERM
3 ‐4
TERMINAL DESCRIPTION
Input Start/Stop Control – Applying a ZVC signal to these pins will
energize the exciter. WARNING! Do not connect to the +24V to Start
terminals and the Close to Start terminals at the same time.
LINE STATUS TERM.
5‐6
TERMINAL DESCRIPTION
Provides a closed contact signal when has proper input voltage to operate.
FAULT STATUS TERM.
7‐ 8
TERMINAL DESCRIPTION
Provides a closed contact signal spark rate is greater than 20SPS .
Provides an open contact signal spark rate is less than 20SPS .
FAULT LAST RUN TERM.
8 ‐9
TERMINAL DESCRIPTION
Provides a latched open contact signal when a fault occurs during the
current run. Contacts will reset closed when a start signal is applied. Pin 8
is a shared in Common between “Fault status” and “Fault Latch status”.
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Ignition Connection Diagram
The standard Igniter Tip length is 12” (305 mm).
IGNITER TIP
WEATHERPROOF
The Rod base section has a Military style twist connector
that allows connection with a gloved hand. Rod extension
pieces are also available for restricted access applications.
The harness is insulated conduit with two conductors.
BASE ROD
WEATHERPROOF
OUTPUT HARNESS
WEATHERPROOF
EXCITER
ENCLOSURE: NEMA4
P/N 07000102(D)
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75 C MAX
System Maintenance
WARNING –DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF.
AVERTISSEMENT –AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE COURANT
WARNING –DO NOT REPLACE IGNITER UNLESS POWER HAS BEEN SWITCHED OFF.
AVERTISSEMENT –COUPER LE COURANT AVANT DE REPLACEER L’ IGNITER
Inspection
EXCITER – Visually inspect the inside of the exciter enclosure for any debris such as loose screws or nuts
that would be indicative of damage. Check to ensure that the sub‐assembly is firmly mounted. Check
the electrical connections to ensure that they are secure.
CABLE – Check to ensure that the pins on the connectors are straight and intact. Check to ensure that
the connectors are secured to the cable hose. Using an ohmmeter, check the cable conductors to
ensure continuity and insulation integrity by making the measurements in the table below:
MEASUREMENT POINTS
REQUIRED VALUE
Pin “A” to Pin “A”
Less than one (1) ohm
Pin “B” to Pin “B”
Less than one (1) ohm
Pin “A” to Pin “B”
Greater than ten (10) meg‐
ohms
ROD – Check to ensure that the rod has not been bent or damaged during transport. Using an
ohmmeter, check the conduction paths in the rod to insure insulation integrity.
MEASUREMENT POINTS
REQUIRED VALUE
Pin “B” to the center conductor
Less than one (1) ohm
Pin “A” to the rod connector outer shell
Less than one (1) ohm
Pin “A” to the center conductor
Greater than ten (10) meg‐
ohms
IGNITER TIP – Visually inspect to ensure that the firing end is not damaged or cracked.
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Cleaning
WARNING! All power to the ignition exciter should be turned “OFF” and precautions
taken to make sure it is not accidentally turned “ON” at least five (5) minutes prior to
the opening of the Ignition Exciter Enclosure. This will allow time for the stored
energy in the capacitors to dissipate. Failure to do this will result in severe personnel
hazard. Dangerous and potential lethal voltages are present.
EXCITER ‐ Remove debris that may have accumulated inside the exciter enclosure with a vacuum or
non‐metallic brush.
CABLE – CAUTION: do not use acid or carbon tetrachloride as cleaning agents on conduit. Clean
the exterior with a stiff non‐metallic brush moistened in cleaning solvents. Protect cable
terminations from solvent contamination during cleaning. Heat or oil stains, which persist on the
conduit after cleaning, are permissible.
SPARK BASE ROD – The ceramic well at the Base Rod end of the rod should be sprayed with a
cleaning solvent or alcohol and if necessary, cleaned with a lint free rag.
EXTENSION ROD – The ceramic well at the igniter end of the rod should be sprayed with a cleaning
solvent or alcohol and if necessary, cleaned with a lint free rag. The ceramic terminal end should be
cleaned with a cleaning solvent or alcohol.
IGNITER TIP – The ceramic terminal end should be cleaned with a cleaning solvent or alcohol. The
tip should be sprayed to remove oil or other hydrocarbons that may contaminate the ceramic
surface.
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Repair
WARNING! All power to the ignition exciter should be turned “OFF” and precautions
taken to make sure it is not accidentally turned “ON” at least five (5) minutes prior to
the opening of the Ignition Exciter Enclosure. This will allow time for the stored
energy in the capacitors to dissipate. Failure to do this will result in severe personnel
hazard. Dangerous and potential lethal voltages are present.
CAUTION – In the unlikely event that the charge on the capacitor has not dissipated
the capacitor may be charged with high voltage. Confirm the removal of all charge with
a DC VOLTMETER before proceeding. Measure the DC voltage between the output
terminals and case ground to confirm that all charge is dissipated.
After confirmation that no voltage is present on the terminal connections, the modular
assembly can be removed for replacement. Remove all electrical connections by
unscrewing the terminal lugs and removing the wires from the input and output
terminal blocks.
WARNING! The internal exciter module is NOT REPAIRABLE. It must be returned to
the Factory to be refurbished. Failure to do this can result in severe personnel hazard.
Dangerous and potential lethal voltages are present.
The internal ON/OFF control relay is manufactured by Potter & Brumfield. Please reference their P/N
KUIP‐14D15‐24 for replacements.
In summary:

3 pole, double throw (Form 3C)

95°C maximum operating temperature (with clear polycarbonate dust cover)

24 VDC coil voltage (Class B coil insulation)

PC board quick connect mounting

Silver‐cadmium oxide contacts, rated 10A
VDE approved design (0435), Registration 1792
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Semi­Conductor Igniter Resistance Measurements
Depending on construction, semiconductor igniters are classified as thin film or bulk. The resistance of thin
film semiconductor is typically 10 to 100 times greater than the resistance of bulk semiconductors when
both are new. Chentronics manufactures thin film semiconductor igniters. Resistance for a new igniter is
typically 10kΩ to 30kΩ when measuring current is near 1mA. A constant current source is required to
measure resistance.
Megohmmeter: (Biddle Model BM200, Fluke Model 1520) ‐ The electronic megohmmeter provides a
constant measuring current for measurements below 100k when using the 1kV scale.
IGNITER TIP CONDITION
NEW
USED
MAXIMUM
30 KΩ
300 KΩ
TYPICAL
10 KΩ
30 KΩ to 300 KΩ
Multimeter: (Fluke Model 87) ‐ Semiconductor material resistance decreases logarithmically as measuring
current increases. Measuring current for the Fluke Model 87 Multimeter varies from 2 μA to 20 μA.
Therefore resistance measurements with the Fluke Multimeter are approximately 50% greater than the
Biddle Megohmmeter.
CURRENT (μA)
10
100
1000
10000
RESISTANCE (kΩ Typical)
13.7
12.7
10.5
8.1
Using a Multimeter to measure resistance of new igniters is normally not a problem. Igniters that have
been placed in service and occasionally new igniters can develop a hairline crack, such that contact is lost
between the semiconductor and the center electrode. When this happens, the 0.6V source voltage of the
Multimeter cannot bridge the hairline crack, and the resistance appears as an open circuit. During igniter
operation, it is normal for hairline cracks to develop. A long as the trigger voltage from the exciter is within
specification; these cracks can be bridged and healed over. (That is, an electrode that has lost contact with
the semiconductor material will, after further operation, make contact again). As igniters age, the
resistance of the semiconductor material can increase by a factor of 25. Measuring current from the
Multimeter is similarly decreased while the current from the Megohmmeter remains nearly constant. For
worn semiconductors, the Multimeter can read 10 to 20 times higher than the Megohmmeter. The high
source voltage, 1000V, and the constant current make the Megohmmeter a better choice for measuring
semiconductor igniter resistance.
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Drawings
Internal Exciter, P/N 07000102D­1, Standard Base­plate for Safe Area Enclosure
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Exciter with NEMA4 Enclosure, PN 07000102D
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Internal Exciter, P/N 07600102D­1, Standard Base­plate for Hazardous Area Enclosure
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Exciter with EExD Enclosure, PN 07600102D
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Diagnostic Module Quick Connection Table
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Diagnostic Module, P/N 07002038
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MAXON Series 8000
Pneumatic Shut-off Valves
Technical Catalog
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
TABLE OF CONTENTS
Product overview ..................................................................................................................................
1
Features & benefits ..................................................................................................................................
Body styles ..............................................................................................................
Valve body material and trim selections ..................................................................
Fire safe valves ........................................................................................................
Valve cycle requirements .........................................................................................
1
2
2
2
3
Agency approvals and certifications ..................................................................................................................................
4
Valve model number description ..................................................................................................................................
Options and accessories .........................................................................................
5
6
Valve body assembly options & specifications .....................................................................................................................
7
Valve body assembly specifications ..................................................................................................................................
9
Valve body assembly - gas compatibility ............................................................................................................................... 10
Valve actuator assembly specifications ................................................................................................................................. 11
Electrical data .................................................................................................................................. 12
General Purpose - Series 8011, 8111, 8021 & 8121 ............................................... 13
Non-incendive Valves - Series 8012, 8112, 8022 & 8122 ....................................... 13
Dimensions & weights ..................................................................................................................................
Series 8100 valve bodies: .75” (DN20) to 3” (DN80) ...............................................
Series 8100 actuator: .75” (DN20) to 3” (DN80) ......................................................
Series 8000 valve body: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100) ...............
Series 8000 actuator: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100) ...................
Series 8100 valve body: 2.5” CP, 3” CP, 4” CP ........................................................
Series 8100 actuator: 2.5” CP, 3” CP, 4” CP ............................................................
Series 8000 and 8100: 6” and 8” .............................................................................
17
17
18
19
20
21
22
23
Accessories .................................................................................................................................. 24
Installation, operation and maintenance instructions .......................................................................................................... 27
Component identification ......................................................................................... 29
Installation ............................................................................................................... 30
Electrical data .................................................................................................................................. 36
Normally-Closed Shut-Off Valves ............................................................................ 36
Normally-Open Vent Valves ..................................................................................... 38
Operating instructions .................................................................................................................................. 40
Maintenance instructions ..................................................................................................................................
Solenoid replacement procedure .............................................................................
Actuator assembly rotation/replacement .................................................................
Field installation of valve position switch .................................................................
43
44
47
48
IEC 61508 Instruction Requirements .................................................................................................................................. 50
FITTING CERTIFICATE .................................................................................................................................. 51
0
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
PRODUCT OVERVIEW
•
•
•
•
•
•
•
•
•
•
•
•
Pneumatically actuated valves with powerful closing spring for reliable operation
Compact design with integral solenoid, quick exhaust and position switches that protects components, simplifies piping and minimizes space requirements
Factory Mutual, CSA, CE, IECEx, INMETRO and KTL (KC mark) approved safety shut-off and vent valves
Hazardous Location approved: Intrinsically Safe and Non-Incendive constructions available
Full assessment to IEC 61508 as SIL 3 capable
Large top mounted 360-degree open-shut visual position indication, configurable in red/green or yellow/black color schemes
Cast iron, carbon steel, low temperature carbon steel and stainless steel body assemblies with internal trim options to handle
general purpose or corrosive gases; oxygen compatibility, NACE compliance, and fire safe conformance to API 6FA
Ambient temperature ranges of -58°F (-50°C) to 140°F (60°C); Gas temperature range of -58°F (-50°C) to 212°F (100°C)
Actuator assemblies are field-replaceable and available in 120VAC 50/60 Hz, 240VAC 50/60 Hz, and 24VDC (with low power
option), rated for NEMA 4, NEMA 4X and IP65
Unique bonnet design eliminates packing adjustments, reducing maintenance and minimizing drag on closing
Series 8000 Valves meet Fluid Control Institute (FCI) 70-2 control valve standard for Class VI seat leakage
Option available to utilize customer-supplied, externally mounted solenoids. When used in hazardous locations, the component must
be rated for the Class and Division of the hazardous area.
FEATURES & BENEFITS
MAXON Series 8000 Pneumatic Safety Shut-off
Valves combine a unique space-saving design with a
maintenance-free bonnet seal and a replaceable
actuator for easy installation and smooth, trouble-free
operation.
The valve's quick exhaust and powerful closing
spring provide valve closure in less than one second
and reliable, long-life operation.
Series 8000 Valve's compact design simplifies piping
design and minimizes space requirements.
The field-replaceable actuator provides easier
maintenance and reduced downtime. The actuator can
also be rotated around the valve body in 90° increments
to fit your specific application requirements.
A unique bonnet design eliminates packing
adjustments for reduced maintenance and minimized
drag on closing.
The large top-mounted open-shut indicator is visible
from all angles for easy proof of valve position. SIL 3
capable design provides easy design for safety
instrumented systems in the IEC 61508 and 61511
process. FM, CSA and CE approvals for use as a fuel
safety shut-off valve making easy integration with
worldwide certifications.
MAXON offers MAXON PSCheck partial stroke test
technology designed especially for Series 8000 valves,
to minimize probability of failure on demand by testing
valve function without line shutdown. The combination of
MAXON PSCheck and SIL 3 capable Series 8000
valves will help ensure safe, reliable operation of your
process.
32M-05003E
1
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Body styles
Normally-closed shut-off valves use instrument air to open quickly. Removal of electrical signal
allows release of control air through solenoid and quick exhaust valve allowing the powerful
closing spring in the Series 8000 Valve to close the valve in less than one second. Optional
speed control set available for slower opening adjustment.
Series 8011, 8012 & 8013
require 40-100 psig instrument air
Series 8111, 8112 & 8113
require 65-100 psig instrument air
Normally-open vent valves use instrument air to close quickly. Removal of electrical signal
allows release of control air through solenoid and quick exhaust valve allowing the Series 8000
Valve to open in less than one second. Optional speed control set available for slower closing
adjustment.
Series 8021, 8022 & 8023
require 45-100 psig instrument air
Series 8121, 8122 & 8123
require 70-100 psig instrument air
Valve body material and trim selections
Cast iron, carbon steel and stainless steel body assemblies feature metal-to-metal seating that meets the FCI 70-2 control valve standard
for Class VI seat leakage. Various trim options are available depending on the fuel gas used in your application. Industrial strength trim
options are available with a stainless steel seat and disc and PEEK follower for corrosive fuels that may contain traces of H2S and/or CO2
which meet NACE MR0175 requirements. Contact MAXON with your specific application details.
Valve bodies are available in your choice of threaded, flanged, and socket-welded connections. Bodies are currently available in 3/4”
(DN20) through 8” (DIN200) sizes. MAXON valve bodies are designed in accordance with many ASME/ANSI piping and valve standards.
While no one ASME/ANSI specification covers our valve in its entirety, our valve pipe connections comply with the applicable standard(s)
listed below.
•
•
•
•
•
•
•
NPT threaded connections (end connections, test connections)
Cast iron valve flanged ends (125# Class end connections)
Cast iron valve threaded connections (end connections)
Steel & stainless steel valve flanged ends (Class 150# ends)
Face-to-face and end-to-end dimensions
Flanged facings
Valve body wall thickness
ASME/ANSI B.1.20.2
ASME/ANSI B.16.1
ASME/ANSI B.16.4
ASME/ANSI B.16.5
ASME/ANSI B.16.10
MSS SP-6
ASME/ANSI B16.34
Fire safe valves
Fire safe valves are offered with carbon steel and stainless steel body and
bonnet materials. Fire safe trim options feature a stainless steel seat, disc
and follower, preserving the high quality MAXON metal-to-metal seating
and providing tight shut-off according to FCI 70-2 seat leakage
requirements. A fire safe trim option is also available for those applications
which necessitate NACE MR0175 compliance. All fire safe trims include
graphite packing which provides a redundant seal to prevent leakage in
case of a fire. The graphite packing used in fire safe trims is maintenancefree and requires no adjustment, allowing for the long life and reliability
inherent to MAXON valves. MAXON fire safe design is validated against
API 6FA requirements.
2
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
2
1)
2)
3)
4)
5)
6)
O-rings
Retaining ring
Packing washer
Graphoil stem ring
Flat washer
Graphoil body-to-bonnet ring
3
1
4
5
6
Valve cycle requirements
This is based on the standards that MAXON valves are approved to and the corresponding minimum number of cycles to be completed
without failure as shown in the chart below.
CSA (CSA 6.5)
FM (FM 7400)
Automatic - Normally Closed
Series 8011, 8111, 8012, 8112, 8013, 8113
100,000
20,000
Vent Valves
Series 8021, 8121, 8022, 8122, 8023, 8123
No special
requirements
No special
requirements
32M-05003E
European (EN161)
<= 1” 200,000
<= 3” 100,000
<= 8” 50,000
No special
requirements
3
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
AGENCY APPROVALS AND CERTIFICATIONS
4
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
VALVE MODEL NUMBER DESCRIPTION
Every MAXON Series 8000 Valve can be accurately identified by the model number shown on the valve nameplate. The example below
shows a typical Series 8000 Valve model number, along with the available choices for each item represented in the model number. The
first five choices determine the valve’s configured item number. Valve body and actuator options are identified by the next nine characters
in the model number. Options and accessories are listed on the next page.
1
1
-
Visual
Indication
A
Instruction
Language
A
Enclosure
Rating
-
Switch
Option
1
Primary
Voltage
1
Internal Trim
Package
Area
Classification
81
Body
Material
Normal
Position
C
Body Seals
Pressure
Rating
300
Actuator
Body
Connection
Flow
Capacity
Valve Body
Valve
Size
Configured Item Number
B
1
A
1
1
Primary Voltage
Body Connection
A – 120VAC 50Hz
A – NPT
B – 120VAC 60Hz
B – ANSI Flanged (ISO 7005 PN 20)
D – 240VAC 50Hz
C – ISO 7-1 Threaded
E – 240VAC 60Hz
D – DIN PN 16 Flanged
G – 24VDC
E – Socket Welded Nipple
F – Socket Welded Nipple w/Class 150 H – 24VDC IS [1]
J – 24VDC IS-ATEX [1]
Flange (ISO 7005 PN 20)
G – Socket Welded Nipple w/Class 300 X – Special
Z – None (customer-supplied,
Flange (ISO 7005 PN 50)
H – EN1092-1 PN16 (ISO 7005-1 PN16) external mount)
* - Valve Body Only
J – ANSI Class 300 Flange (ISO 7005
PN 50)
Flow Capacity
Switch Option
* - Actuator Only
S – Standard
0 – None
C – CP Body Construction
1 – VOS1/VCS1 - V7
Body Seals
2 – VOS2/VCS2 - V7
A – Buna-N
Operating Pressure Rating
3 – VOS1/VCS1 - IP67
B – Viton
80 – Pneumatic Standard Pressure
4 – VOS2/VCS2 - IP67
C – Ethylene Propylene [2]
81 – Pneumatic High Pressure
X – Special
F – Omniflex
* - Valve Body Only
X – Special
Normal Position
* - Actuator Only
1 – Normally-Closed Shut-Off Valve
Enclosure Rating
2 – Normally-Open Vent Valve
A – NEMA 4, IP65
Body Material
B – NEMA 4X, IP65
1 – Cast Iron
Area Classification
X – Special
2 – Carbon Steel
1 – General Purpose
* - Valve Body Only
5 – Stainless Steel
2 – Non-incendive, Class I, II and III Division 2
3 – Intrinsically Safe, Class I, II and III Division 1 6 – Low Temp Carbon Steel
Instruction Language
X – Special
(and ATEX Zone 1/21 when ordered with the
0 – English
* - Actuator Only
ATEX IS solenoid) [1]
1 – French
4 – Valve Body Only
3 – German
Internal Trim Package
4 – Portuguese
1 – Trim Package 1
5 – Spanish
2 – Trim Package 2
3 – Trim Package 3 (NACE)
Visual Indication
4 – Trim Package 2, oxy clean [2]
1 – Red closed/green open
5 – Trim Package 3, oxy clean [2]
2 – Green closed/red open
6 – Trim 2 fire safe
3 – Black closed/yellow open
7 – Trim 3 fire safe
X – Special [2]
* - Actuator Only
Valve Size
075 – 3/4” (DN 20)
100 – 1” (DN 25)
125 – 1-1/4” (DN 32)
150 – 1-1/2” (DN 40)
200 – 2” (DN 50)
250 – 2-1/2” (DN 65)
300 – 3” (DN 80)
400 – 4” (DN 100)
600 – 6” (DN 150)
800 – 8” (DN 200)
[1] 122°F maximum ambient temperature limit
[2] 0°F minimum ambient temperature limit
32M-05003E
5
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Options and accessories
Casting Inspection
(NDE) 1
Casting Inspection
(NDE) 2
Weld Inspection
Specification
Weld Inspection
(NDE) 1
Weld Inspection
(NDE) 2
Pre-build
Material FAT
Final Verification
FAT
Redundant
Solenoid
Speed Control
Accessories
Casting Inspection
Specification
Inspections
Material Cert Required
Certifications [1]
N
1
1
1
1
1
0
N
N
1
2
Material Cert Required
N – No
Y – Yes
Casting Inspection Specification
0 – None
1 – Casting per ASME B31.1
2 – Casting per ASME B31.3
3 – Casting per ASME B16.34
4 – MSS-SP55
Casting Inspection (NDE) 1 [1]
0 – None
1 – Liquid Penetrant Inspection (PT)
2 – Magnetic Particle Inspection (MT)
4 – Positive Material Identification (PMI)
Casting Inspection (NDE) 2 [1]
0 – None
1 – Liquid Penetrant Inspection (PT)
2 – Magnetic Particle Inspection (MT)
4 – Positive Material Identification (PMI)
Weld Inspection Specification
0 – None
1 – Weld per ASME B31.1
2 – Weld per ASME B31.3
Weld Inspection (NDE) 1 [1]
0 – None
1 – Liquid Penetrant Inspection (PT)
2 – Magnetic Particle Inspection (MT)
Weld Inspection (NDE) 2 [1]
0 – None
1 – Liquid Penetrant Inspection (PT)
2 – Magnetic Particle Inspection (MT)
Redundant Solenoid [2]
0 – None
1 – External Redundant Solenoid
2 – External Redundant Manual
Reset Solenoid
Speed Control
0 – None
1 – Speed Control Valve, Steel
2 – Speed Control Valve, Stainless
Steel
Pre-build Material FAT
N – No
X – Special
Final Verification FAT
N – No
X – Special
[1] Material certifications provided for valve body, bonnet, pipe nipples (when applicable) and flanges (when applicable). Material certifications for other
components may be available by special request.
[2] Agency approvals and certifications apply to valve only and do not apply to optional external accessories, such as redundant solenoids.
6
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
VALVE BODY ASSEMBLY OPTIONS & SPECIFICATIONS
Series 8000 Normally-Closed Shut-Off Valves
Nominal
Pipe Size
Flow
Capacity
Actuator
Pressure Class
.75”
Std.
High Press.
Body Connections
Available
A, C
A, C, E, F, G
A, C
1”
1.25”
1.5”
Std.
Std.
Std.
High Press.
High Press.
High Press.
A, C, E, F, G
Std.
Std.
High Press.
High Press.
Std.
2.5”
CP
Std.
High Press.
Std.
3”
CP
1, 2, 3, 4, 5
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, 2, 3, 4, 5
A, C, E, F, G
A, B, C, D
B, D, H G
B, D, H, G
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1
1, Cast Iron
1, 2, 3, 4, 5
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
1
1, 2, 3, 4, 5
B, D, H, G
B, D, H, G
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
1, Cast Iron
Std.
2, 6 Carbon Steel
B, D, H
High Press.
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
2, 6 Carbon Steel
Std.
Std.
B, D, H, J
High Press.
Body Connections:
A - NPT
B - ANSI Flanged (ISO 7005 PN20)
C - ISO 7-1 Threaded
D - DIN PN16 Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/Class 150 Flange
(ISO 7005 PN20)
G - Socket Welded Nipple
w/Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
J - ANSI Class 300 Flange (ISO 7005 PN50)
5, Stainless Steel
Body Material:
1 - Cast Iron
2 - Carbon Steel
5 - Stainless Steel
6 - Low Temp Carbon
Steel
1, 2, 3, 4, 5
255
200
200
53
255
200
86
127
255
150
50
304
175
173
150
40
2, 3, 4, 5
423
135
2, 3, 4, 5, 6, 7
1, 2, 3, 4, 5
40
2, 3, 4, 5
1, 2, 3, 4, 5
490
135
2, 3, 4, 5, 6, 7
1, 2, 3, 4, 5
60
2, 3, 4, 5, 6, 7
1, 2, 3, 4, 5
1172
100
2, 3, 4, 5, 6, 7
2, 3, 4, 5, 6, 7
5, Stainless Steel
2, 6 Carbon Steel
45
2, 3, 4, 5, 6, 7
1, Cast Iron
5, Stainless Steel
8”
1, 2, 3, 4, 5
255
200
20
2, 3, 4, 5
A, C
B, D, H, G
Std.
2, 3, 4, 5, 6, 7
MOPD Rating
(psig)
200
19
1, 2, 3, 4, 5
A, B, C, D, H
High Press.
6”
2, 3, 4, 5, 6, 7
1, Cast Iron
1, Cast Iron
CP
2, 3, 4, 5, 6, 7
1, 2, 3, 4, 5
A, C, E, F, G
Cv
Rating
1, 2, 3, 4, 5
1, Cast Iron
Std.
4”
2, 3, 4, 5, 6, 7
1, Cast Iron
A, B, C, D, H
High Press.
1, Cast Iron
2, 6 Carbon Steel
A, C
A, B, C, D, H
High Press.
Trim Package
Options
A, C
A, B, C, D, H
2”
Body
Material
2, 3, 4, 5, 6, 7
60
1320
100
Trim Package Options and Typical Material:
1 - 400 Series Stainless Steel Seat, Hardened Ductile Iron Disc, PEEK Follower Ring
2 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, PEEK Follower
Ring
3 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, 300 Series Stainless Steel Stem, PEEK Follower Ring (NACE compliant)
4 - Oxy Clean, Trim 2
5 - Oxy Clean, Trim 3
6 - Trim 2 fire safe
7 - Trim 3 fire safe
Body Seals:
All configurations allow for Buna-N and Viton elastomers as standard. Omniflex and
Ethylene Propylene are available for special services. Consult MAXON for proper
application.
32M-05003E
7
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Nominal
Pipe Size
Flow
Capacity
.75”
Std.
Series 8000 Normally-Open Vent Valves
Actuator
Body
Body
Pressure
Connections
Material
Class
Available
A, C
High Press.
A, C, E, F, G
A, C
1”
Std.
High Press.
A, C, E, F, G
A, C
1.5”
Std.
High Press.
A, C, E, F, G
A, B, C, D, H
2”
Std.
High Press.
A, C, E, F, G
A, B, C, D
Std.
2.5”
CP
B, D, H
A, B, C, D, H
High Press.
B, D, H
A, B, C, D, H
Std.
3”
CP
B, D, H
A, B, C, D, H
High Press.
B, D, H
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
1, Cast Iron
Std.
4”
CP
2, 6 Carbon Steel
B, D, H
High Press.
5, Stainless Steel
1, Cast Iron
2, 6 Carbon Steel
5, Stainless Steel
Body Connections:
A - NPT
B - ANSI Flanged
(ISO 7005 PN20)
C - ISO 7-1 Threaded
D - DIN PN16 Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/
Class 150 Flange (ISO 7005
PN20)
G - Socket Welded Nipple w/
Class 300 Flange (ISO 7005
PN50)
H - EN1092-1 PN16 (ISO 7005-1
PN16)
8
Body Material:
1 - Cast Iron
2 - Carbon Steel
5 - Stainless Steel
6 - Low Temp Carbon Steel
www.maxoncorp.com
Trim
Package
Options
Cv
Rating
1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
200
19
1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
255
200
53
1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
255
200
20
1, 2, 3, 4, 5
2, 3, 4, 5, 6, 7
MOPD
Rating
(psig)
255
200
86
255
1, 2, 3, 4, 5
50
2, 3, 4, 5
1, 2, 3, 4, 5
304
175
2, 3, 4, 5, 6, 7
1, 2, 3, 4, 5
40
2, 3, 4, 5
1, 2, 3, 4, 5
423
135
2, 3, 4, 5, 6, 7
1, 2, 3, 4, 5
40
2, 3, 4, 5
1, 2, 3, 4, 5
490
2, 3, 4, 5, 6, 7
135
Trim Package Options and Typical Material:
1 - 400 Series Stainless Steel Seat, Hardened Ductile Iron Disc, PEEK Follower Ring
2 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, PEEK Follower Ring
3 - 300 Series Stainless Steel Seat, 300 Series Stainless Steel Disc, 300 Series Stainless Steel
Stem, PEEK Follower Ring (NACE compliant)
4 - Oxy Clean, Trim 2
5 - Oxy Clean, Trim 3
6 - Trim 2 fire safe
7 - Trim 3 fire safe
Body Seals:
All configurations allow for Buna-N and Viton elastomers as standard. Omniflex and
Ethylene Propylene are available for special services. Consult MAXON for proper
application.
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
VALVE BODY ASSEMBLY SPECIFICATIONS
10
11
13
12
19
A
16
3
17
15
5
18
2
DETAIL A
4
9
1
8
6
7
Body Seal Material
Item No.
Description
1
Seat O-Ring
2
Body O-Ring
3
Stem O-Ring
Material
Standard material options are Buna-N and Viton.
Omniflex and Ethylene Propylene are available for special service.
Consult MAXON for proper material selection.
Body and Bonnet Materials
Item No.
Description
4
Body
5
Bonnet
Material Code
1
2
5
6
Cast Iron
ASTM A126, Class B
Cast Steel
ASTM A216 Gr. WCB
Stainless Steel
ASTM A351 Gr. CF8M
Low Temp Carbon Steel
ASTM A352 Gr. LCB
Trim Package Materials
Item No.
Description
Internal Trim Package
1
Seat
Hardened 400 Series
Stainless Steel
7
Disc
Hardened Ductile Iron
8
Follower Ring
9
Wavy Spring
10
Stem
6
2
3
6
7
300 Series Stainless Steel
300 Series Stainless Steel
PEEK
300 Series Stainless Steel
300 Series Stainless Steel
300 Series
Stainless Steel
17-4 PH Stainless Steel
17-4 PH Stainless
Steel
300 Series
Stainless Steel
11
Spring Retainer
12
Compression Spring
Blackened Carbon Steel
17-7 PH Stainless Steel
13
Jam Nut
Zinc Plated Carbon Steel
14
Spring Pin (when req’d.)
15
Body Graphite Ring
---
---
---
Flexible Graphite
16
Packing Washer
---
---
---
300 Series Stainless Steel
17
Stem Graphite Ring
---
---
---
Flexible Graphite
18
Flat Washer
---
---
---
300 Series Stainless Steel
19
Retaining Ring
---
---
---
Zinc Plated Carbon Steel
Carbon Steel
32M-05003E
9
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
VALVE BODY ASSEMBLY - GAS COMPATIBILITY
Gas
Code
Gas
Air
Ammonia
Butane Gas
Coke Oven Gas
Delco
Digester [1]
Endothermic AGA
Exothermic Gas
Hydrogen Gas
Manufactured [1]
Natural Gas
Nitrogen
Oxygen High
Oxygen Low
Oxygen X
Propane
Refinery [1]
Sour Natural [1]
Town Gas [1]
Land Fill Gas
AIR
AMM
BUT
COKE
DEL
DIG
ENDO
EXO
HYD
MFGD
NAT
NIT
OXYH
OXYL
OXYX
PROP
REF
SOUR
TOWN
LAND
Suggested Material Options
MOPD
Rating
Body Seal
Body &
Bonnet
Trim
Package [5]
A, B, C, F
A, C, F
A, B, F
B, F
A, B, F
Analysis Required
A, B, F
A, B, F
A, B, C, F
Analysis Required
A, B, F
A, B, C, F
B, C, F
B, C, F
B, C, F
A, B, F
Analysis Required
Analysis Required
Analysis Required
Analysis Required
1, 2, 5, 6
1, 2, 5, 6
1, 2, 5, 6
5
1, 2, 5, 6
5
1, 2, 5, 6
1, 2, 5, 6
1, 2, 5, 6
5
1, 2, 5, 6
1, 2, 5, 6
2, 5, 6
1, 2, 5, 6
2, 5, 6
1, 2, 5, 6
5
5
5
5
1, 2, 3, 6, 7
1, 2, 3, 6 ,7
1, 2, 3, 6, 7
Analysis Required
1, 2, 3, 6, 7
Analysis Required
1, 2, 3, 6, 7
1, 2, 3, 6, 7
1, 2, 3, 6, 7
Analysis Required
1, 2, 3, 6, 7
1, 2, 3, 6, 7
4, 5
4, 5
4, 5
1, 2, 3, 6, 7
Analysis Required
Analysis Required
Analysis Required
Analysis Required
Std.
Std.
Std.
Std.
Std.
Std.
Std.
Std.
[2]
Std.
Std.
Std.
200 psig max
30 psig max
Std.
Std.
Std.
Std.
Std.
Std.
Agency Approvals and
Certifications
CE [4]
CSA
FM
[3] GAD MD
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
Notes:
[1] Other body and trim packages may be acceptable pending fuel analysis. For pricing inquiry, Viton body seals will be standard option. Contact MAXON for details.
[2] Valve maximum operating pressure (MOPD) to be reduced by 25% from standard ratings.
[3] ISO connections are not recognized by CSA standards.
[4] All 8000 Valves do meet the essential requirements of the Low Voltage (73/23/EC) and the EMC (89/336/EC) Directives. GAD refers to the Gas Appliances Directive (2009/142/EC): this Directive only covers the use of commercially available fuels (natural gas, butane, town gas and LPG). MD stands for Machinery Directive
(2006/42/EC). All Series 8000 valves meet the essential requirements for fuel shut-off on Industrial Thermal Equipment as specified in EN746-2.
[5] Trim Package 1 is only allowed with body and bonnet 1.
Body Seals:
A - Buna-N
B - Viton
C - Ethylene Propylene
F - Omniflex
10
www.maxoncorp.com
Body & Bonnet:
1 - Cast Iron
2 - Carbon Steel
5 - Stainless Steel
6 - Low Temp Carbon Steel
32M-05003E
Trim Package:
1 - Trim Package 1
2 - Trim Package 2
3 - Trim Package 3 (NACE)
4 - Trim Package 2, Oxy Clean
5 - Trim Package 3, Oxy Clean
6 - Trim 2 fire safe
7 - Trim 3 fire safe
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
VALVE ACTUATOR ASSEMBLY SPECIFICATIONS
50
28
51
34
13
22
29
16
15
3
27
26
25
20
35
19
21 23
30
20
17 18
View Without Top Plate
12
24
7
14
36
46A
46
48A
48
5
9
45
5
8
32
31
49
34
7
10
47 47A
36
11
36B
29 6
42
29 6
36A
43
12
12
4
1
44
1
2
Typical Actuator Assembly
Item Number
Description
38
Typical Cylinder Assembly Mounting
39
37
General Purpose Switch Assembly
Item No.
29
41
40
4
Description
1
Base Plate
M6-1.0 x 20 Cap Screw
2
Bonnet Gasket
30
3/4” Pipe Plug
3
Drive Pin
31
.125 Inlet Pipe Plug
4
Filter Vent
32
Info Plate
5
Cylinder Assembly
33
Actuator Bolts (not shown)
6
M6 Lock Washer
34
Switch Assembly
7
M5-0.8 x 40 Hex Screw
35
Liquid Tight Connector
8
O-Ring
36
Solenoid w/Quick Exhaust Assembly
9
O-Ring
36A
Solenoid Coil
10
Solenoid Adapter Inlet
36B
Solenoid Cap
11
Housing
37
Switch & Terminal Bracket
12
Housing Gasket
38
DIN Rail
13
M6-1.0 x 60 Soc HD Cap Screw
39
End Stop
14
O-Ring
40
Terminal Block
15
Top Plate
41
End Cover
16
Switch Indicator
42
Marker Strips
17
Washer
43
M4-0.7 x 6 Slotted Screw
18
M5-0.8 x 10 Ground Screw
44
Switch Bracket
19
Top Housing
45
Switch Insulator
20
M4-0.7 x 6 Slotted Screw
46
V7 Switch
21
Terminal Block Cover Gasket
46A
IP67 Switch
22
Info Label
47
#4-40 x .75 Slotted Screw
23
Terminal Block Cover
47A
#2-56 x .437 Slotted Screw
24
M5-0.8 x 12 Cap Screw
48
#4-40 Hex Nut
25
Top Housing Gasket
48A
#2-56 Hex Nut
26
External Retaining Ring
49
Wire
27
O-Ring
50
Visual Indicator
28
Indicator Cover
51
Spring
32M-05003E
11
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
ELECTRICAL DATA
GENERAL
Series 8000 Valves are pneumatically operated and a solenoid valve controls the air supply. The solenoid valve is directly wired into the
control system.
Position switch wiring diagrams (reproduced below) are part of each valve assembly, summarizing electrical data and wiring for a
valve equipped with terminal block and a full complement of optional switches.
Good practice normally dictates that auxiliary switches in valves should be used for signal duty only, not to operate additional safety
devices.
Valve position switches are offered in SPDT (Single Pole/Double Throw). Recommended packages include one open switch and one
closed switch (VOS1/VCS1) and additional auxiliary switches designated by VOS2/VCS2.
VCS (Valve Closed Switch) is actuated at the end of the closing stroke.
VOS (Valve Open Switch) is actuated at the end of the opening stroke.
Switch amperage ratings are shown on the schematic wiring diagrams below. DO NOT EXCEED rated amperage or total load shown.
Diagrams show valve with a full complement of switches. The indicated internal wiring is present only when the appropriate auxiliary
switches are specified.
Figure 1: Normally-Closed Shut-Off Valve
VOS-1
1
2
L
3
4
VCS-1
5
6
7
VOS-2
8
9
10
VCS-2
11
12
13
14
N
VOS-1
3-5
3-4
V7
VOS-2
VCS-1
6-7
6-8
9-10
9-11
VCS-2
12-13
12-14
IP67
24VDC
0.5 Amps
24VDC
2.0 Amps
120VAC
11 Amps
120VAC
2.0 Amps
240VAC
11 Amps
240VAC
2.0 Amps
Figure 2: Normally-Open Vent Valve
VCS-1
1
L
2
3
4
VOS-1
5
6
7
VCS-2
8
9
10
VCS-1
V7
IP67
24VDC
0.5 Amps
24VDC
2.0 Amps
120VAC
11 Amps
120VAC
2.0 Amps
240VAC
11 Amps
240VAC
2.0 Amps
www.maxoncorp.com
11
12
13
14
N
3-4
12
VOS-2
32M-05003E
3-5
VOS-1
6-7
6-8
VCS-2
9-10
9-11
VOS-2
12-13
12-14
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
General Purpose - Series 8011, 8111, 8021 & 8121
Voltage
24VDC
120VAC 50 Hz
120VAC 60 Hz
240VAC 50 Hz
240VAC 60 Hz
Solenoid valve power ratings
Amperage (A)
In-Rush
Holding
0.20
0.20
0.09
0.07
0.08
0.05
0.05
0.04
0.04
0.03
Power
In-Rush
4.8 W
11 VA
9.4 VA
11 VA
9.4 VA
Holding
4.8 W
8.5 VA
6.9 VA
8.5 VA
6.9 VA
Standard switch amperage ratings
as shown on the valve switch wiring diagram
Voltage
24VDC
120VAC 50/60 Hz
240VAC 50/60 Hz
Maximum Amperage (A)
0.5
11
11
Non-incendive Valves - Series 8012, 8112, 8022 & 8122
Voltage
24VDC
120VAC 50 Hz
120VAC 60 Hz
240VAC 50 Hz
240VAC 60 Hz
24VDC IS
Solenoid valve power ratings
Amperage (A)
In-Rush
Holding
0.20
0.20
0.09
0.07
0.08
0.05
0.05
0.04
0.04
0.03
0.09
0.09
Power
In-Rush
4.8 W
11 VA
9.4 VA
11 VA
9.4 VA
2.1 W
Holding
4.8 W
8.5 VA
6.9 VA
8.5 VA
6.9 VA
2.1 W
IP67 switch amperage ratings
as shown on the valve switch wiring diagram
Voltage
24VDC
120VAC 50/60 Hz
240VAC 50/60 Hz
Maximum Amperage (A)
2.0
2.0
2.0
32M-05003E
13
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
INTRINSICALLY SAFE VALVES - SERIES 8013, 8023, 8113 & 8123
The Series 8000 Valve achieves Class I Div.1 hazardous location certification through the Intrinsically Safe (IS) protection method. Below
is a representation of the Control Drawing. The MAXON standard offering does not include the barriers/isolators that are depicted below
in the non-hazardous location; however, they can be provided as an additional accessory. Consult MAXON for details.
The intrinsic safety and operational criteria for most applications can be met with a 24 VDC supply and the barriers described in the
Control Drawing. Specific installations with long cable runs, low power requirements, or other complications may require a barrier with
different parameters.
HAZARDOUS (CLASSIFIED) LOCATION
CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
CLASS III, DIVISION 1
NON-HAZARDOUS LOCATION
Factory Mutual/CSA Approved
Barrier(s) used in an Approved Configuraton
with “V” max. greater than “VI” or
“Voc” and “I” max. greater than “I t” or “I sc”
Power
Supply
Solenoid
Valve
250 RMS max.
Solenoid Entity Parameters
V max. = 28 VDC
I max. = 115 mA
Pi = 1.6 W
Ci = O µF
Li = O µH
CSA/FM/ATEX certified Barrier
rated 28 V max. / 300 Ohms
min. or equivalent
Valve
Position
Switch
Switch Entity Parameters
V max. = 30 VDC
I max. = 500 mA
Pi = 2 W
Ci= O µF
Li = O µH
“CSA/FM/ATEX certified Barrier
for a simple apparatus”
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two FM approved (CSA Certified when installed in Canada) Intrinsically Safe
devices with entity parameters not specifically examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II and Class III environments.
3) Control equipment connected to the Associated Apparatus must not use or generate more than 250 Vrms or Vdc.
4) Installation in the U.S. should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations” and the National Electric Code® (ANSI/NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved (CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Approval and CSA International.
14
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
CONTROL DRAWING FOR CUSTOMER-SUPPLIED, EXTERNALLY MOUNTED SOLENOIDS
NON-HAZARDOUS LOCATION
HAZARDOUS (CLASSIFIED) LOCATION
CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
CLASS III, DIVISION 1
Factory Mutual/CSA Approved
Barrier(s) used in an Approved configuration with "V" max. greater than "Vt"
or "Voc" and "I" max. greater than "I t" or "I sc"
Power
supply
Solenoid
Valve
see note 3
Customer Supplied Solenoid Valve
-To be mounted external to valve actuator.
-Component must be rated for the Class
and Division of the hazardous environment
as stated above.
-Component must be rated for instrinsic
safety and be interconnected with other
intrinsically safe devices as required under
the Intrinsic Safety Entity Concept (see note 1).
Valve
Position
Switch
Switch Entity Parameters
V max.=30 VDC
I max.=500 mA
Pi= 2 W
Ci= O µF
Li= O µH
"CSA/FM/ATEX certified Barrier
for a simple apparatus"
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two FM approved (CSA Certified when installed in Canada) Intrinsically Safe
devices with entity parameters not specifically examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II and Class III environments.
3) Control equipment connected to the Associated Apparatus must not use or generate more than the maximum permissible safe area voltage
(Um) for the barrier.
4) Installation in the U.S. should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations” and the National Electric Code® (ANSI/NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved (CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Approval and CSA International.
32M-05003E
15
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
To select a different safety barrier, choose a design that limits voltage, current, and power under worst-case fault conditions to values less
than the IS entity parameters, while still meeting the minimum operational requirements under worst-case non-fault conditions. The IS
entity parameters and operational requirements are listed in the following tables.
The barrier will specify a maximum voltage peak Voc 1, a maximum short-circuit current, Isc 2 and maximum power output Po 3. These
barrier ratings must be less than or equal to the IS entity parameters of the field device, i.e., Voc  Vmax, Isc  Imax, and Po  Pi.The
barrier will also specify a maximum allowed capacitance Ca and inductance La, which must be greater than or equal to the sum of those
of the load device and field wiring, i.e., Ca  Ci + Ccable and La  Li + Lcable.
The solenoid requires a minimum current (Imin) to operate properly. The nominal barrier input voltage (Vworking, as specified by the
barrier) must be adequate to provide Imin through the maximum barrier resistance, the maximum wiring resistance, the resistance of any
fuses, and the maximum solenoid resistance (Ri).
NOTE: Vworking will always be less than Vmax or Voc. Never intentionally supply Voc to the barrier, as this
could blow an internal fuse and ruin the barrier.
[1] The maximum voltage possible at the barrier input or output under a no-load condition.
[2] Found when the barrier input is at Voc and a short-circuit appears on the barrier output.
[3] Found when the barrier input is at Voc and a matched load appears on the barrier output. Note that this value is the transmitted power, and does not
include the power dissipated by the barrier itself.
BARRIER SELECTION CRITERIA FOR SOLENOID
IS entity parameters 4
Maximum voltage input (Vmax)
28 V 5
Maximum current input (Imax)
115 mA
Maximum power input (Pi)
1.6 W
Internal capacitance (Ci)
0 μF
Internal inductance (Li)
0 μH
Operational Parameters
Minimum operational current (Imin)
37 mA
Solenoid internal resistance (Ri)
275 ohms ± 8%
BARRIER SELECTION CRITERIA FOR SWITCH
IS entity parameters (simple apparatus)
Maximum voltage input (Vmax)
30 V 6
Maximum current input (Imax)
500 mA 6
Maximum power input (Pi)
1.3 W 7
Internal capacitance (Ci)
0 μF
Internal inductance (Li)
0 μH
Operational Parameters
Minimum operational current (Imin)
Application specific
Switch internal on-resistance (Ri)
< 1 ohm
[4] Obtained from the manufacturer’s published entity parameters.
[5] Never intentionally supply Vmax to the barrier, as this could blow an internal fuse and ruin the barrier.
[6] Obtained from the switch’s safety ratings.
[7] Standard Pi for a simple apparatus.
16
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
DIMENSIONS & WEIGHTS
Series 8100 valve bodies: .75” (DN20) to 3” (DN80)
Body Connection A & C
Body Connection B, D & H
1
1
N
P
H
H
R
S
K
K
L
L
1) 2x 1/4” NPT test
connection
Body Connection E
Body Connection F & G
1
1
N
P
H
H
K
R
S
K
L
L
Valve
Flow
Body
Size Capacity Connection
A, C
Body/
Bonnet
Material
H
Cast Iron
A, C
.75”
S
E
F
Carbon Steel
& Stainless
Steel
G
A, C
Cast Iron
2.0
S
E
F
Carbon Steel
& Stainless
Steel
G
1.25”
S
A, C
Cast Iron
A, C
Cast Iron
1.9
3.8
N/A
8
20
3.8
N/A
9
21
6.9
13.8
23
14.5
N/A
11
3.88
2.75
0.62
15
27
4.62
3.25
0.75
17
29
S
E
F
Carbon Steel
& Stainless
Steel
1.9
3.8
N/A
8
20
3.8
N/A
9
21
6.9
13.8
23
N/A
11
4.3
3.1
0.62
15
27
4.9
3.5
0.75
17
29
7.3
14.5
N/A
9
21
2.0
4.0
N/A
11
23
N/A
11
6.8
13.6
N/A
14
7.2
14.4
2.2
4.4
2.4
2.7
G
A, C
B
Cast Iron
D, H
2”
S
A, C
E
F
3.3
Carbon Steel
& Stainless
Steel
A, C
2.5”
S
B
Cast Iron
D
3”
S
Flow Capacity:
S - Standard
C - CP Body Construction
A, C
Cast Iron
3.5
7.0
2.2
4.4
6.9
13.8
7.3
14.5
2.9
2.5
5.0
3.1
3.8
7.5
3.0
2.6
5.2
G
4
1.9
A, C
1.5”
Approximate Weight (lbs)
Body
Actuator
Total Weight
Assembly Assembly
1.9
7.3
A, C
1”
Approximate Dimensions (inches)
N
P
R
S
K
L
Ø
Ø
Ø
# of holes
5.0
3.9
0.62
6.1
4.5
0.88
6.0
4.8
6.5
4.9
0.71
4
23
12
26
21
33
26
38
N/A
16
28
0.75
26
38
4
4
N/A
N/A
26
38
18
30
23
35
6.0
4.8
0.75
4
33
45
6.5
5.0
0.75
8
37
49
19
31
N/A
7.0
5.5
0.75
7.3
5.7
0.71
N/A
Body Connection:
A - NPT
B - ANSI Flanged (ISO 7005 PN20)
C - ISO 7-1 Threaded
4
30
42
30
42
20
32
D - DIN PN16 Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/ Class150 Flange (ISO 7005 PN20)
G - Socket Welded Nipple w/ Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
32M-05003E
17
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Series 8100 actuator: .75” (DN20) to 3” (DN80)
A
B
H
H
2
4
C
1
1) 1/8” NPT air inlet connection
2) Visual indication of valve
position
3) Air exhaust - do not block
4) 2x 3/4” conduit connection
5) 2x 1/4” NPT test connection
G
F
E
3
5
D
Valve Size
.75”
1”
1.25”
1.5”
2”
2.5”
3”
18
A
B
C
Approximate dimensions (inches)
D
E
F
7
3.5
2.8
12
2.6
8
9
www.maxoncorp.com
32M-05003E
G
H
15
4
16
17
2.5
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Series 8000 valve body: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100)
Body Connection A & C
Body Connection B, D & H
1
1
N
P
H
H
R
S
K
K
L
L
1) 2x 1/4” NPT
test connection
Body Connection E
Body Connection F & G
1
1
N
P
H
H
K
R
S
K
L
L
Approximate Dimensions (inches)
Valve
Size
Flow
Body
Body/Bonnet
Capacity Connection
Material
A, C
B
D
2.5”
C
D
H
C
G
3”
C
C
CS & SS
D, H
G
CS & SS
B
4”
C
C
Flow Capacity:
S - Standard
C - CP Body Construction
B
2.5
5.0
3.8
7.5
4.4
6.1
12.3
5.1
2.8
5.5
5.2
4.0
8.0
5.2
6.6
13.3
D, H
G
CS & SS
5.5
5.1
4.5
7.4
P
Ø
R
Ø
7.0
5.5
0.75
7.3
5.7
0.75
7.3
5.7
0.75
7.0
5.5
0.75
7.3
5.7
0.71
4
8
4
9.0
15.3
Body
Actuator
Assembly Assembly
Total
Weight
19
32
31
44
31
44
31
44
34
47
34
47
7.3
5.7
0.71
8
30
43
7.5
5.9
0.88
8
39
51
7.5
6.0
0.75
4
46
7.9
6.3
0.75
8
46
59
7.5
6.0
0.75
4
47
60
N/A
Cast Iron
Carbon Steel &
Stainless Steel
N
Ø
N/A
Cast Iron
Carbon Steel &
Stainless Steel
D, H
4.3
Carbon Steel &
Stainless Steel
D, H
B
L
4.5
A, C
B
K
Cast Iron
H
B
H
Approximate Weight (lbs)
S
# of
holes
24
37
13
59
7.9
6.3
0.71
8
47
60
8.3
6.6
0.88
8
56
68
9.0
7.5
0.75
64
77
8.7
7.1
0.75
64
77
9.0
7.5
0.75
64
77
8.7
7.1
0.71
10
7.9
0.88
8
8
64
77
83
96
Body Connection
A - NPT
B - ANSI Flanged (ISO 7005 PN20)
C - ISO 7-1 Threaded
D - DIN PN16 Flanged
E - Socket Welded Nipple
F - Socket Welded Nipple w/ Class 150 Flange (ISO 7005 PN20)
G - Socket Welded Nipple w/ Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
32M-05003E
19
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Series 8000 actuator: 2.5” CP (DN65), 3” CP (DN80), 4” CP (DN100)
A
H
B
H
2
4
C
1
1) 1/8” NPT air inlet connection
2) Visual indication of valve
position
3) Air exhaust - do not block
4) 2x 3/4“ conduit connection
5) 2x 1/4” NPT test connection
G
F
E
3
5
D
20
Valve Size
Flow
Capacity
2.5”
3”
4”
CP
CP
CP
www.maxoncorp.com
A
B
3.5
2.8
Approximate Dimensions (inches)
C
D
E
F
11.1
14.8
2.6
5.3
11.8
32M-05003E
G
20.6
21.3
H
2.5
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Series 8100 valve body: 2.5” CP, 3” CP, 4” CP
Body Connection A & C
Body Connection B, D & H
1
1
N
P
H
H
R
S
K
K
L
L
1) 2x 1/4” NPT
test connection
Body Connection E
Body Connection F & G
1
1
N
P
H
H
K
R
S
K
L
L
Approximate Weight
(lbs)
Approximate Dimensions (inches)
Valve
Flow
Body
Size Capacity Connection
Body/Bonnet
Material
A, C
B
D
2.5”
C
D
H
C
G
3”
C
C
CS & SS
D, H
G
CS & SS
4”
C
C
Flow Capacity:
S - Standard
C - CP Body Construction
D, H
B
2.5
5.0
3.8
7.5
4.4
6.1
12.3
5.1
2.8
5.5
Cast Iron
Carbon Steel &
Stainless Steel
B
4.3
Carbon Steel &
Stainless Steel
D, H
B
L
4.5
A, C
B
K
Cast Iron
H
B
H
5.2
4.0
8.0
5.2
6.6
13.3
Cast Iron
D, H
Carbon Steel &
Stainless Steel
G
CS & SS
5.5
5.1
4.5
7.4
9.0
15.3
N
Ø
P
Ø
R
Ø
7.0
5.5
0.75
7.3
5.7
0.75
7.3
5.7
0.75
7.0
5.5
0.75
7.3
5.7
0.71
7.3
5.7
0.71
7.5
5.9
0.88
S
# of
holes
N/A
4
8
Body
Actuator Total
Assembly Assembly Weight
19
32
31
44
31
44
31
44
34
47
34
47
8
34
47
8
39
51
4
N/A
27
7.5
6.0
0.75
4
48
40
13
61
7.9
6.3
0.75
8
48
61
7.5
6.0
0.75
4
49
62
7.9
6.3
0.71
8
49
62
8.3
6.6
0.88
8
56
68
9.0
7.5
0.75
66
79
8.7
7.1
0.75
66
79
9.0
7.5
0.75
67
80
8.7
7.1
0.71
10
7.9
0.88
8
8
67
80
83
96
Body Connection:
A - NPT
B - ANSI Flanged (ISO 7005 PN20)
C - ISO 7-1 Threaded
D - DIN PN16 Flanged
E - Socket Welded Nipples
F - Socket Welded Nipples w/ Class 150 Flange (ISO 7005 PN20)
G - Socket Welded Nipples w/ Class 300 Flange (ISO 7005 PN50)
H - EN1092-1 PN16 (ISO 7005-1 PN16)
32M-05003E
21
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Series 8100 actuator: 2.5” CP, 3” CP, 4” CP
A
H
B
H
2
4
1
C
1) 1/8” NPT air inlet connection
2) Visual indication of valve
position
3) Air exhaust - do not block
4) 2x 3/4” conduit connection
5) 2x 1/4” NPT test connection
G
F
E
3
5
D
22
Valve Size
Flow
Capacity
2.5”
3”
4”
CP
CP
CP
www.maxoncorp.com
A
B
4.5
3.3
Approximate Dimensions (inches)
D
E
F
12.2
16.3
3.6
6.4
12.9
C
32M-05003E
G
22.1
22.8
H
3.0
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Series 8000 and 8100: 6” and 8”
A
C
E
B
E
2
4
1
1) 1/8” NPT air inlet connection
2) Visual indication of valve
position
3) 1/8” NPT air exhaust - do
not block
4) 2x 3/4” conduit connection
5) 2x 1/4” NPT test connection
D
J
3
M
N
INLET
OUTLET
5
P
H
R
S
K
L
Approximate Dimensions (inches)
Valve
Flow
Body
Size Capacity Conn.
B
6”
S
D, H
B
D
B
8”
S
D, H
J
Flow Capacity:
S - Standard
Body/Bonnet
Material
A
B
C
D
E
H
J
K
L
M
Cast Iron
Carbon Steel &
Stainless Steel
Carbon Steel &
Stainless Steel
4.6
4.6
3.3
3.3
3.6
3.6
6.5
6.5
3.0
3.0
8.6 33.1 5.25 10.5 21.8
8.6 33.1
5.75 11.5
5.75 11.5
Approximate Weight (lbs)
N
Ø
P
Ø
R
Ø
S
Body
Actuator
#of
Assembly Assembly
holes
Total
Weight
11.0
9.5
0.88
117
140
11.2
9.5
0.86
117
140
11.0
9.5
0.88
11.2
9.5
0.86
8
8
21.8 13.38 11.61 0.86
12
13.0
1.0
23
126
13.5 11.75 0.88
15.0
126
12
170
217
149
149
23
193
240
Body Connection:
B - ANSI 150 lbs (ISO7005 - PN20)
D - DIN PN16 Flanged
H - EN1092-1 PN16 (ISO 7005-1 PN16)
J - ANSI Class 300 Flange (ISO 7005 PN50)
32M-05003E
23
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
ACCESSORIES
SPEED CONTROL SET
Manually adjustable valve restricts flow to the actuator inlet and so reduces opening speed of the normallyclosed shut-off valve or reduces the closing speed of normally-open vent valves.
• Available in carbon steel and stainless steel construction
• 90° mating elbow provided for easy assembly
• Tamper-proof set screw prevents accidental misadjustment
Carbon Steel construction
Stainless Steel construction
A
B
1) Speed control adjustment
knob
C
D
1
E
Speed Control Set
Carbon Steel
Stainless Steel
24
www.maxoncorp.com
A
5.6
6.2
B
4.2
4.6
C
1.3
1.7
32M-05003E
D
2.6
2.8
E
1.0
1.0
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
EXTERNAL REDUNDANT SOLENOID WITH MANUAL RESET
Combination of both external redundant solenoids and manual reset option. If either solenoid trips, the valve will close and cannot be
reset until it is done manually at the site of the valve before operations can resume.
1) Manual reset latching
pin
2) Manual reset button
3) 1/8” NPT exhaust filter
(do not block)
4) Speed control
(optional)
5) Speed adjustment lock
screw
6) Speed control adjustment knob
7) 1/8” NPT air inlet connection
A
7.5
A
E
D
C
F
7
1
6
5
2
B
4
3
B
2.7
C
4.9
D
3.6
E
2.1
F
5.3
EXTERNAL REDUNDANT SOLENOID
Dual shut-off solenoids provide additional SIL 2 certification levels to offer a higher level of protection against potential solenoid failure.
The double redundant solenoid valve will automatically trip as a series shut-down mode and will close or open the valve (depending on
set-up) if either of the solenoid valves trip.
General Purpose
Intrinsically Safe
A
B
A
B
D
D
E
E
F
F
C
Solenoid type
General Purpose
Intrinsically Safe
A
7.2
7.2
B
5.2
5.1
32M-05003E
C
--5.9
D
1.0
1.0
E
2.2
3.8
F
1.0
0.4
25
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
EXTERNAL REDUNDANT SOLENOID WITH SPEED CONTROL SET
Combination of both external redundant solenoids and speed control set option. If either solenoid trips, the valve will close and cannot be
reset until it is done manually. Speed control set features manually adjustable valve that restricts flow to the actuator inlet and so reduces
opening speed of the normally-closed shut-off valve or reduces the closing speed of normally-open vent valves.
General Purpose
Intrinsically Safe
G
E
A
A
E
G
B
D
C
D
F
Solenoid type / speed control set type
General Purpose / carbon steel
General Purpose / stainless steel
Intrinsically Safe / stainless steel
C
H
A
5.2
5.2
5.1
B
2.2
2.2
---
C
2.7
2.8
2.8
D
1.1
1.1
1.7
E
1.0
1.0
1.0
F
0.5
0.5
---
G
8.7
8.9
8.9
H
5.2
5.2
---
INTRINSIC SAFETY INTERFACES
Approved units interposed between the hazardous and safe area circuits limit parameters such as voltage, current or power.
• Suitable for use in Class I, Div. 2 areas
• DIN rail mounted
• Complements intrinsically safe Series 8000 Valves
Manufacturer
MTL
Engineering recommendations for barriers and isolator option
IS interface type
Model no.
Application
MTL 7728+
Solenoid
Zener Diode [1]
MTL 7787+
Switch [2]
MTL 5025
Solenoid
Isolator [3]
MTL 5018
Switch [4]
[1] Circuit must be isolated from earth in hazardous area
[2] Two barriers required for VOS1 / VCS1
[3] Circuit may be earthed at one point in hazardous area
[4] One barrier required for VOS1 / VCS1
26
www.maxoncorp.com
32M-05003E
MAXON no.
1067656
1067655
1067660
1067659
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Please read the operating and mounting instructions before using the equipment. Install the equipment in
compliance with the prevailing regulations.
Bedrijfs- en montagehandleiding voor gebruik goed lezen! Apparaat moet volgens de geldende voorschriften
worden geïnstalleerd.
Lire les instructions de montage et de service avant utilisation! L’appareil doit imperativement être installé selon
les règlementations en vigueur.
Betriebs- und Montageanleitung vor Gebrauch lesen! Gerät muß nach den geltenden Vorschriften installiert
werden.
32M-05003E
27
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
The Installation, Operating and Maintenance Instructions contain important information that must be
read and followed by anyone operating or servicing this product. Do not operate or service this
equipment unless the instructions have been read. IMPROPER INSTALLATION OR USE OF THIS
PRODUCT COULD RESULT IN BODILY INJURY OR DEATH.
DESCRIPTION
The Series 8000 Valve is a pneumatically operated fuel shut-off valve. These valves require compressed air for actuation. The 8000
Series valve will open or close by the addition of a control voltage signal. Removal of the signal will cause a fast acting return to the at
rest position.Options are available in both normally-closed and normally-open versions.
Series 8*1* Normally-Closed will shut off flow when de-energized and pass flow when energized.
Series 8*2* Normally-Open will shut off flow when energized and pass flow when de-energized.
The Series 8000 Valve has optional configurations that meet hazardous locations.
The Series 8000 Valve has fire safe trim configurations that meet API 6FA.
NAMEPLATE AND ABBREVIATIONS
Consult the nameplate on your valve. This lists the maximum operating pressure, temperature limitations, voltage requirements and
service conditions of your specific valve. Do not exceed nameplate ratings.
Abbreviation or Symbol
Maximum Operating Pressure
M.O.P. (PS)
Description
PACT
Required actuator pressure
TS(AMB)
Ambient service temperature range
TS(FL)
Fluid service temperature range
Visual indication determined by text, color and symbol; valve is shown in open
position
Visual indication determined by text, color and symbol; valve is shown in closed
position
Valve is shut
Valve is partially open
Valve is full open
VOS-1/2
VCS-1/2
28
Valve open switch(es)
Valve closed switch(es); proof of closure
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Component identification
2
4
9
3
5
1) Flow arrow
2) Visual indication
3) Terminal block cover screws, M5 x 12
4) Switch access cover
5) Terminal block cover
6) Actuator bolts, M8 x 45 or M10 x 1.50
7) Valve body
8) Actuator
9) Switch access cover screws, M6 x 20
10) Nameplate
11) Nameplate screws, M4 x 6
8
10
11
6
7
1
32M-05003E
29
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Installation
1. A gas filter or strainer of 40 mesh (0.6 mm maximum) or greater is recommended in the fuel gas piping to protect the downstream
safety shut-off valves.
2. Properly support and pipe the valve in the direction of the flow arrow on the valve body. Valve seats are directional. Sealing will be
maintained at full rated pressures in one direction only. Sealing will be provided in reverse flow only at reduced pressures.
3. Mount valve so that open/shut indicator will not face downward.
4. Series 8000 Valves require clean, dry compressed air or gas piped to the inlet of the actuator. Guidelines for various actuating gases:
A. Compressed Air
1. The vent, located on the underside of the base plate, should be protected from blockage.
2. Although MAXON Series 8000 Valves do not require lubrication, they do contain Buna-N (-40°F) or silicone (-58°F) seals in
the actuator sub-assembly. Compressed air supply must not contain any lubricant that is not compatible with Buna-N or
silicone elastomers.
B. Natural gas and other fuel gases can be used to actuate the Series 8000 Valve when the appropriate considerations are taken
into account.
1. Apply only the Intrinsically Safe Series 8000 Valve for the application. The general purpose and non-incendive options are not
suitable for fuel gas activation.
2. The activating fuel gas must be clean and free of moisture. The Series 8000 actuator contains Buna-N elastomers and brass
components that will come in contact with the activating gas. The quality of the gas must not contain any constituents that are
not compatible with Buna-N or brass.
3. The exhaust gas must be vented to the atmosphere in a safe manner by piping from the filtered vent, located on the underside
of the actuator’s base. A 1/8” NPT female connection in the base plate allows for proper piping.
4. The use of fuel gases for actuation is not permitted in EC areas due to ATEX Zone 2 restrictions.
5. Actuators for fuel gas activation are only rated from -40°F to 140°F.
C. For applications that are governed by the ATEX Directive (94/9/EC), use of fuel gas activation is not acceptable.
5. In some instances, it may be desired to utilize a slow opening feature for either application or code-related reasons. If a slow opening
feature is required for normally-closed shut-off valves, use MAXON’s optional speed control set.
6. Wire the valve in accordance with all applicable local and national codes and standards. In U.S. and Canada, wiring must conform to
the NEC ANSI/NFPA 70 and/or CSA C22.1, Part 1.
A. Supply voltages must agree with valve’s nameplate voltage within -15%/+10% for proper operation. For electrical wiring
schematic, see instructions or sample affixed inside valve terminal block cover.
B. Grounding is achieved with a grounding screw, which is located in the top assembly.
C. Customer connections are provided via terminal block located in the top assembly.
D. Main power wiring (120 VAC or 240 VAC) must be segregated from lower voltage 24 VDC signal wiring, when both are required.
E. WARNING: For Division 2 installations using the intrinsically safe solenoid, the power source is not to exceed 28VDC with a
minimum series resistance of 300 ohms.
7. Maintain integrity of the Series 8000 actuator enclosure by using the appropriate electrical connectors for the (2) 3/4” NPT conduit
threaded connections.The Series 8000 electrical enclosure is NEMA 4 and IP65 rated with an option for NEMA 4X.
8. All access cover plate screws should be tightened using an alternate cross-corner tightening pattern to the values shown in Table 1.
Item Number
3
9
6
6
11
Table 1 - Torque Specifications
Description
Terminal Block Cover Screws, M5 x 12
Switch Access Cover Screws, M6 x 20
Actuator Bolts, M8 x 45
Actuator Bolts, M10 x 1.50
Nameplate Screws, M4 x 6
Torque
20 in-lbs
20 in-lbs
13 ft-lbs
13 ft-lbs
10 in-lbs
9. Verify proper installation and operation by electrically actuating the valve for 10-15 cycles prior to the first introduction of gas.
10.When customer-supplied, externally mounted solenoids are used, the component must be rated for the Class and Division of the
hazardous area. MAXON 8112, 8122, 8012, 8022 valves will only carry FM approval to FM 3611, 3600 and 3810 standards. MAXON
8113, 8123, 8013, 8023 valves will only carry FM approval to 3610, 3600 and 3810 standards.
30
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
SPECIFICATIONS
Valve Body Assemblies
Valve Size
Flow Capacity
Actuator
Pressure
Class
.75”
(DN 20)
Std.
High
Pressure
1”
(DN 25)
Std.
1.25”
(DN 32)
Std.
HIgh
Pressure
1.5”
(DN 40)
Std.
High
Pressure
2”
(DN 50)
Std.
Std.
High
Pressure
High
Pressure
High
Pressure
Body
Connections
Available [1]
Body
Material
A, C
Std.
CP
High
Pressure
Std.
High
Pressure
A, C, E, F, G
3”
(DN 80)
CP
High
Pressure
MOP
cfh
------------m3 h
psig
----------bar
200/13.8
19
1060 / 30
20
1115 / 31
45
2510 / 71
53
2956 / 83
86
4796 / 135
127
7083 / 200
Stainless
A, C
Iron
A, C, E, F, G
Steel
A, C
Iron
A, C
Iron
A, C, E, F, G
Steel
A, C, E, F, G
Iron
Steel
Iron
Stainless
A, B, C, D, H
255/17.6
150/10.3
Iron
50/3.4
304
16955 / 480
Steel
B, D, H
255/17.6
Iron
Steel
B, D, H
200/13.8
200/13.8
Stainless
A, B, C, D, H
255/17.6
200/13.8
Stainless
A, B, C, D, H
255/17.6
200/13.8
Stainless
175/12.1
Stainless
A, C
Iron
A, B, C, D, H
Std.
Flow Rate [2]
Iron
Steel
A, B, C, D, H
2.5”
(DN 65)
Cv
Rating
173
9648 / 273
Iron
Steel
B, D, H
Stainless
A, B, C, D, H
Iron
40/2.7
423
23591 / 668
Steel
B, D, H
150/10.3
135/9.3
Stainless
Iron
Std.
4”
(DN 100)
CP
Steel
Stainless
B, D, H
Iron
High
Pressure
40/2.7
490
27328 / 773
Steel
135/9.3
Stainless
Iron
Std.
6”
(DN 150)
8”
(DN 200)
Std.
Steel
Stainless
B, D, H
Iron
High
Pressure
Note 1: Body Connections
A - NPT
B - ANSI 150 lb Flange (ISO 7005 PN 20)
C - ISO Threaded
D - DIN PN16 Flange
High
Pressure
1172
65364 / 1850
Steel
100/6.9
Stainless
Steel
Std.
Std.
60/4.1
B, D, H, J
Stainless
Steel
60/4.1
1320
73406 / 2078
Stainless
100/6.9
E - Socket Welded Nipple
F - Socket Welded Nipple w/ANSI 150 lb flange (ISO 7005 PN20)
G - Socket Welded Nipple w/ANSI 300 lb flange (ISO 7005 PN50)
H - EN 1092-1 PN16 (ISO 7005-1 PN16)
J - ANSI Class 300 Flange (ISO 7005 PN50)
Note 2: Flow for Natural Gas (S.G. 0.60) at differential pressure = 1” wc and standard temperature (68°F) and pressure (14.696 psi)
32M-05003E
31
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
OPERATING CHARACTERISTICS
• Opening time varies per valve size, 3 seconds or less for largest size. For slower opening, a speed control set can be supplied by
MAXON.
• Closing time is less than 1 second.
• Type of Gas
Gas Compatibility and Valve Approvals/Certifications
Gas
Code
Gas
Air
Ammonia
Butane Gas
Coke Oven Gas
Delco
Digester [1]
Endothermic AGA
Exothermic Gas
Hydrogen Gas
Manufactured [1]
Natural Gas
Nitrogen
Oxygen High
Oxygen Low
Oxygen X
Propane
Refinery [1]
Sour Natural [1]
Town Gas [1]
Land Fill Gas
AIR
AMM
BUT
COKE
DEL
DIG
ENDO
EXO
HYD
MFGD
NAT
NIT
OXYH
OXYL
OXYX
PROP
REF
SOUR
TOWN
LAND
Suggested Material Options
Body seals
Body &
bonnet
Trim
Package [5]
A, B, C, F
A, C, F
A, B, F
B, F
A, B, F
Analysis Required
A, B, F
A, B, F
A, B, C, F
Analysis Required
A, B, F
A, B, C, F
B, C, F
B, C, F
B, C, F
A, B, F
Analysis Required
Analysis Required
Analysis Required
Analysis Required
1, 2, 5, 6
1, 2, 5, 6
1, 2, 5, 6
5
1, 2, 5, 6
5
1, 2, 5, 6
1, 2, 5, 6
1, 2, 5, 6
5
1, 2, 5, 6
1, 2, 5, 6
2, 5, 6
1, 2, 5, 6
2, 5, 6
1, 2, 5, 6
5
5
5
5
1, 2, 3, 6, 7
1, 2, 3, 6, 7
1, 2, 3, 6, 7
Analysis Required
1, 2, 3, 6, 7
Analysis Required
1, 2, 3, 6, 7
1, 2, 3, 6, 7
1, 2, 3, 6, 7
Analysis Required
1, 2, 3, 6, 7
1, 2, 3, 6, 7
4, 5
4, 5
4, 5
1, 2, 3, 6, 7
Analysis Required
Analysis Required
Analysis Required
Analysis Required
MOPD
Rating
Std.
Std.
Std.
Std.
Std.
Std.
Std.
Std.
[2]
Std.
Std.
Std.
200 psig max
30 psig max
Std.
Std.
Std.
Std.
Std.
Std.
Agency Approvals and
Certifications
CE [4]
CSA
FM
[3]
GAD MD
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
X
X
NA
X
X
X
X
X
X
X
NA
X
Notes:
[1] Other body and trim packages may be acceptable pending fuel analysis. For pricing inquiry, Viton body seals will be standard option. Contact MAXON for details.
[2] Valve maximum operating pressure (MOPD) to be reduced by 25% from standard ratings.
[3] ISO connections are not recognized by CSA standards.
[4] All 8000 Valves do meet the essential requirements of the Low Voltage (73/23/EC) and the EMC (89/336/EC) Directives. GAD refers to the Gas Appliances Directive (2009/142/EC): this Directive only covers the use of commercially available fuels (natural gas, butane, town gas and LPG). MD stands for Machinery Directive
(2006/42/EC). All Series 8000 valves meet the essential requirements for fuel shut off on Industrial Thermal Equipment as specified in EN746-2.
[5] Trim Package 1 is only allowed with body and bonnet 1.
Body Seals:
A - Buna-N
B - Viton
C - Ethylene Propylene
F - Omniflex
Body & Bonnet:
1 - Cast Iron
2 - Carbon Steel
5 - Stainless Steel
6 - Low Temp Carbon Steel
Trim Package:
1 - Trim Package 1
2 - Trim Package 2
3 - Trim Package 3 (NACE)
4 - Trim Package 2, Oxy Clean
5 - Trim Package 3, Oxy Clean
6 - Trim 2 fire safe
7 - Trim 3 fire safe
AUXILIARY FEATURES
• Non-adjustable Proof of Closure Switch(es) with valve seal over travel interlock.
• Auxiliary switch for indication of full travel (open for normally-closed valves, closed for normally-open valves).
32
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
OPERATING ENVIRONMENT
• Fluid temperature range of -40°F to 212°F , with options available for -58°F to 212°F.
• Actuators are rated for NEMA 4, IP65 or optional NEMA 4X, IP65.
• Ambient temperature range of -40°F to 140°F for the 8011, 8111, 8021 and 8121 General Purpose and 8012, 8112, 8022 and 8122
Non-Incendive series valves; option of -58°F to 140°F also available.
• Ambient temperature range of -40°F to 122°F for 8013, 8113, 8023 and 8123 Intrinsically Safe series valves; option of -58°F to 122°F
also available.
• All valves for oxygen service or using Ethylene Propylene body seals are limited to a minimum ambient and fluid temperature of 0°F.
32M-05003E
33
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
PRODUCT APPROVALS
34
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
VALVE CYCLE REQUIREMENTS
This is based on the standards that MAXON valves are approved to and the corresponding minimum number of cycles to be completed
without failure as shown in the chart below.
CSA (CSA 6.5)
FM (FM 7400)
Automatic - Normally-Closed
Series 8011, 8111, 8012, 8112, 8013, 8113
100,000
20,000
Vent Valves
Series 8021, 8121, 8022, 8122, 8023, 8123
No special
requirements
No special
requirements
32M-05003E
European (EN161)
<= 1” 200,000
<= 3” 100,000
<= 8” 50,000
No special
requirements
35
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
ELECTRICAL DATA
Normally-Closed Shut-Off Valves
GENERAL PURPOSE NORMALLY-CLOSED VALVES
Series 8011 & Series 8111
Switches: V7
Solenoid Valve: Standard
24 VDC, 4.8W
120VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
240VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
See page 12 or inside valve cover for wiring schematic.
NON-INCENDIVE NORMALLY-CLOSED VALVES
Series 8012 & Series 8112
Switches: IP67
Solenoid Valve: Standard
24 VDC, 4.8W
120VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
240VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
24VDC IS, .09A, 2.1W
INTRINSICALLY SAFE NORMALLY-CLOSED VALVES
Series 8013 & Series 8113
Switches: V7 with optional IP67
Solenoid Valve: Intrinsically Safe
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of
HAZARDOUS (CLASSIFIED) LOCATION
two FM approved (CSA Certified when installed in Canada)
CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
Intrinsically safe devices with entity parameters not specifically
CLASS III, DIVISION 1
examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+
Ccable, La or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II
and Class III environments.
3) Control equipment connected to the Associated Apparatus
must not use or generate more than 250 Vrms or Vdc.
4) Installation in the U.S. should be in accordance with ANSI/ISA
Solenoid
RP12.06.01 “Installation of Intrinsically Safe Systems for
Valve
Hazardous (Classified) Locations” and the National Electric
Code® (ANSI/NFPA 70) Sections 504 and 505.
Solenoid Entity Parameters
5) Installation in Canada should be in accordance with the
V max = 28 VDC
Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.
I max. = 115 mA
6) Installation in the European Union should be in accordance to
Pi = 1.6 W
Ci = 0µF
Directive 94/9/EC (ATEX 95).
Li = 0 µH
7) The configuration of associated Apparatus must be FM
Approved (CSA Certified when in Canada) under Entity
Valve
Concept.
Position
8) Associated Apparatus manufacturer’s installation drawing must
Switch
be followed when installing this equipment.
Switch Entity Parameters
9) No revision to drawing without prior authorization from FM
V max. = 30 VDC
I max. = 500 mA
Approval and CSA International.
Pi = 2 W
Ci = 0µF
Li = 0 µH
36
www.maxoncorp.com
32M-05003E
NON-HAZARDOUS LOCATION
Factory Mutual/CSA Approved
Barrier(s) used in an Approved Config.
with “V” max. greater than “VI” or
“Voc” and “I” max greater than
“I t” or “I sc”
Power
Supply
250 RMS max.
CSA/FM certified Barrier
rated 28 V max./300 ohms
min. or equivalent
“CSA/FM certified Barrier
for a simple apparatus”
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
INTRINSICALLY SAFE NORMALLY-CLOSED VALVES
Series 8013 & Series 8113
Switches: V7 with optional IP67
Solenoid Valve: Customer-supplied, externally mounted
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two
FM approved (CSA Certified when installed in Canada) Intrinsically
safe devices with entity parameters not specifically examined in
combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La
or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II and
Class III environments.
3) Control equipment connected to the Associated Apparatus must
not use or generate more than the maximum permissible safe area
voltage (Um) for the barrier.
4) Installation in the U.S. should be in accordance with ANSI/ISA
RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous
(Classified) Locations” and the National Electric Code® (ANSI/
NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Canadian
Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to
Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved
(CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be
followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Approval
and CSA International.
HAZARDOUS (CLASSIFIED) LOCATION
CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
CLASS III, DIVISION 1
NON-HAZARDOUS LOCATION
Factory Mutual/CSA Approved
Barrier(s) used in an Approved configuration with "V" max. greater than "Vt"
or "Voc" and "I" max. greater than "I t" or "I sc"
Power
supply
Solenoid
Valve
see note 3
Customer Supplied Solenoid Valve
-To be mounted external to valve actuator.
-Component must be rated for the Class
and Division of the hazardous environment
as stated above.
-Component must be rated for instrinsic
safety and be interconnected with other
intrinsically safe devices as required under
the Intrinsic Safety Entity Concept (see note 1).
32M-05003E
Valve
Position
Switch
Switch Entity Parameters
V max.=30 VDC
I max.=500 mA
Pi= 2 W
Ci= O µF
Li= O µH
"CSA/FM/ATEX certified Barrier
for a simple apparatus"
37
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Normally-Open Vent Valves
GENERAL PURPOSE NORMALLY-OPEN VENT VALVES
Series 8021 & Series 8121
Switches: V7
Solenoid Valve: Standard
24 VDC, 4.8W
120VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
240VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
See page 12 or inside valve cover for wiring schematic.
NON-INCENDIVE NORMALLY-OPEN VENT VALVES
Series 8022 & Series 8122
Switches: IP67
Solenoid Valve: Standard
24 VDC, 4.8W
120VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
240VAC, 50/60 Hz, 11/9.4 VA Peak, 8.5/6.9 VA Holding
24VDC IS, .09A, 2.1W
INTRINSICALLY SAFE NORMALLY-OPEN VENT VALVES
Series 8023 & Series 8123
Switches: V7 with optional IP67
Solenoid Valve: Intrinsically Safe
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of
two FM approved (CSA Certified when installed in Canada)
Intrinsically safe devices with entity parameters not specifically
examined in combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+
Ccable, La or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II
and Class III environments.
3) Control equipment connected to the Associated Apparatus
must not use or generate more than 250 Vrms or Vdc.
4) Installation in the U.S. should be in accordance with ANSI/ISA
RP12.06.01 “Installation of Intrinsically Safe Systems for
Hazardous (Classified) Locations” and the National Electric
Code® (ANSI/NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the
Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to
Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM
Approved (CSA Certified when in Canada) under Entity
Concept.
8) Associated Apparatus manufacturer’s installation drawing must
be followed when installing this equipment.
9) No revision to drawing without prior authorization from FM
Approval and CSA International.
38
www.maxoncorp.com
HAZARDOUS (CLASSIFIED) LOCATION
CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
CLASS III, DIVISION 1
NON-HAZARDOUS LOCATION
Factory Mutual/CSA Approved
Barrier(s) used in an Approved Config.
with “V” max. greater than “VI” or
“Voc” and “I” max greater than
“I t” or “I sc”
Power
Supply
Solenoid
Valve
250 RMS max.
Solenoid Entity Parameters
V max = 28 VDC
I max. = 115 mA
Pi = 1.6 W
Ci = 0µF
Li = 0 µH
CSA/FM certified Barrier
rated 28 V max./300 ohm
min. or equivalents
Valve
Position
Switch
Switch Entity Parameters
V max. = 30 VDC
I max. = 500 mA
Pi = 2 W
Ci = 0µF
Li = 0 µH
32M-05003E
“CSA/FM certified Barrier
for a simple apparatus”
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
INTRINSICALLY SAFE NORMALLY-OPEN VENT VALVES
Series 8023 & Series 8123
Switches: V7 with optional IP67
Solenoid Valve: Customer-supplied, externally mounted
NOTES:
1) The Intrinsic Safety Entity concept allows the interconnection of two
FM approved (CSA Certified when installed in Canada) Intrinsically
safe devices with entity parameters not specifically examined in
combination as a system when:
Voc or Uo or Vt Vmax, Isc or Io or It Imax, Ca or Co Ci+ Ccable, La
or Lo Li + Lcable, and for FM only: Po Pi.
2) Dust-tight conduit seal must be used when installed in Class II and
Class III environments.
3) Control equipment connected to the Associated Apparatus must
not use or generate more than the maximum permissible safe area
voltage (Um) for the barrier.
4) Installation in the U.S. should be in accordance with ANSI/ISA
RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous
(Classified) Locations” and the National Electric Code® (ANSI/
NFPA 70) Sections 504 and 505.
5) Installation in Canada should be in accordance with the Canadian
Electrical Code, CSA C22.1, Part 1, Appendix F.
6) Installation in the European Union should be in accordance to
Directive 94/9/EC (ATEX 95).
7) The configuration of associated Apparatus must be FM Approved
(CSA Certified when in Canada) under Entity Concept.
8) Associated Apparatus manufacturer’s installation drawing must be
followed when installing this equipment.
9) No revision to drawing without prior authorization from FM Approval
and CSA International.
HAZARDOUS (CLASSIFIED) LOCATION
CLASS I, DIVISION 1, GROUPS A,B,C,D
CLASS II, DIVISION 1, GROUPS E,F,G
CLASS III, DIVISION 1
NON-HAZARDOUS LOCATION
Factory Mutual/CSA Approved
Barrier(s) used in an Approved configuration with "V" max. greater than "Vt"
or "Voc" and "I" max. greater than "I t" or "I sc"
Power
supply
Solenoid
Valve
see note 3
Customer Supplied Solenoid Valve
-To be mounted external to valve actuator.
-Component must be rated for the Class
and Division of the hazardous environment
as stated above.
-Component must be rated for instrinsic
safety and be interconnected with other
intrinsically safe devices as required under
the Intrinsic Safety Entity Concept (see note 1).
Valve
Position
Switch
Switch Entity Parameters
32M-05003E
V max.=30 VDC
I max.=500 mA
Pi= 2 W
Ci= O µF
Li= O µH
"CSA/FM/ATEX certified Barrier
for a simple apparatus"
39
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
OPERATING INSTRUCTIONS
Refer to appropriate catalog page for operating features applying to your specific valve. Never operate valve until all essential allied
equipment is operative and any necessary purges completed. Failure of valve to operate normally indicates that it is not powered or
supply air pressure is not adequate. Check this first!
Main system shut-off should always be accomplished with an upstream leak-tight manual fuel cock.
The Series 8000 Pneumatic Safety Shut-off Valve is not intended to be used for end of line service.
Users are responsible for providing protection against surface temperatures.
Users are responsible for providing suitable protective devices to protect against over pressure conditions.
Users are responsible for limiting momentary pressure surges to within 10% of the maximum allowed pressure in accordance with the
Pressure Equipment Directive.
•
•
40
Normally-closed shut-off valves begin opening cycle immediately upon being powered.
Normally-open vent valves begin to close immediately upon being powered.
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
ALTERNATE OPERATOR PRESSURES
Series 8000 Valves may be operated within a range of actuator pressures. Consult charts below for application fluid pressure and
corresponding required actuator pressure.
32M-05003E
41
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
42
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32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
MAINTENANCE INSTRUCTIONS
MAXON Series 8000 Valves are endurance tested far in excess of the most stringent requirements of the various approval agencies.
They are designed for long life even if frequently cycled, and to be as maintenance-free and trouble-free as possible.
A valve operational test should be performed on an annual basis. If abnormal opening or closing is observed, the valve should be
removed from service and your MAXON representative should be contacted. (See Valve Technical Data page 10-35.1.)
Valve leak test should be performed on an annual basis to assure continued safe and reliable operation. Every MAXON valve is
operationally tested and meets the requirements of FCI 70-2 Class VI Seat Leakage when in good operable condition. Zero leakage may
not be obtained in the field after it has been in service. For specific recommendations on leak test procedures, see MAXON Valve
Technical Data page 10-35.2. Any valve that exceeds the allowable leakage, as set forth by your local codes or insurance requirements,
should be removed from service and your MAXON representative should be contacted.
Actuator assembly components require no field lubrication and should never be oiled.
Auxiliary switches, solenoids or complete actuator may be replaced in the field.
Do not attempt field repair of valve body or actuator. Any alterations void all
warranties and can create potentially hazardous situations.
If foreign material or corrosive substances are present in the fuel line, it will be necessary to inspect the valve to make certain it is
operating properly. If abnormal opening or closing is observed, the valve should be removed from service. Contact your MAXON
representative for instructions.
Operator should be aware of and observe characteristic opening/closing action of the valve. Should operation ever become sluggish,
remove valve from service and contact MAXON for recommendations.
Address inquiries to MAXON. Local worldwide offices may be located at www.maxoncorp.com or by phoning 011-765-284-3304.
Include valve serial number and nameplate information.
32M-05003E
43
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Solenoid replacement procedure
•
•
•
All power sources, both pneumatic and electric, must be de-energized and follow all proper safety procedures prior to servicing valve.
Use a 4 mm allen wrench to remove the top plate. A 3 mm allen wrench is used to remove the terminal block cover.
Use a 5/16” open end wrench to hold the cylinder shaft, then use a pair of pliers to unthread the switch indicator from the cylinder shaft.
When using pliers, grab the indicator from the top.
1
2
3
1) Top plate screw M6 x 20
socket head cap screw
2) M6 Lock washer
3) Top plate
4) Switch indicator
5) Cylinder shaft
6) Terminal block cover
7) M5 Lock washer
8) Terminal block cover
screw M5 x 12 socket
head cap screw
4
5
6
7
8
•
Loosen the liquid tight connector nut where the solenoid wires come into the top housing. Remove #1 and #2 wire from the terminal
block.
1
1) Liquid tight connector
44
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32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
•
Use a 3/4” wrench to remove the solenoid inlet fitting. An adjustable wrench is used to loosen the housing collar. Slightly loosen the
housing collar but do not remove, due to the nut and o-ring located inside the housing becoming dislocated.
1
2
1) Housing collar
2) Solenoid inlet fitting
•
Use a 4 mm allen wrench and remove the 4 screws that hold the housing to the base plate. Pull the housing straight up and remove.
Old solenoid wires will pass through liquid tight connector.
1
1) Housing
2) Base plate
3) Housing screws M6 x 20
cap screws
2
3
•
Use a 4 mm allen wrench and remove the 2 screws that hold the solenoid on. Replace the solenoid ensuring that there are 2 o-rings,
one on the solenoid inlet and one on the solenoid outlet. The solenoid must be level when tightening screws.
1
1) Solenoid o-ring
2) Solenoid
3) M5 x 40 socket head cap
screw
4) Solenoid o-ring
2
3
4
32M-05003E
45
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
•
•
•
•
•
46
Run the new solenoid wires back up through the liquid tight connector in the housing and align the cylinder shaft with the hole in the
housing. Carefully slide housing back into position. Replace the 4 housing screws and leave loose.
Verify the o-ring is still on the solenoid inlet by looking through the housing collar. Reinstall solenoid inlet fitting tight. Leave the housing
collar loose.
Reinstall solenoid wire #1 and #2 back to the terminal block and tighten down the liquid tight connector nut.
A locking sealant must be used on the cylinder shaft threads and then reinstall the switch indicator. Make sure to remove any locking
sealant that runs down the cylinder shaft. Re-energize pneumatic and electric power and cycle the valve several times to ensure it
operates smoothly. Tighten down the 4 housing screws that hold the housing to the base plate using a cross pattern (see torque values in Table 1 on page 30). Then tighten the housing collar on the solenoid inlet fitting. The o-ring under the housing collar must not be
pinched while tightening the housing collar.
Cycle valve several more times to see if it still operates smoothly. If not, loosen the 4 screws that hold the housing to the base plate and
cycle again. Retighten the 4 housing screws. Put the top plate and terminal block covers back on valve (see torque values in Table 1 on
page 30).
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Actuator assembly rotation/replacement
MAXON Series 8000 Valves should be ordered in a configuration compatible with planned piping. If
valve orientation is not correct, the actuator assembly can be rotated in 90° increments around the
valve body centerline axis using the procedure below. This procedure should also be followed for field
replacement of the actuator.
•
•
•
•
•
•
•
•
•
•
•
•
•
Shut off all electrical power and close off upstream manual cock.
Remove terminal block access cover plate [4] and disconnect power lead wires. Caution: Label all wires prior to disconnection
when servicing valve. Wiring errors can cause improper and dangerous operation.
Remove conduit and electrical leads.
Remove all pneumatic lines.
Unscrew the actuator/body bolts [5] screwed up from the bottom. These bolts secure the valve actuator [7] to the valve body [6].
Gently lift the actuator [7] off valve body assembly enough to break the seal between body assembly and the rubber gasket adhering to the bottom of the actuator base plate.
Carefully rotate/replace actuator assembly to the desired position. Reposition the actuator back down onto the valve body casting.
Realign holes in valve body casting with the corresponding tapped holes in the bottom of the actuator base plate. Be sure the gasket
is still in place between the body and actuator base plate.
Reinsert the body bolts up from the bottom through the body and carefully engage threads of the actuator assembly. Tighten
securely referring to Table 1 on page 10-30.3-30 for appropriate torque specifications.
Reconnect conduit, electrical leads, and all pneumatic lines, then check that signal switch wands are properly positioned. Failure
to correct any such misalignment can result in extensive damage to the internal mechanism of your valve.
Energize valve and cycle several times from closed to full open position. Also electrically trip the valve in a partially opened position
to prove valve operates properly.
Replace and secure cover plates.
Verify proper operation after servicing.
8
3
2
1) Flow arrow on valve body
2) Open/shut indicator (see
Note 1 below)
3) Switch access cover
4) Terminal block cover and
screws
5) Actuator/body bolts
6) Valve body
7) Actuator assembly
8) Switch access cover
screws
4
7
5
6
1
Note 1: Open/Shut indication is 360°. If required, the observation window may be cleaned with a damp cloth.
32M-05003E
47
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
Field installation of valve position switch
Instructions below are written for normally-closed shut-off valves. For normally-open vent valves,
reverse switch nomenclature. (VOS becomes VCS and vice versa.)
General: Shut off fuel supply upstream of valve, then de-energize valve electrically.
Remove top cover and terminal block cover to provide access, being careful not to damage gasket.
See pages 48 and 49 for instructions on adding or replacing switches.
Substitution of components may affect suitability for Hazardous Locations.
FIELD REPLACEMENT ITEMS
• Position Switches
• Actuators
• Solenoids
Contact MAXON with valve serial numbers to locate appropriate switch kit assembly.
Figure 3: Typical switch sub-assemblies
V7 assembly for General Purpose and
Intrinsically Safe valves
IP67 Switch assembly for Non-Incendive
and optional Intrinsically Safe valves
REPLACEMENT SWITCHES:
• Carefully remove field wiring from the terminal block (see page 29, item 5). Insure field wires are clearly marked to correct terminal.
• Unwire the solenoid valve lead wires from terminals labeled #1 and #2.
• Remove screws that secure the switch sub-assembly to the actuator housing. The switch sub-assembly should be easily removable
from actuator assembly (see Figure 3: Typical Switch Sub-Assemblies).
• Note wand position and mounting hole location. Carefully remove the 2 screws and lift existing switch. Reference Figures 4 through 9
(page 49) to ensure correct switch location.
• Install replacement switch in same mounting holes on bracket and verify correct wand position.
• Replace existing wiring one connection at a time, following original route and placement.
• Reassemble switch sub-assembly in actuator housing. Dowel pins are provided to insure proper placement of switch sub-assembly.
• Wire the solenoid valve leads to terminals labeled #1 and #2.
• Cycle valve, checking switch actuation points carefully. VCS switch actuates at top of stem stroke and VOS at bottom for normallyclosed shut-off valves; vice-versa for normally-open vent valves.
• Replace covers using torque values in Table 1 on page 30, and then return valve to service.
48
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32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
ADD SWITCHES:
• Carefully remove field wiring from the terminal block (see page 29, item 5). Insure field wires are clearly marked to correct terminal.
• Unwire the solenoid valve lead wires from terminals labeled #1 and #2.
• Remove screws that secure the switch sub-assembly to the actuator housing. The switch sub-assembly should be easily removable
from actuator assembly (see Figure 3: Typical Switch Sub-Assemblies).
• Reference Figures 4 through 9 (below) to ensure correct switch location. Valve size is depicted in the model number by the first 4 digits. For example, a 3” CP valve should have Model No. 300C.
• Install switch and insulators, when provided, to correct hole. Insure proper alignment. VCS switch should have activation wand pointed
upward and VOS activation wand should be pointed downward.
• Wire new switches to terminals provided.
• Reassemble switch sub-assembly in actuator housing. Dowel pins are provided to insure proper placement of switch sub-assembly.
• Wire the solenoid valve leads to terminals labeled #1 and #2.
• Cycle valve, checking switch actuation points carefully. VCS switch actuates at top of stem stroke and VOS at bottom for normallyclosed shut-off valves; vice-versa for normally-open vent valves.
• Replace covers using torque values in Table 1 on page 30, and then return valve to service.
2.5”CP, 3”CP, 4”CP
2.5”CP, 3”CP, 4”CP
.75”, 1”, 1.25”, 1.5”
2”, 2.5” & 3” VCS
.75”, 1”, 1.25”, 1.5”
2”, 2.5” & 3” VCS
.75” & 1” VOS
.75” & 1” VOS
2.5”CP VOS
2.5”CP VOS
1.25” VOS
1.5” VOS
1.25” VOS
1.5” VOS
2”, 2.5” & 3” VOS
3”CP, 4”CP
3”CP, 4”CP
2”, 2.5” & 3” VOS
Figure 4:
IP67 Switch Bracket
Figure 8:
6” & 8” Valve IP67
Switch Bracket
Figure 6:
General Purpose
Switch Bracket
Figure 5:
IP67 Switch Bracket
Figure 7:
General Purpose
Switch Assembly
Figure 9:
6” & 8” Valve General
Purpose Switch Bracket
32M-05003E
49
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
IEC 61508 INSTRUCTION REQUIREMENTS
PRODUCT DESCRIPTION
A Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available from MAXON. Detailed failure rate data is available in the
FMEDA reports. Data for Series 8000 Valves with internal solenoids only can be found in Exida Report MAX 08/09-07 R002. Data for
Series 8000 Valves with internal solenoid and redundant external solenoid can be found in Exida Report MAX 1208063 R002.
PRIMARY SAFETY FUNCTION
a. Series 8*1*, Normally Closed will pass flow when energized and shut off flow within the stated leakage specification when deenergized.
b. Series 8*2*, Normally Open will pass flow when de-energized and shut off flow within the stated leakage specification when
energized.
c. The valves are designed for low demand applications.
d. The valve must be within specified operating conditions, as found in the instruction manual.
PROOF TEST
The objective of proof testing is to detect failures within the Series 8000 Valve that prevent the valve from performing its safety function.
The frequency of proof testing, or the proof test interval, is to be determined in reliability calculations for the safety instrumented functions
for which the Series 8000 Valve is applied. The proof tests must be performed more frequently or as frequently as specified in the
calculation in order to maintain the required safety integrity of the safety instrumented function.
Maintenance instructions include a Valve Leak Test. These instructions must be followed during the proof test. This Valve Leak Test will
detect approximately 99% of possible DU (Dangerous Undetected) failures resulting in a Proof Test Coverage of 99% for the valve. For
specific recommendations on leak test procedures, see MAXON Valve Technical Document 10-35.2-1.
The person(s) performing the proof test of the Series 8000 Valve should be trained in SIS (Safety Instrumented Systems) operations,
including bypass procedures, valve maintenance and Company Management of Change procedures.
If implementing partial stroke testing of Series 8000 Valves, see MAXON PSCheck documentation (Form Number 32M-05004) for
diagnostic coverage information related to Series 8000 Valves.
RELIABILITY DATA AND LIFETIME LIMIT
A detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available from MAXON. This report details all failure rates
and failure modes, common cause factors for applications with redundant devices and the expected lifetime of the Series 8000 Valve.
50
www.maxoncorp.com
32M-05003E
SERIES 8000 PNEUMATIC SHUT-OFF VALVES
FITTING CERTIFICATE
We:
Maxon Corporation
Address:
201 E. 18th Street
Muncie, IN 47302
USA
Declare that all fittings produced at the above address within the following product group:
Maxon Series 8000 Air Actuated Valves
Conform to all applicable provisions of the European Gas Appliance Directive.
Certification: Product Identification Number C86CM45 applies
EC Surveillance: BSI (Notified Body Number 0086)
This certificate issued by: Maxon Corporation
Name: Lora Davis
Title/Position: Product Engineering Manager
Date of issue: April 15, 2011
32M-05003E
51
SERIES 8000 GAS SHUT-OFF VALVE
Commercial & Industrial Combustion
(C&IC)
Maxon
201 East 18th Street
P.O. Box 2068
Muncie, IN 47307-0068
Tel: 765.284.3304
Fax: 765.286.8394
Canada Sales Office
Maxon Industrial Equipment
3333 Unity Drive
Mississauga, Ontario L5L 3S6
Tel: 800.489.4111
Fax: 855.262.0792
European Sales Office
Maxon International BVBA
Luchthavenlaan 16-18
1800 Vilvoorde, Belgium
Tel: 32.2.255.09.09
Fax: 32.2.251.82.41
Asia/Pacific Sales Office
Maxon
Honeywell Building
17 Changi Business Park, Central 1
Singapore 486073
Tel: 65.6580.3358
Fax:65.6580.3345
China Sales Office
Maxon Combustion Equipment
(Shanghai) Co., Ltd.
1st Floor & Section A, 4th Floor
225 Meisheng Road
Wai Gao Qiao Free Trade Zone
Pudong New Area
Shanghai 200131, P.R. China
Tel: 86.21.5866.1166
Fax:86.21.5868.1569
India Sales Office
Maxon
53, 54, 56, 57 Hadapsar Industrial Estate
Environmental & Combustion Controls
Sapphire Building 2nd Floor, A Wing
Pune 411013 India
Tel: 91.98.50907894
91.20.66008330
91.20.66008509
Sales Offices &
Representatives Worldwide
www.maxoncorp.com
customer.honeywell.com
32M-05003E - Imperial version
Maxon P/N 50111985-001/A01
August 2014 Printed in USA
© 2014 Honeywell International Inc.
Product Data Sheet
September 2014
00813-0100-4001, Rev SA
Rosemount 3051 Pressure Transmitter
With the Rosemount 3051 Pressure Transmitter, you’ll gain more control over your plant. You’ll be able to
reduce product variation and complexity as well as your total cost of ownership by leveraging one device
across a number of pressure, level and flow applications. You’ll have access to information you can use to
diagnose, correct and even prevent issues. And with unparalleled reliability and experience, the Rosemount
3051 is the industry standard that will help you perform at higher levels of efficiency and safety so you can
remain globally competitive.
Rosemount 3051
September 2014
Setting the Standard for Pressure Measurement
Proven best-in-class performance,
reliability and safety
 Over 7 million installed
 Reference accuracy 0.04% of span
 Installed total performance of 0.14% of span
 10-year stability of 0.2% of URL
 SIL2/3 certified (IEC 61508)
Maximize installation and application
flexibility with the coplanar platform
 Improve reliability and performance with integrated DP
Flowmeters, DP Level solutions and integral manifolds
 Easy installation with all solutions fully assembled,
leak-tested and calibrated
 Meet your application needs with an unsurpassed offering
Advanced functionality
Power advisory diagnostics
 Detect on-scale failures caused by electrical loop issues before they impact your process
operation
 This capability is safety certified for your most critical applications
Local operator interface
 Straightforward menus and built-in configuration buttons allow you commission the device in less
than a minute
 Configure in hazardous-area locations without removing the transmitter cover using external
buttons
Contents
Rosemount 3051C Coplanar™ Pressure Transmitter . . . . . . 4
Rosemount 3051L Level Transmitter . . . . . . . . . . . . . . . . . . 38
Rosemount 3051T In-Line Pressure Transmitter . . . . . . . . . 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rosemount 3051CF Flowmeter Selection Guide . . . . . . . . . 17
3051 Product Certifications . . . . . . . . . . . . . . . . . . . . . . . . 56
Rosemount 3051CFA Annubar Flowmeter . . . . . . . . . . . . . 18
Pipe I.D. Range Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Rosemount 3051CFC Compact Flowmeter . . . . . . . . . . . . . 26
Rosemount 3051 Dimensional Drawings . . . . . . . . . . . . . . 66
Rosemount 3051CFP Integral Orifice Flowmeter . . . . . . . . 32
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2
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September 2014
Rosemount 3051
Industry leading capabilities extended to IEC 62591
(WirelessHART®)

Cost effectively implement wireless on the industry's most proven platform

Optimize safety with the industry's only intrinsically safe power module

Eliminate wiring design and construction complexities to lower costs by 40-60%

Quickly deploy new pressure, level and flow measurements in 70% less time
Innovative, integrated DP Flowmeters

Fully assembled, configured, and leak tested for out-of-the-box installation

Reduce straight pipe requirements, lower permanent pressure loss and achieve accurate
measurement in small line sizes

Up to 1.65% volumetric flow accuracy at 8:1 turndown
Proven, reliable, and innovative DP Level Technologies

Connect to virtually any process with a comprehensive offering of process connections, fill
fluids, direct mount or capillary connections and materials

Quantify and optimize total system performance with QZ option

Operate at higher temperature and in vacuum applications

Optimize level measurement with cost efficient Rosemount Tuned-System™ Assemblies
Instrument manifolds – quality, convenient, and easy
www.rosemount.com

Designed and engineered for optimal performance with Rosemount transmitters

Save installation time and money with factory assembly

Offers a variety of styles, materials and configurations
3
Rosemount 3051
September 2014
Rosemount 3051C Coplanar™ Pressure Transmitter
Rosemount 3051C Coplanar Pressure Transmitters are the industry standard for Differential,
Gage, and Absolute pressure measurement. The Coplanar Platform enables seamless
integration with manifolds, flow and level solutions. Capabilities include:
 Power Advisory can proactively detect degraded electrical loop integrity issues (Option Code
DA0)
 Local Operator Interface with straightforward menus and built-in configuration buttons
(Option Code M4)
3051C Coplanar
Pressure Transmitter
 Safety Certification (Option Code QT)
See Specifications and options for more details on each configuration. Specification and selection of product materials, options, or
components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model
Transmitter type
3051C(1)
Coplanar Pressure Transmitter
Measurement type
D
Differential
H
G
Gage
H
A(2)
Absolute
Pressure range
Differential (3051CD)
Gage (3051CG)
Absolute (3051CA)
1
–25 to 25 inH2O
(-62,16 to 62,16 mbar)
–25 to 25 inH2O
(-62,16 to 62,16 mbar)
0 to 30 psia
(0 to 2,06 bar)
H
2
–250 to 250 inH2O
(-621,60 to 621,60 mbar)
–250 to 250 inH2O
(-621,60 to 621,60 mbar)
0 to 150 psia
(0 to 10,34 bar)
H
3
–1000 to 1000 inH2O
(-2,48 to 2,48 bar)
–393 to 1000 inH2O
(-0,97 to 2,48 bar)
0 to 800 psia
(0 to 55,15 bar)
H
4
–300 to 300 psi
(-20,68 to 20,68 bar)
–14.2 to 300 psi
(-0,97 to 20,68 bar)
0 to 4000 psia
(0 to 275,79 bar)
H
5
–2000 to 2000 psi
(-137,89 to 137,89 bar)
–14.2 to 2000 psi
(-0,97 to 137,89 bar)
N/A
H
0(3)
–3 to 3 inH2O
(-7,46 to 7,46 mbar)
N/A
N/A
Transmitter output
A(4)
4–20 mA with Digital Signal Based on HART Protocol
H
F
FOUNDATION™ fieldbus Protocol
H
W(5)
PROFIBUS® PA Protocol
H
Wireless (requires wireless options and engineered polymer housing)
H
X
(6)
M(7)
4
Low-Power, 1-5 Vdc with Digital Signal Based on HART® Protocol
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September 2014
Rosemount 3051
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Materials of construction
Process flange type
Flange material
Drain/vent
2
Coplanar
SST
SST
H
3(8)
Coplanar
Cast C-276
Alloy C-276
H
4
Coplanar
Alloy 400
Alloy 400/K-500
H
5
Coplanar
Plated CS
SST
H
7(8)
Coplanar
SST
Alloy C-276
H
8(8)
Coplanar
Plated CS
Alloy C-276
H
0
Alternate Process Connection
H
Isolating diaphragm
2(8)
316L SST
H
3(8)
Alloy C-276
H
4(9)
Alloy 400
5(9)
Tantalum (available on 3051CD and CG, Ranges 2–5 only; not available on 3051CA)
6(9)
Gold-plated Alloy 400 (use in combination with O-ring Option Code B)
7(9)
Gold-plated 316 SST
O-ring
A
Glass-filled PTFE
H
B
Graphite-filled PTFE
H
Sensor fill fluid
1
Silicone
H
2(9)
Inert (Differential and Gage only)
H
Housing material
Conduit entry size
A
Aluminum
½–14 NPT
H
B
Aluminum
M20 × 1.5
H
J
SST
½–14 NPT
H
K
SST
M20 × 1.5
H
P(10)
Engineered Polymer
No Conduit Entries
H
D(11)
Aluminum
G½
M(11)
SST
G½
Wireless options (requires Wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3
User Configurable Transmit Rate, 2.4GHz WirelessHART
Antenna and SmartPower
WP5
H
™
Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately)
H
HART Revision configuration (requires HART Protocol Output Code A)
HR5(4)
Configured for HART Revision 5
H
HR7(4)
Configured for HART Revision 7
H
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5
Rosemount 3051
September 2014
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Options (include with selected model number)
Extended product warranty
WR3
3-year limited warranty
H
WR5
5-year limited warranty
H
PlantWeb® control functionality
A01(12)
FOUNDATION fieldbus Control Function Block Suite
H
PlantWeb diagnostic functionality
DA0(13)
Power Advisory HART Diagnostic
H
D01(12)
FOUNDATION fieldbus Diagnostics Suite
H
Alternate flange
(14)
H2
Traditional Flange, 316 SST, SST drain/vent
H
H3(8)
Traditional Flange, Alloy C, Alloy C-276 drain/vent
H
H4
Traditional Flange, Cast Alloy 400, Alloy 400/K-500 drain/vent
H
H7(8)
Traditional Flange, 316 SST, Alloy C-276 drain/vent
H
HJ
DIN-Compliant Traditional Flange,SST,7/16 in. Adapter/Manifold Bolting
H
FA
Level Flange, SST, 2 in., ANSI Class 150, Vertical Mount 316 SST drain/vent
H
FB
Level Flange, SST, 2 in., ANSI Class 300, Vertical Mount 316 SST drain/vent
H
FC
Level Flange, SST, 3 in., ANSI Class 150, Vertical Mount 316 SST drain/vent
H
FD
Level Flange, SST, 3 in., ANSI Class 300, Vertical Mount 316 SST drain/vent
H
FP
DIN Level Flange, SST, DN 50, PN 40, Vertical Mount 316 SST drain/vent
H
FQ
DIN Level Flange, SST, DN 80, PN 40, Vertical Mount 316 SST drain/vent
H
HK(15)
DIN Compliant Traditional Flange, SST, 10 mm Adapter/Manifold Bolting 316 SST
HL
DIN Compliant Traditional Flange, SST, 12mm Adapter/Manifold Bolting 316 SST
Manifold assembly(16)
S5
Assemble to Rosemount 305 Integral Manifold
H
S6
Assemble to Rosemount 304 Manifold or Connection System
H
Integral mount primary element(15)(16)
S3
(17)
S4
Assemble to Rosemount 405 Compact Orifice Plate
®
Assemble to Rosemount Annubar or Rosemount 1195 Integral Orifice
H
H
(16)
Seal assemblies
S1(18)
Assemble to one Rosemount 1199 seal
H
S2(19)
Assemble to two Rosemount 1199 seals
H
Mounting bracket(20)
B4
Coplanar flange bracket, all SST, 2-in. pipe and panel
H
B1
Traditional flange bracket, CS, 2-in. pipe
H
B2
Traditional flange bracket, CS, panel
H
B3
Traditional flange flat bracket, CS, 2-in. pipe
H
B7
Traditional flange bracket, B1 with SST bolts
H
B8
Traditional flange bracket, B2 with SST bolts
H
B9
Traditional flange bracket, B3 with SST bolts
H
BA
Traditional flange bracket, B1, all SST
H
BC
Traditional flange bracket, B3, all SST
H
6
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September 2014
Rosemount 3051
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Product certifications
E8
(21)
ATEX Flameproof and Dust Certification
H
ATEX Intrinsic Safety and Dust
H
IA
ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocol only
H
N1
ATEX Type n Certification and Dust
H
K8
ATEX Flameproof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1)
H
E4(22)
TIIS Flame-proof
H
E5
FM Explosion-proof, Dust Ignition-Proof
H
I1
(23)
FM Intrinsically Safe, Nonincendive
H
IE
FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocol only
H
K5
FM Explosion-proof, Dust Ignition-Proof, Intrinsically Safe, and Division 2
H
C6
CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
H
I6(10)
CSA Intrinsic Safety
H
K6
CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1)
H
E7
IECEx Flameproof, Dust Ignition-proof
H
I7
IECEx Intrinsic Safety
H
N7
IECEx Type n Certification
H
K7
IECEx Flame-proof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7, and E7)
H
E2
INMETRO Flameproof
H
I2
INMETRO Intrinsic Safety
H
IB
INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
K2
INMETRO Flameproof, Intrinsic Safety
H
E3
China Flameproof
H
I3
China Intrinsic Safety
H
N3
China Type n
H
EM
Technical Regulations Customs Union (EAC) Flameproof
H
IM
Technical Regulations Customs Union (EAC) Intrinsic Safety
H
KM
Technical Regulations Customs Union (EAC) Flameproof and Intrinsic Safety
H
KB
FM and CSA Explosion-proof, Dust Ignition Proof, Intrinsically Safe, and Division 2 (combination of K5 and C6)
H
KD
FM, CSA, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8)
H
I5
Drinking water approval
DW(24)
NSF drinking water approval
H
Shipboard approvals
SBS(9)
American Bureau of Shipping
H
SBV(9)(25)
Bureau Veritas (BV)
H
SDN(9)
Det Norske Veritas
H
SLL(9)(25)
Lloyds Register (LR)
H
Custody transfer
C5(13)
Measurement Canada Accuracy Approval (limited availability depending on transmitter type and range;
contact an Emerson Process Management representative)
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H
7
Rosemount 3051
September 2014
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Bolting material
L4
Austenitic 316 SST Bolts
H
L5
ASTM A 193, Grade B7M Bolts
H
L6
Alloy K-500 Bolts
H
Display and interface options
M4(26)
LCD Display with Local Operator Interface
H
M5
LCD Display
H
Calibration certificate
Q4
Calibration Certificate
H
QG(27)
Calibration Certificate and GOST Verification Certificate
H
QP
Calibration certification and tamper evident seal
H
Material traceability certification
Q8
H
Material Traceability Certification per EN 10204 3.1
Quality certification for safety
QS(13)
Prior-use certificate of FMEDA data
H
QT(13)
Safety certified to IEC 61508 with certificate of FMEDA
H
Configuration buttons
D4(13)
Analog Zero and Span
H
DZ(28)
Digital Zero Trim
H
Transient protection
T1(9)(29)
H
Transient Protection Terminal Block
Software configuration
C1(28)
Custom Software Configuration (completed CDS 00806-0100-4007 for wired and 00806-0100-4100 for
Wireless required with order)
H
Low power output
C2
0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (available with Output code M only)
H
Gage pressure calibration
Gage Calibration (Model 3051CA4 only)
H
C4(13)
Analog Output Levels Compliant with NAMUR Recommendation NE 43, Alarm High
H
CN(13)
Analog Output Levels Compliant with NAMUR Recommendation NE 43, Alarm Low
H
CR(13)
Custom alarm and saturation signal levels, high alarm (requires C1 and Configuration Data Sheet)
H
CS(13)
Custom alarm and saturation signal levels, low alarm (requires C1 and Configuration Data Sheet)
H
CT(13)
Rosemount standard low alarm
H
C3
Alarm levels
Pressure testing
P1
8
Hydrostatic Testing with Certificate
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September 2014
Rosemount 3051
Table 1. 3051C Coplanar Pressure Transmitters Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Cleaning process area
P2
Cleaning for Special Service
P3
Cleaning for <1 PPM Chlorine/Fluorine
Flange adapters
DF(30)
1
/2 -14 NPT flange adapter(s)
H
Vent/drain valves
D7
Coplanar Flange Without Drain/Vent Ports
Conduit plug
DO(9)(31)
1
316 SST Conduit Plug
H
1
RC /4 RC /2 process connection
D9(32)
RC ¼ Flange with RC ½ Flange Adapter - SST
Max static line pressure
P9
4500 psig (310,26 bar) Static Pressure Limit (3051CD Ranges 2–5 only)
H
External Ground Screw Assembly
H
Surface finish certification for sanitary remote seals
H
Ground screw
V5(9)(33)
Surface finish
Q16
Toolkit total system performance reports
QZ
Remote Seal System Performance Calculation Report
H
Conduit electrical connector
GE(9)
M12, 4-pin, Male Connector (eurofast®)
H
GM(9)
A size Mini, 4-pin, Male Connector (minifast®)
H
NACE certificate
Q15(34)
Certificate of Compliance to NACE MR0175/ISO 15156 for wetted materials
H
Q25(34)
Certificate of Compliance to NACE MR0103 for wetted materials
H
Typical model number: 3051CD 2 A 2 2 A 1 A B4
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) If ordered with Wireless output code X, only Range 1-4, 316L SST diaphragm material (code 2), silicone fill fluid (code 1) and wireless housing (code P) are
available.
(3) 3051CD0 is only available with output code A and X. For output code A, only process flange code 0 (Alternate flange H2, H7, HJ or HK), isolating diaphragm code
2, O ring code A and bolting option L4 are available. For output code X, only process flange code 0 (Alternate flange H2), isolating diaphragm code 2, O ring code
A and bolting option L4 are available.
(4) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(5) For local addressing and configuration, M4 (Local Operator Interface) is required.
(6) Available approvals are FM Intrinsically Safe, (Option Code I5), CSA Intrinsically Safe (Option Code I6), ATEX Intrinsic Safety (Option Code I1), IECEx Intrinsic Safety
(Option Code I7) and EAC Intrinsic Safety (option code IM).
(7) Only available with C6, E2, E5, I5, K5, KB and E8 product certifications. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
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9
Rosemount 3051
September 2014
(8) Materials of Construction comply with recommendations per NACE MR0175/ISO 15156 for sour oil field production environments. Environmental limits apply to
certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(9) Not available with Wireless Output (code X).
(10) Only available with Wireless Output (code X).
(11) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(12) Only valid with FOUNDATION fieldbus Output Code F.
(13) Only available with HART 4-20 mA Output (code A).
(14) Requires 0 code in Materials of Construction for Alternate Process Connection.
(15) Not valid with Option Code P9 for 4500 psi Static Pressure.
(16) “Assemble-to” items are specified separately and require a completed model number.
(17) Process flange limited to Coplanar (Option Codes 2, 3, 5, 7, 8) or Traditional (Option Codes H2, H3, H7).
(18) Not valid with Option Code D9 for RC1/2 Adapters.
(19) Not valid for Option Codes DF and D9 for Adapters.
(20) Panel mounting bolts are not supplied.
(21) Dust approval not applicable to Output Code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals.
(22) Only available with output codes A - 4-20mA HART, F - FOUNDATION fieldbus, and W - PROFIBUS PA. Also only available with G1/2 housing thread types.
(23) Nonincendive certification not provided with Wireless output option code (X).
(24) Not available with Alloy C-276 isolator (code 3), tantalum isolator (code 5), all cast C-276 flanges, all plated CS flanges, all DIN flanges, all Level flanges,
assemble-to manifolds (codes S5 and S6), assemble-to seals (codes S1 and S2), assemble-to primary elements (codes S3 and S4), surface finish certification (code
Q16), and remote seal system report (code QZ).
(25) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7
(26) Not available with FOUNDATION fieldbus (Output Code F), Wireless (Output Code X), or Low Power Output (output code M).
(27) Contact an Emerson Process Management representative for availability.
(28) Only available with HART 4-20 mA Output (output code A) and Wireless Output (output code X)
(29) The T1 option is not needed with FISCO Product Certifications; transient protection is included in the FISCO product certification codes IA, IB, and IE.
(30) Not valid with Alternate Process Connection options S3, S4, S5, and S6.
(31) Transmitter is shipped with a 316 SST Conduit plug (uninstalled) in place of standard carbon steel conduit plug.
(32) Not available with Alternate Process Connection; DIN Flanges and Level Flanges.
(33) The V5 option is not needed with the T1 option; external ground screw assembly is included with the T1 option.
(34) NACE compliant wetted materials are identified by Footnote 8.
10
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September 2014
Rosemount 3051
Rosemount 3051T In-Line Pressure Transmitter
Rosemount 3051T In-Line Pressure Transmitters are the industry standard for Gage and
Absolute pressure measurement. The in-line, compact design allows the transmitter to
be connected directly to a process for quick, easy and cost effective installation.
Capabilities include:
 Power Advisory can proactively detect degraded electrical loop integrity issues
(Option Code DA0)
 Local Operator Interface with straightforward menus and built-in configuration
buttons (Option Code M4)
3051T In-Line
Pressure Transmitter
 Safety Certification (Option Code QT)
See “Specifications” on page 45 and options for more details on each configuration. Specification and selection of product materials,
options, or components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 2. 3051T In-Line Pressure Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model
Transmitter type
3051T(1)
In-Line Pressure Transmitter
Pressure type
G
A(2)
H
H
Gage
Absolute
Pressure range
1
2
3
4
5
Gage (3051TG)(3)
Absolute (3051TA)
-14.7 to 30 psi (-1,01 to 2,06 bar)
-14.7 to 150 psi (-1,01 to 10,34 bar)
-14.7 to 800 psi (-1,01 to 55,15 bar)
-14.7 to 4000 psi (-1,01 to 275,79 bar)
-14.7 to 10000 psi (-1,01 to 689,47 bar)
0 to 30 psia (0 to 2,06 bar)
0 to 150 psia (0 to 10,34 bar)
0 to 800 psia (0 to 55,15 bar)
0 to 4000 psia (0 to 275,79 bar)
0 to 10000 psia (0 to 689,47 bar)
H
H
H
H
H
Transmitter output
A(4)
F
W(5)
X(6)
M(7)
4–20 mA with Digital Signal Based on HART Protocol
FOUNDATION fieldbus Protocol
PROFIBUS PA Protocol
Wireless (requires wireless options and engineered polymer housing)
Low-Power 1-5 Vdc with Digital Signal Based on HART Protocol
H
H
H
H
Process connection style
2B
2C(8)
2F(9)
61(9)
1
/2–14 NPT Female
G½ A DIN 16288 Male (Range 1–4 only)
Coned and Threaded, Compatible with Autoclave Type F-250-C (Range 5 only)
Non-threaded Instrument flange (Range 1-4 only)
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H
H
11
Rosemount 3051
September 2014
Table 2. 3051T In-Line Pressure Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Isolating diaphragm
Process connection wetted parts material
2(10)
316L SST
Alloy C-276
3(10)
316L SST
Alloy C-276
H
H
Sensor fill fluid
1
2(9)
H
H
Silicone
Inert
Housing material
Conduit entry size
A
B
J
K
P(11)
D(12)
M(12)
½–14 NPT
M20 × 1.5
½–14 NPT
M20 × 1.5
No conduit entries
G½
G½
Aluminum
Aluminum
SST
SST
Engineered polymer
Aluminum
SST
H
H
H
H
H
Wireless options (requires wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3
H
User Configurable Transmit Rate, 2.4GHz WirelessHART
Antenna and SmartPower
WP5
Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately)
H
HART Revision configuration (requires HART Protocol Output Code A)
HR5(4)
HR7(4)
Configured for HART Revision 5
Configured for HART Revision 7
H
H
Options (include with selected model number)
Extended product warranty
WR3
WR5
3-year limited warranty
5-year limited warranty
H
H
PlantWeb control functionality
A01(13)
FOUNDATION fieldbus Control Function Block Suite
H
PlantWeb diagnostic functionality
DA0(22)
D01(13)
Power Advisory HART Diagnostic
FOUNDATION fieldbus Diagnostics Suite
H
H
Integral assembly
S5(14)
Assemble to Rosemount 306 Integral Manifold
H
Diaphragm seal assemblies
S1(14)
Assemble to one Rosemount 1199 seal
H
Mounting bracket(15)
B4
Bracket for 2-in. Pipe or Panel Mounting, All SST
H
Product certifications
E8
I1(16)
12
ATEX Flameproof and Dust Certification
ATEX Intrinsic Safety and Dust
H
H
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September 2014
Rosemount 3051
Table 2. 3051T In-Line Pressure Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
IA
N1
K8
E4(17)
E5
I5(18)
IE
K5
C6
I6(11)
K6
E7
I7
N7
K7
E2
I2
IB
K2
E3
I3
N3
EM
IM
KM
KB
KD
ATEX Intrinsic Safety for FISCO; for FOUNDATION fieldbus or PROFIBUS PA protocols only
ATEX Type n Certification and Dust
ATEX Flame-proof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1)
TIIS Flameproof
FM Explosion-proof, Dust Ignition-proof
FM Intrinsically Safe, Nonincendive
FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
FM Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
CSA Intrinsic Safety
CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1)
IECEx Flameproof, Dust Ignition-proof
IECEx Intrinsic Safety
IECEx Type n Certification
IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7, and E7)
INMETRO Flameproof
INMETRO Intrinsic Safety
INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
INMETRO Flameproof, Intrinsic Safety
China Flameproof
China Intrinsic Safety
China Type n
Technical Regulations Customs Union (EAC) Flameproof
Technical Regulations Customs Union (EAC) Intrinsic Safety
Technical Regulations Customs Union (EAC) Flameproof and Intrinsic Safety
FM and CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of K5 and C6)
FM, CSA, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8)
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
Drinking water approval
DW(19)
NSF drinking water approval
H
Shipboard approvals
SBS(9)
SBV(9)(20)
SDN(9)
SLL(9)(20)
American Bureau of Shipping
Bureau Veritas (BV)
Det Norske Veritas
Lloyds Register (LR)
H
H
H
H
Custody transfer
C5
Measurement Canada Accuracy Approval (Limited availability depending on transmitter type and range. Contact
an Emerson Process Management representative)
H
Calibration certification
Q4
QG(21)
QP
Calibration Certificate
Calibration Certificate and GOST Verification Certificate
Calibration Certification and tamper evident seal
H
H
H
Material traceability certification
Q8
Material Traceability Certification per EN 10204 3.1
H
Quality certification for safety
QS(22)
QT(22)
Prior-use certificate of FMEDA Data
Safety certified to IEC 61508 with certificate of FMEDA
www.rosemount.com
H
H
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September 2014
Table 2. 3051T In-Line Pressure Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Configuration buttons
D4(22)
DZ(23)
H
H
Analog Zero and Span
Digital Zero Trim
Display and interface options
M4(24)
M5
H
H
LCD Display with Local Operator Interface
LCD Display
Wireless SST sensor module
WSM(11)
Wireless SST Sensor Module
H
316 SST Conduit Plug
H
Conduit plug
DO(9)(25)
Transient terminal block
T1(9)(26)
H
Transient Protection Terminal Block
Software configuration
C1(23)
Custom Software Configuration (Completed CDS 00806-0100-4007 for wired and 00806-0100-4100 for
wireless required with order)
H
Low power output
C2
0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (Available with Output code M only)
Alarm levels
C4(22)
CN(22)
CR(22)
CS(22)
CT(22)
Analog Output Levels Compliant with NAMUR Recommendation NE 43, Alarm High
Analog Output Levels Compliant with NAMUR Recommendation NE 43, Low Alarm
Custom alarm and saturation signal levels, high alarm (requires C1 and Configuration Data Sheet)
Custom alarm and saturation signal levels, low alarm (requires C1 and Configuration Data Sheet)
Rosemount standard low alarm
H
H
H
H
H
Pressure testing
P1
Hydrostatic Testing with Certificate
Cleaning process area(27)
P2
P3
Cleaning for Special Service
Cleaning for <1 PPM Chlorine/Fluorine
Ground screw
V5(9)(28)
External Ground Screw Assembly
H
Surface finish
Q16
Surface finish certification for sanitary remote seals
H
Toolkit total system performance reports
QZ
Remote Seal System Performance Calculation Report
H
Conduit electrical connector
GE(9)
GM(9)
14
M12, 4-pin, Male Connector (eurofast)
A size Mini, 4-pin, Male Connector (minifast)
H
H
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September 2014
Rosemount 3051
Table 2. 3051T In-Line Pressure Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
NACE certificate
Q15(29)
Q25(29)
Certificate of Compliance to NACE MR0175/ISO15156 for wetted materials
Certificate of Compliance to NACE MR0103 for wetted materials
H
H
Typical model number: 3051T G 5 F 2A 2 1 A B4
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) Wireless Output (code X) only available in absolute measurement type (code A) in range 1-5 with 1/2 14 NPT process connection (code 2B), and polymer housing
(code P).
(3) 3051TG lower range limit varies with atmospheric pressure.
(4) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(5) For local addressing and configuration, M4 (Local Operator Interface) is required.
(6) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (Option Code I5), CSA Intrinsically Safe (Option Code I6),
ATEX Intrinsic Safety (Option Code I1), IECEx Intrinsic Safety (Option Code I7), and EAC Intrinsic Safety (Option Code IM).
(7) Only available with C6, E2, E5, I5, K5, KB and E8 product certifications. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(8) Wireless Output (code X) only available in G1/2 A DIN 16288 Male process connection (code 2C) with range 1-4, 316 SST isolating Diaphragm (code 2), Silicone
Fill Fluid (code 1) and Housing Code (code P).
(9) Not available with Wireless Output (output code X).
(10) Materials of Construction comply with recommendations per NACE MR0175/ISO 15156 for sour oil field production environments. Environmental limits apply to
certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(11) Only available with Wireless Output (output code X).
(12) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(13) Only valid with FOUNDATION fieldbus Output Code F.
(14) “Assemble-to” items are specified separately and require a completed model number.
(15) Panel mounting bolts are not supplied.
(16) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals.
(17) Only available with output codes A - 4-20mA HART, F - FOUNDATION fieldbus, and W - PROFIBUS PA. Also only available with G1/2 housing thread types.
(18) Nonincendive certification not provided with Wireless output option code (X).
(19) Not available with Alloy C-276 isolator (option code 3), Assemble-to manifolds (option code S5), assemble-to seals (option code S1), surface finish certification
(option code Q16), and remote seal system report (option code QZ).
(20) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7.
(21) Contact an Emerson Process Management representative for availability.
(22) Only available with HART 4-20 mA output (output code A).
(23) Only available with HART 4-20 mA output (output code A) and Wireless output (output code X).
(24) Not available with FOUNDATION fieldbus (output code F) and Wireless output (output code X) or Low Power (output code M).
(25) Transmitter is shipped with 316 SST conduit plug (uninstalled) in place of standard carbon steel conduit plug.
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Rosemount 3051
September 2014
(26) The T1 option is not needed with FISCO Product Certifications; transient protection is included in the FISCO product certification codes IA, IB, and IE.
(27) Not valid with Alternate Process Connection S5.
(28) The V5 option is not needed with T1 option; external ground screw assembly is included with the T1 option.
(29) NACE compliant wetted materials are identified by Footnote 10.
16
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September 2014
Rosemount 3051
Rosemount 3051CF Flowmeter Selection Guide
Rosemount 3051CF Flowmeters combine the proven Rosemount 3051 Pressure Transmitter and the latest primary element
technologies. All flowmeters are fully assembled, calibrated, configured, and leak tested for out-of-the-box installation and are
available with wired or wireless capabilities to meet all of your application needs.
Rosemount 3051CFA Annubar Flowmeter
Rosemount Annubar technology minimizes permanent pressure loss
while delivering best in class accuracy.
 Lowest material costs for large line sizes
 Flo-tap enables installation without process shutdown
 Realize up to 96% less permanent pressure loss compared to
traditional orifice plate installations
Rosemount 3051CFC Compact Conditioning Flowmeter
Rosemount Compact Conditioning technologies provide
unprecedented performance with minimal straight-run requirements.
Solutions include Conditioning Orifice Plate or Annubar primary
elements.
 Conditioning Orifice requires only 2 pipe diameters up and
downstream
 Eliminate swirl and regular profiles resulting in more stable and
accurate flow measurement
 Savings up to 55% when compared to a traditional orifice plate
installation can be realized
Rosemount 3051CFP Integral Orifice Flowmeter
Rosemount Integral Orifice Flowmeters deliver highly accurate
small-bore flow measurement capability with minimal installation and
maintenance requirements.
 Best performance for small line sizes 1/2” (15 mm) to 11/2” (40 mm)
 Precision honed pipe section and tight machining tolerances deliver
higher installed performance
 Reduces uncertainty by up to 5% compared to traditional orifice plate
installation
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Rosemount 3051
September 2014
Rosemount 3051CFA Annubar Flowmeter
The Rosemount 3051CFA Annubar Flowmeter utilizes the T-shaped sensor design that
delivers best in class accuracy and performance while meeting the needs of diverse
process applications, whether it is high accuracy for precision control or high strength
for severe flow applications. Main capabilities include:

Up to 1.8% of flow rate accuracy

Available in 2 to 96-in. (50 - 2400 mm) line sizes

Fully assembled and leak tested for out-of-the-box installation

Power Advisory can proactively detect degraded electrical loop integrity issues
(Option Code DA0)

Local Operator Interface with straightforward menus and built-in configuration
buttons (Option Code M4)
See “Specifications” on page 45 and options for more details on each configuration. Specification and selection of product materials,
options, or components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model
Product description
3051CFA(1)
Annubar Flowmeter
Measurement type
Differential Pressure
H
L
Liquid
H
G
Gas
H
S
Steam
H
2-in. (50 mm)
H
D
Fluid type
Line size
020
1
025
2 /2-in. (63.5 mm)
H
030
3-in. (80 mm)
H
035
31/2-in. (89 mm)
H
040
4-in. (100 mm)
H
050
5-in. (125 mm)
H
060
6-in. (150 mm)
H
070
7-in. (175 mm)
H
080
8-in. (200 mm)
H
100
10-in. (250 mm)
H
120
12-in. (300 mm)
H
140
14-in. (350 mm)
18
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September 2014
Rosemount 3051
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
160
16-in. (400 mm)
180
18-in. (450 mm)
200
20-in. (500 mm)
240
24-in. (600 mm)
300
30-in. (750 mm)
360
36-in. (900 mm)
420
42-in. (1066 mm)
480
48-in. (1210 mm)
600
60-in. (1520 mm)
720
72-in. (1820 mm)
780
78-in (1950 mm)
840
84-in. (2100 mm)
900
90-in. (2250 mm)
960
96-in (2400 mm)
Pipe I.D. range
C
Range C from the Pipe I.D. Range Codes table
H
D
Range D from the Pipe I.D. Range Codes table
H
A
Range A from the Pipe I.D. Range Codes table
B
Range B from the Pipe I.D. Range Codes table
E
Range E from the Pipe I.D. Range Codes table
Z
Non-standard Pipe I.D. Range Codes or Line Sizes greater than 12 inches
Pipe material/mounting assembly material
C
Carbon steel (A105)
H
S
316 Stainless Steel
H
0
No Mounting (customer supplied)
H
G
Chrome-Moly Grade F-11
N
Chrome-Moly Grade F-22
J
Chrome-Moly Grade F-91
Piping orientation
H
Horizontal Piping
H
D
Vertical Piping with Downwards Flow
H
U
Vertical Piping with Upwards Flow
H
Annubar type
P
Pak-Lok
H
F
Flanged with opposite side support
H
L
Flange-Lok
G
Gear-Drive Flo-Tap
M
Manual Flo-Tap
Sensor material
S
316 Stainless Steel
H
Alloy C-276
www.rosemount.com
H
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Rosemount 3051
September 2014
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Sensor size
1
Sensor size 1 — Line sizes 2-in. (50 mm) to 8-in. (200 mm)
H
2
Sensor size 2 — Line sizes 6-in. (150 mm) to 96-in. (2400 mm)
H
3
Sensor size 3 — Line sizes greater than 12-in. (300 mm)
H
Mounting type
T1
Compression or Threaded Connection
H
A1
150# RF ANSI
H
A3
300# RF ANSI
H
A6
600# RF ANSI
H
D1
DN PN16 Flange
H
D3
DN PN40 Flange
H
D6
DN PN100 Flange
H
A9(2)
900# RF ANSI
AF(2)
1500# RF ANSI
AT(2)
2500 # RF ANSI
R1
150# RTJ Flange
R3
300# RTJ Flange
R6
600# RTJ Flange
R9(2)
900# RTJ Flange
RF(2)
1500# RTJ Flange
RT(2)
2500# RTJ Flange
Opposite side support or packing gland
0
H
No opposite side support or packing gland (required for Pak-Lok and Flange-Lok models)
Opposite Side Support – Required for Flanged Models
C
NPT Threaded Opposite Support Assembly – Extended Tip
H
D
Welded Opposite Support Assembly – Extended Tip
H
Packing Gland – Required for Flo-Tap Models
Packing Gland Material
Rod Material
Packing Material
(3)
Stainless Steel Packing Gland/Cage Nipple
Carbon Steel
PTFE
K(3)
Stainless Steel Packing Gland/Cage Nipple
Stainless Steel
PTFE
L(3)
Stainless Steel Packing Gland/Cage Nipple
Carbon Steel
Graphite
N(3)
Stainless Steel Packing Gland/Cage Nipple
Stainless Steel
Graphite
R
Alloy C-276 Packing Gland/Cage Nipple
Stainless Steel
Graphite
J
Isolation valve for Flo-Tap models
0
Not Applicable or Customer Supplied
1
Gate Valve, Carbon Steel
2
Gate Valve, Stainless Steel
5
Ball Valve, Carbon Steel
6
Ball Valve, Stainless Steel
H
Temperature measurement
T
Integral RTD – not available with Flanged model greater than class 600#
H
0
No Temperature Sensor
H
R
Remote Thermowell and RTD
20
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September 2014
Rosemount 3051
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Transmitter connection platform
3
Direct-mount, Integral 3-valve Manifold– not available with Flanged model greater than class 600
H
5
Direct -mount, 5-valve Manifold – not available with Flanged model greater than class 600
H
1
H
7
Remote-mount NPT Connections ( /2-in. NPT)
6
Direct-mount, high temperature 5-valve Manifold – not available with Flanged model greater than class 600
8
Remote-mount SW Connections (1/2-in.)
Differential pressure range
1
0 to 25 in H2O (0 to 62,16 mbar)
H
2
0 to 250 in H2O (0 to 621,60 mbar)
H
3
0 to 1000 in H2O (0 to 2,48 bar)
H
Transmitter output
A(4)
4–20 mA with digital signal based on HART Protocol
H
F
FOUNDATION fieldbus Protocol
H
W(5)
PROFIBUS PA Protocol
H
X(6)
Wireless (Requires wireless options and engineered polymer housing)
H
M(7)
Low-Power 1-5 Vdc with Digital Signal Based on HART Protocol
Transmitter housing material
Conduit entry size
A
Aluminum
1
/2-14 NPT
H
B
Aluminum
M20 x 1.5
H
J
SST
1/2-14 NPT
H
K
SST
M20 x 1.5
H
P(8)
Engineered polymer
No conduit entries
H
D(9)
Aluminum
G1/2
M(9)
SST
G1/2
Transmitter performance class
1
1.8% flow rate accuracy, 8:1 flow turndown, 5-yr. stability
H
Wireless options (requires Wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3
User Configurable Transmit Rate, 2.4GHz WirelessHART
H
Antenna and SmartPower
WP5
Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately)
H
HART Revision configuration (requires HART Protocol Output Code A)
HR5(4)
Configured for HART Revision 5
H
HR7(4)
Configured for HART Revision 7
H
Options (include with selected model number)
Extended product warranty
WR3
3-year limited warranty
H
WR5
5-year limited warranty
H
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Rosemount 3051
September 2014
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Pressure testing
P1(10)
Hydrostatic Testing with Certificate
PX(10)
Extended Hydrostatic Testing
Special cleaning
P2
Cleaning for Special Services
PA
Cleaning per ASTM G93 Level D (Section 11.4)
Material testing
V1
Dye Penetrant Exam
Material examination
V2
Radiographic Examination
Flow calibration
W1
Flow Calibration (Average K)
Special inspection
QC1
Visual & Dimensional Inspection with Certificate
H
QC7
Inspection & Performance Certificate
H
Surface finish
RL
Surface finish for Low Pipe Reynolds # in Gas & Steam
H
RH
Surface finish for High Pipe Reynolds # in Liquid
H
Material traceability certification
Q8(11)
Material Traceability Certification per EN 10474:2004 3.1
Code conformance
H
(12)
J2
ANSI/ASME B31.1
J3
ANSI/ASME B31.3
Materials conformance
J5(13)
NACE MR-0175 / ISO 15156
Country certification
J6
European Pressure Directive (PED)
J1
Canadian Registration
H
Installed in flanged pipe spool section
H3
150# Flanged Connection with Rosemount Standard Length and Schedule
H4
300# Flanged Connection with Rosemount Standard Length and Schedule
H5
600# Flanged Connection with Rosemount Standard Length and Schedule
Instrument connections for remote mount options
G2
Needle Valves, Stainless Steel
H
G6
OS&Y Gate Valve, Stainless Steel
H
G1
Needle Valves, Carbon Steel
G3
Needle Valves, Alloy C-276
G5
OS&Y Gate Valve, Carbon Steel
G7
OS&Y Gate Valve, Alloy C-276
22
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Rosemount 3051
Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Special shipment
Y1
Mounting Hardware Shipped Separately
H
Special dimensions
VM
Variable Mounting
VT
Variable Tip
VS
Variable length Spool Section
PlantWeb control functionality
A01(14)
FOUNDATION fieldbus Control Function Block Suite
H
PlantWeb diagnostic functionality
DA0(15)
Power Advisory HART Diagnostic
H
D01(14)
FOUNDATION fieldbus Diagnostics Suite
H
Product certifications
E8
ATEX Flameproof, Dust
H
I1(16)
ATEX Intrinsic Safety and Dust
H
IA
ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
N1
ATEX Type n and Dust
H
K8
ATEX Flameproof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1)
H
E5
FM Explosion-proof, Dust Ignition-proof
H
I5(17)
FM Intrinsically Safe, Nonincendive
H
IE
FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
K5
FM Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of E5 and I5)
H
C6
CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
H
I6 (8)
CSA Intrinsically Safe
H
K6
CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1)
H
E7
IECEx Flameproof, Dust Ignition-proof
H
I7
IECEx Intrinsic Safety
H
N7
IECEx Type n
H
K7
IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7 and E7)
H
E2
INMETRO Flameproof
H
I2
INMETRO Intrinsic Safety
H
IB
INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
K2
INMETRO Flameproof, Intrinsic Safety
H
E3
China Flameproof
H
I3
China Intrinsic Safety
H
KB
FM and CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of K5 and C6)
H
KD
CSA, FM, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8)
H
Sensor fill fluid and O-ring options
L1(18)
Inert Sensor Fill Fluid Note: Silicone fill fluid is standard.
H
L2
Graphite-Filled (PTFE) O-ring
H
LA(18)
Inert Sensor Fill Fluid and Graphite-Filled (PTFE) O-ring
H
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Table 3. Rosemount 3051CFA Annubar Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Shipboard approvals
SBS(18)
American Bureau of Shipping
SLL(18)(19)
Lloyds Register (LR)
H
Display and interface options
M4(20)
LCD Display with Local Operator Interface
H
M5
LCD Display
H
Transmitter calibration certification
Q4
H
Calibration Certificate for Transmitter
Quality certification for safety
QS(15)
Prior-use certificate of FMEDA data
H
QT(15)
Safety certified to IEC 61508 with certificate of FMEDA
H
Transient protection
T1(18)(21)
H
Transient terminal block
Manifold for remote mount option
F2
3-Valve Manifold, Stainless Steel
H
F6
5-Valve Manifold, Stainless Steel
H
F1
3-Valve Manifold, Carbon Steel
F3
3-Valve Manifold, Alloy C-276
F5
5-Valve Manifold, Carbon Steel
F7
5-Valve Manifold, Alloy C-276
Lower power output
C2
0.8-3.2 Vdc Output with Digital Signal based on HART Protocol (Available with Output code M only)
Alarm levels
C4(15)
NAMUR Alarm and Saturation Levels, High Alarm
H
CN(15)
NAMUR Alarm and Saturation Levels, Low Alarm
H
CR(15)
Custom alarm and saturation signal levels, high alarm
H
CS(15)
Custom alarm and saturation signal levels, low alarm
H
CT(15)
Rosemount Standard low alarm
H
Configuration buttons
D4(15)
Analog Zero and Span
H
DZ(22)
Digital Zero Trim
H
Ground screw
V5(18)(23)
H
External Ground Screw Assembly
Typical model number:
3051CFA
D
L
060
D
C
H
P
S
2
T1
0
0
0
3
2
A
A
1
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) Available in remote mount applications only.
(3) The cage nipple is constructed of 304 SST.
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September 2014
Rosemount 3051
(4) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(5) For local addressing and configuration, M4 (Local Operator Interface) is required.
(6) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (option code I5), CSA Intrinsically Safe (option code I6),
ATEX Intrinsic Safety (option code I1), and IECEx Intrinsic Safety (option code I7).
(7) Only available with C6, E2, E5, I5, K5, KB and E8 approval. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(8) Only available with Wireless Output (output code X).
(9) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(10) Applies to assembled flowmeter only, mounting not tested.
(11) Instrument Connections for Remote Mount Options and Isolation Valves for Flo-tap Models are not included in the Material Traceability Certification.
(12) Not available with Transmitter Connection Platform 6.
(13) Materials of Construction comply with metallurgical requirements within NACE MR0175/ISO for sour oil field production environments. Environmental limits
apply to certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(14) Only valid with FOUNDATION fieldbus output (output code F).
(15) Only available with 4-20 mA HART Output (output Code A).
(16) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals
(17) Nonincendive certification not provided with Wireless output option code (X).
(18) Not available with Wireless Output (output code X).
(19) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7
(20) Not available with FOUNDATION Fieldbus (Output Code F) or Wireless Output (output code X) or Low Power (output code M).
(21) The T1 option is not needed with FISCO Product Certifications, transient protection is included with the FISCO Product Certification codes IA, IB, and IE.
(22) Only available with 4-20 mA HART Output (output code A) and Wireless output (Output Code X).
(23) The V5 option is not needed with the T1 option; external ground screw assembly is included with the T1 option.
www.rosemount.com
25
Rosemount 3051
September 2014
Rosemount 3051CFC Compact Flowmeter
Rosemount 3051CFC Compact Flowmeters provide a quick, reliable installation
between existing raised face flanges. Depending on your application needs, you can
reduce energy loss with the Compact Annubar or minimize straight run requirements
with the Conditioning Orifice.

Up to 1.8% of flow rate accuracy

Available in 1/2 to 12-in. (15 - 300 mm) line sizes

Fully assembled and leak tested for out-of-the-box installation

Power Advisory can proactively detect degraded electrical loop integrity issues.
(Option Code DA0)

Local Operator Interface with straightforward menus and built-in configuration
buttons (Option Code M4)
See “Specifications” on page 45 and options for more details on each configuration. Specification and selection of product materials,
options, or components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 4. Rosemount 3051CFC Compact Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model
Product description
3051CFC(1)
Compact Flowmeter
Measurement type
D
Differential Pressure
H
Primary element technology
A
C
P
Annubar Averaging Pitot Tube
Conditioning Orifice Plate
Orifice Plate
H
H
H
Material type
S
316 SST
H
1/2-in. (15 mm)
H
H
H
H
H
H
H
H
H
H
Line size
005(2)
010(2)
015(2)
020
030
040
060
080
100(3)
120(3)
26
1-in. (25 mm)
11/2-in. (40 mm)
2-in. (50 mm)
3-in. (80 mm)
4-in. (100 mm)
6-in. (150 mm)
8-in. (200 mm)
10-in. (250 mm)
12-in. (300 mm)
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September 2014
Rosemount 3051
Table 4. Rosemount 3051CFC Compact Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Primary element type
N000
N040
N050
N065(4)
H
H
Annubar Sensor Size 1
0.40 Beta Ratio
0.50 Beta Ratio
0.65 Beta Ratio
H
Temperature measurement
0
R
H
No Temperature Sensor
Remote Thermowell and RTD
Transmitter connection platform
3
7
H
H
Direct-mount
Remote-mount, NPT Connections
Differential pressure range
1
2
3
H
H
H
0 to 25 in H2O (0 to 62,16 mbar)
0 to 250 in H2O (0 to 621,60 mbar)
0 to 1000 in H2O (0 to 2,48 bar)
Transmitter output
A(5)
F
W(6)
X(7)
M(8)
4–20 mA with digital signal based on HART Protocol
FOUNDATION fieldbus Protocol
PROFIBUS PA Protocol
Wireless (Requires wireless options and engineered polymer housing)
Low-Power 1-5 Vdc with Digital Signal Based on HART Protocol
Transmitter housing material
Conduit entry size
A
B
J
K
P(9)
D(10)
M(10)
1
Aluminum
Aluminum
SST
SST
Engineered polymer
Aluminum
SST
/2-14 NPT
M20 x 1.5
1
/2-14 NPT
M20 x 1.5
No conduit entries
G1/2
G1/2
H
H
H
H
H
H
H
H
H
Transmitter performance class
1
Up to ±1.65% flow rate accuracy, 8:1 flow turndown, 5-year stability
H
Wireless options (requires Wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3
User Configurable Transmit Rate, 2.4GHz WirelessHART
H
Antenna and SmartPower
WP5
Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately)
H
HART Revision Configuration (requires HART Protocol Output Code A)
HR5(5)
HR7(5)
Configured for HART Revision 5
Configured for HART Revision 7
H
H
Options (include with selected model number)
Extended product warranty
WR3
WR5
3-year limited warranty
5-year limited warranty
www.rosemount.com
H
H
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Rosemount 3051
September 2014
Table 4. Rosemount 3051CFC Compact Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Installation accessories
AB
AC
AD
DG
DH
DJ
JB
JR
JS
ANSI Alignment Ring (150#) (Only required for 10-in. (250 mm) and 12-in. (300mm) line sizes)
ANSI Alignment Ring (300#) (Only required for 10-in. (250 mm) and 12-in. (300mm) line sizes)
ANSI Alignment Ring (600#) (Only required for 10-in. (250 mm) and 12-in. (300mm) line sizes)
DIN Alignment Ring (PN16)
DIN Alignment Ring (PN40)
DIN Alignment Ring (PN100)
JIS Alignment Ring (10K)
JIS Alignment Ring (20K)
JIS Alignment Ring (40K)
H
H
H
H
H
H
Remote adapters
FE
H
Flange Adapters 316 SST (1/2-in NPT)
High temperature application
HT
Graphite Valve Packing (Tmax = 850 °F)
Flow calibration
WC(11)
WD(11)(12)
Flow Calibration, 3 pt, Conditioning Orifice Option C (all pipe schedules)
Flow Calibration, 10 pt, Conditioning Option C (All Schedules), Annubar Option A (Schedule 40)
Pressure testing
P1
Hydrostatic Testing with Certificate
Special cleaning
P2(13)
PA
Cleaning for Special Services
Cleaning per ASTM G93 Level D (Section 11.4)
Special inspection
QC1
QC7
Visual & Dimensional Inspection with Certificate
Inspection and Performance Certificate
H
H
Transmitter calibration certification
Q4
Calibration Certificate for Transmitter
H
Quality certification for safety
QS(14)
QT(14)
Prior-use certificate of FMEDA data
Safety certified to IEC 61508 with certificate of FMEDA
H
H
Material traceability certification
Q8
Material Traceability Certification per EN 10204:2004 3.1
H
Code conformance
J2
J3
J4
ANSI/ASME B31.1
ANSI/ASME B31.3
ANSI/ASME B31.8
Materials conformance
J5(15)
NACE MR-0175 / ISO 15156
Country certification
J1
Canadian Registration
Product certifications
E8
I1(16)
28
ATEX Flameproof, Dust
ATEX Intrinsic Safety and Dust
H
H
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September 2014
Rosemount 3051
Table 4. Rosemount 3051CFC Compact Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
IA
N1
K8
E5
I5(17)
IE
K5
C6
I6(9)
K6
E7
I7
N7
K7
E2
I2
IB
K2
E3
I3
KB
KD
ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocols only
ATEX Type n and Dust
ATEX Flameproof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1)
FM Explosion-proof, Dust Ignition-proof
FM Intrinsically Safe, Nonincendive
FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
FM Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of E5 and I5)
CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
CSA Intrinsically Safe
CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1)
IECEx Flameproof, Dust Ignition-proof
IECEx Intrinsic Safety
IECEx Type n
IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7 and E7)
INMETRO Flameproof
INMETRO Intrinsic Safety
INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
INMETRO Flameproof, Intrinsic Safety
China Flameproof
China Intrinsic Safety
FM and CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of K5 and C6)
CSA, FM, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8)
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
Sensor fill fluid and O-ring options
L1(18)
L2
LA(18)
Inert Sensor Fill Fluid
Graphite-Filled (PTFE) O-ring
Inert Sensor Fill Fluid and Graphite-Filled (PTFE) O-ring
H
H
H
Shipboard approvals
SBS(18)
SLL(18)(19)
American Bureau of Shipping
Lloyds Register (LR)
H
Display and interface options
M4(20)
M5
LCD Display with Local Operator Interface
LCD Display
H
H
Transient protection
T1(18)(21)
Transient terminal block
H
Manifold for remote mount option
F2
F6
3-Valve Manifold, Stainless Steel
5-Valve Manifold, Stainless Steel
H
H
PlantWeb control functionality
A01(22)
FOUNDATION fieldbus Control Function Block Suite
H
PlantWeb diagnostic functionality
DA0(14)
D01(22)
Power Advisory HART Diagnostic
FOUNDATION fieldbus Diagnostic Suite
H
H
Low power output
C2
0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (available with Output code M only)
www.rosemount.com
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Rosemount 3051
September 2014
Table 4. Rosemount 3051CFC Compact Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Alarm levels
C4(14)
CN(14)
CR(14)
CS(14)
CT(14)
H
H
H
H
H
NAMUR Alarm and Saturation Levels, High Alarm
NAMUR Alarm and Saturation Levels, Low Alarm
Custom alarm and saturation signal levels, high alarm
Custom alarm and saturation signal levels, low alarm
Rosemount Standard low alarm
Ground screw
V5(18)(23)
H
External Ground Screw Assembly
Configuration buttons
D4(14)
DZ(24)
H
H
Analog Zero and Span
Digital Zero Trim
Typical model number:
3051CFC D C S 060 N 065 0 3 2 A A 1 WC E5 M5
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) Available with Primary Element Technology P only.
(3) 10-in. (250 mm) and 12-in. (300 mm) line sizes not available with Primary Element Technology A.
(4) For 2-in. (50 mm) line sizes the Primary Element Type is 0.6 for Primary Element Technology Code C.
(5) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(6) For local addressing and configuration, M4 (Local Operator Interface) is required.
(7) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (option code I5), CSA Intrinsically Safe (option code I6),
ATEX Intrinsic Safety (option code I1), and IECEx Intrinsic Safety (option code I7).
(8) Only available with C6, E2, E5, I5, K5, KB and E8 approval. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(9) Only available with Wireless Output (output code X).
(10) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(11) Available with Primary Element Technology C only.
(12) For Annubar option A, consult factory for pipe schedules other than schedule 40.
(13) Available with Primary Element Technology C or P only.
(14) Only available with HART 4-20 mA Output (output code A).
(15) Materials of Construction comply with metallurgical requirements within NACE MR0175/ISO for sour oil field production environments. Environmental limits
apply to certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(16) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals
(17) Nonincendive certification not provided with Wireless output option code (X).
(18) Not available with Wireless output (output code X).
(19) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7
(20) Not available with output code F - FOUNDATION fieldbus or Wireless output (output code X) or Low Power (output code M).
(21) The T1 option is not needed with FISCO Product Certifications, transient protection is included with the FISCO Product Certification code IA, IB, and IE.
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Rosemount 3051
(22) Only valid with FOUNDATION fieldbus (output code F).
(23) The V5 option is not needed with the T1 option; external ground screw assembly is included with the T1 option.
(24) Only available with 4-20 mA HART Output (output code A) and Wireless output (output code X).
www.rosemount.com
31
Rosemount 3051
September 2014
Rosemount 3051CFP Integral Orifice Flowmeter
Rosemount 3051CFP Integral Orifice Flowmeters enable highly accurate flow
measurement in small line sizes. Integral Orifice utilize precision honed pipe section
for increased accuracy and self-centering plate design to prevent alignment errors
that magnify measurement inaccuracies in small line sizes.

Up to 1.75% of flow rate accuracy

Available in 1/2 to 11/2-in. (15 - 40 mm) line sizes

Fully assembled and leak tested for out-of-the-box installation

Power Advisory can proactively detect degraded electrical loop integrity issues.
(Option Code DA0)

Local Operator Interface with straightforward menus and built-in configuration
buttons (Option Code M4)
See “Specifications” on page 45 and options for more details on each configuration. Specification and selection of product materials,
options, or components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 5. Rosemount 3051CFP Integral Orifice Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model
Product description
3051CFP(1)
Integral Orifice Flowmeter
Measurement type
D
Differential Pressure
H
Body material
S
316 SST
H
1
H
H
H
Line size
005
010
015
/2-in. (15 mm)
1-in. (25 mm)
11/2-in. (40 mm)
Process connection
T1
S1(2)
P1
P2
D1
D2
D3
W1
W3
W6
A1
32
NPT Female Body (Not Available with Remote Thermowell and RTD)
Socket Weld Body (Not Available with Remote Thermowell and RTD)
Pipe Ends: NPT Threaded
Pipe ends: Beveled
Pipe Ends: Flanged, DIN PN16, slip-on
Pipe Ends: Flanged, DIN PN40, slip-on
Pipe Ends: Flanged, DIN PN100, slip-on
Pipe Ends: Flanged, RF, ANSI Class 150, weld-neck
Pipe Ends: Flanged, RF, ANSI Class 300, weld-neck
Pipe Ends: Flanged, RF, ANSI Class 600, weld-neck
Pipe Ends: Flanged, RF, ANSI Class 150, slip-on
H
H
H
H
H
H
H
H
H
H
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September 2014
Rosemount 3051
Table 5. Rosemount 3051CFP Integral Orifice Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
A3
A6
R1
R3
R6
Pipe Ends: Flanged, RF, ANSI Class 300, slip-on
Pipe Ends: Flanged, RF, ANSI Class 600, slip-on
Pipe Ends: Flanged, RTJ, ANSI Class 150, slip-on
Pipe Ends: Flanged, RTJ, ANSI Class 300, slip-on
Pipe Ends: Flanged, RTJ, ANSI Class 600, slip-on
Orifice plate material
S
H
M
316 SST
Alloy C-276
Alloy 400
H
Bore size option
0066
0109
0160
0196
0260
0340
0150
0250
0345
0500
0630
0800
0295
0376
0512
0748
1022
1184
0010
0014
0020
0034
0.066-in. (1.68 mm) for 1/2-in. Pipe
0.109-in. (2.77 mm) for 1/2-in. Pipe
0.160-in. (4.06 mm) for 1/2-in. Pipe
0.196-in. (4.98 mm) for 1/2-in. Pipe
0.260-in. (6.60 mm) for 1/2-in. Pipe
0.340-in. (8.64 mm) for 1/2-in. Pipe
0.150-in. (3.81 mm) for 1-in. Pipe
0.250-in. (6.35 mm) for 1-in. Pipe
0.345-in. (8.76 mm) for 1-in. Pipe
0.500-in. (12.70 mm) for 1-in. Pipe
0.630-in. (16.00 mm) for 1-in. Pipe
0.800-in. (20.32 mm) for 1-in. Pipe
0.295-in. (7.49 mm) for 1 1/2-in. Pipe
0.376-in. (9.55 mm) for 1 1/2-in. Pipe
0.512-in. (13.00 mm) for 1 1/2-in. Pipe
0.748-in. (19.00 mm) for 1 1/2-in. Pipe
1.022-in. (25.96 mm) for 1 1/2-in. Pipe
1.184-in. (30.07 mm) for 1 1/2-in. Pipe
0.010-in. (0.25 mm) for 1/2-in. Pipe
0.014-in. (0.36 mm) for 1/2-in. Pipe
0.020-in. (0.51 mm) for 1/2-in. Pipe
0.034-in. (0.86 mm) for 1/2-in. Pipe
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
Transmitter connection platform
D3
D5
R3
R5
D4
D6
D7
R4
R6
Direct-mount, 3-Valve Manifold, SST
Direct-mount, 5-Valve Manifold, SST
Remote-mount, 3-Valve Manifold, SST
Remote-mount, 5-Valve Manifold, SST
Direct-mount, 3-Valve Manifold, Alloy C-276
Direct-mount, 5-Valve Manifold, Alloy C-276
Direct-mount, High Temperature, 5-Valve Manifold, SST
Remote-mount, 3-Valve Manifold, Alloy C-276
Remote-mount, 5-Valve Manifold, Alloy C-276
H
H
H
H
Differential pressure ranges
1
2
3
0 to 25 in H2O (0 to 62,16 mbar)
0 to 250 in H2O (0 to 621,60 mbar)
0 to 1000 in H2O (0 to 2,48 bar)
www.rosemount.com
H
H
H
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Rosemount 3051
September 2014
Table 5. Rosemount 3051CFP Integral Orifice Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Transmitter output
A(3)
F
W(4)
X(5)
M(6)
H
H
H
H
4–20 mA with digital signal based on HART Protocol
FOUNDATION fieldbus Protocol
PROFIBUS PA Protocol
Wireless
Low-Power 1-5 Vdc with Digital Signal Based on HART Protocol
Transmitter housing material
Conduit entry size
A
B
J
K
P(7)
D(8)
M(8)
1
Aluminum
Aluminum
SST
SST
Engineered polymer
Aluminum
SST
H
H
H
H
H
/2-14 NPT
M20 x 1.5
1
/2-14 NPT
M20 x 1.5
No conduit entries
G1/2
G1/2
Transmitter performance class
1
H
up to ±1.8% flow rate accuracy, 8:1 flow turndown, 5-year stability
Wireless options (requires Wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3
H
User Configurable Transmit Rate, 2.4GHz WirelessHART
Antenna and SmartPower
WP5
Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately)
H
HART revision configuration (requires HART Protocol Output Code A)
HR5(3)
HR7(3)
Configured for HART Revision 5
Configured for HART Revision 7
H
H
Options (include with selected model number)
Extended product warranty
WR3
WR5
3-year limited warranty
5-year limited warranty
H
H
Transmitter body/bolt material
GT
High Temperature (850 °F / 454 °C)
Temperature sensor
RT(9)
Thermowell and RTD
Optional connection
G1
DIN 19213 Transmitter Connection
H
Pressure testing
P1(10)
Hydrostatic Testing with Certificate
Special cleaning
P2
PA
Cleaning for Special Services
Cleaning per ASTM G93 Level D (Section 11.4)
Material testing
V1
34
Dye Penetrant Exam
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September 2014
Rosemount 3051
Table 5. Rosemount 3051CFP Integral Orifice Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Material examination
V2
Radiographic Examination
Flow calibration
WD(11)
Discharge Coefficient Verification
Special inspection
QC1
QC7
Visual & Dimensional Inspection with Certificate
Inspection and Performance Certificate
H
H
Material traceability certification
Q8
Material Traceability Certification per EN 10204:2004 3.1
H
Code conformance
J2(12)
J3(12)
J4(12)
ANSI/ASME B31.1
ANSI/ASME B31.3
ANSI/ASME B31.8
Materials conformance
J5(13)
NACE MR-0175 / ISO 15156
Country certification
J6
J1
European Pressure Directive (PED)
Canadian Registration
H
Transmitter calibration certification
Q4
Calibration Certificate for Transmitter
H
Quality certification for safety
QS(14)
QT(14)
Prior-use certificate of FMEDA data
Safety certified to IEC 61508 with certificate of FMEDA
H
H
Product certifications
E8
I1(15)
IA
N1
K8
E5
I5(16)
IE
K5
C6
I6(7)
K6
E7
I7
N7
K7
E2
I2
IB
K2
ATEX Flameproof, Dust
ATEX Intrinsic Safety and Dust
ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocols only
ATEX Type n and Dust
ATEX Flameproof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1)
FM Explosion-proof, Dust Ignition-proof
FM Intrinsically Safe, Nonincendive
FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
FM Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of E5 and I5)
CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
CSA Intrinsically Safe
CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1)
IECEx Flameproof, Dust Ignition-proof
IECEx Intrinsic Safety
IECEx Type n
IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7 and E7)
INMETRO Flameproof
INMETRO Intrinsic Safety
INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
INMETRO Flameproof, Intrinsic Safety
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H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
35
Rosemount 3051
September 2014
Table 5. Rosemount 3051CFP Integral Orifice Flowmeter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
E3
I3
KB
KD
China Flameproof
China Intrinsic Safety
FM and CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2 (combination of K5 and C6)
CSA, FM, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8)
H
H
H
H
Sensor fill fluid and O-ring options
L1(17)
L2
LA(17)
H
H
H
Inert Sensor Fill Fluid
Graphite-Filled (PTFE) O-ring
Inert Sensor Fill Fluid and Graphite-Filled (PTFE) O-ring
Shipboard approvals
SBS(17)
SLL(17)(18)
H
American Bureau of Shipping
Lloyds Register (LR)
Display and interface options
M4(19)
M5
H
H
LCD Display with Local Operator Interface
LCD Display
Transient protection
T1(17)(20)
H
Transient terminal block
PlantWeb control functionality
A01(21)
H
FOUNDATION fieldbus Control Function Block Suite
PlantWeb diagnostic functionality
DA0(14)
D01(21)
H
H
Power Advisory HART Diagnostic
FOUNDATION fieldbus Diagnostic Suite
Low power output
C2
0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (Available with Output code M only)
Alarm levels
C4(14)
CN(14)
CR(14)
CS(14)
CT(14)
H
H
H
H
H
NAMUR Alarm and Saturation Levels, High Alarm
NAMUR Alarm and Saturation Levels, Low Alarm
Custom alarm and saturation signal levels, high alarm
Custom alarm and saturation signal levels, low alarm
Rosemount Standard low alarm
Ground screw
V5(17)(22)
H
External Ground Screw Assembly
Configuration buttons
D4(14)
DZ(23)
H
H
Analog Zero and Span
Digital Zero Trim
Typical model number:
3051CFP D S 010 W1 S 0500 D3 2 A A 1 E5 M5
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) To improve pipe perpendicularity for gasket sealing, socket diameter is smaller than standard pipe O.D.
(3) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(4) For local addressing and configuration, M4 (Local Operator Interface) is required.
36
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September 2014
Rosemount 3051
(5) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (option code I5), CSA Intrinsically Safe (option code I6),
ATEX Intrinsic Safety (option code I1), and IECEx Intrinsic Safety (option code I7).
(6) Only available with C6, E2, E5, I5, K5, KB and E8 approval. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(7) Only available with Wireless Output (output code X).
(8) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(9) Thermowell Material is the same as the body material.
(10) Does not apply to Process Connection codes T1 and S1.
(11) Not available for bore sizes 0010, 0014, 0020, 0034, 0066, or 0109.
(12) Not available with DIN Process Connection codes D1, D2, or D3.
(13) Materials of Construction comply with metallurgical requirements within NACE MR0175/ISO for sour oil field production environments. Environmental limits
apply to certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(14) Only available with HART 4-20 mA output (Option code A).
(15) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals
(16) Nonincendive certification not provided with Wireless output option code (X).
(17) Not available with Wireless Output (output code X).
(18) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7.
(19) Not available with FOUNDATION fieldbus (Output Code F) or Wireless output (output code X) or Low Power (output code M).
(20) The T1 option is not needed with FISCO Product Certifications, transient protection is included with the FISCO Product Certification code IA, IB, and IE.
(21) Only valid with FOUNDATION fieldbus Output Code F.
(22) The V5 option is not needed with the T1 option; external ground screw assembly is included with the T1 option.
(23) Only available with 4-20 mA output (Output Code A) and Wireless output (Output Code X).
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37
Rosemount 3051
September 2014
Rosemount 3051L Level Transmitter
The Rosemount 3051L Level Transmitter combines the performance and capabilities of
Rosemount 3051 Transmitters with the reliability and quality of a direct mount seal in
one model number. 3051L Level Transmitters offer a variety of process connections,
configurations, and fill fluid types to meet a breadth of level applications. Capabilities of
a Rosemount 3051L Level Transmitter include:
 Quantify and optimize total system performance (Option code QZ)
 Tuned-System Assembly (Option code S1)
 Power Advisory can proactively detect degraded electrical loop integrity issues
3051L Level Transmitter
(Option Code DA0)
 Local Operator Interface with straightforward menus and built-in configuration
buttons (Option Code M4)
See Specifications and options for more details on each configuration. Specification and selection of product materials, options, or
components must be made by the purchaser of the equipment. See page 54 for more information on Material Selection.
Additional information:
Specifications: page 45
Certifications: page 56
Dimensional Drawings: page 66
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Model
Transmitter type
3051L(1)
Level Transmitter
Pressure range
2
–250 to 250 inH2O (-621,60 to 621,60 mbar)
H
3
–1000 to 1000 inH2O (-2,48 to 2,48 bar)
H
4
–300 to 300 psi (-20,68 to 20,68 bar)
H
Transmitter output
A(2)
4–20 mA with Digital Signal Based on HART Protocol
H
F
FOUNDATION fieldbus Protocol
H
W(3)
PROFIBUS PA Protocol
H
X(4)
Wireless (requires wireless options and engineered polymer housing)
H
M(5)
Low-Power 1-5 Vdc with Digital Signal Based on HART Protocol
Process connection size, material, extension length (high side)
Code
Process connection size
Material
Extension length
G0(6)
2-in./DN 50/A
316L SST
Flush Mount Only
H
H0(6)
2-in./DN 50
Alloy C-276
Flush Mount Only
H
J0
2-in./DN 50
Tantalum
Flush Mount Only
H
A0(6)
3-in./DN 80
316L SST
Flush Mount
H
A2(6)
3-in./DN 80
316L SST
2-in./50 mm
H
(6)
3-in./DN 80
316L SST
4-in./100 mm
H
A4
38
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September 2014
Rosemount 3051
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
A6(6)
3-in./DN 80
316L SST
6-in./150 mm
H
(6)
B0
4-in./DN 100
316L SST
Flush Mount
H
B2(6)
4-in./DN 100
316L SST
2-in./50 mm
H
B4(6)
4-in./DN 100
316L SST
4-in./100 mm
H
(6)
B6
4-in./DN 100
316L SST
6-in./150 mm
H
C0(6)
3-in./DN 80
Alloy C-276
Flush Mount
H
C2(6)
3-in./DN 80
Alloy C-276
2-in./50 mm
H
C4(6)
3-in./DN 80
Alloy C-276
4-in./100 mm
H
C6(6)
3-in./DN 80
Alloy C-276
6-in./150 mm
H
D0(6)
4-in./DN 100
Alloy C-276
Flush Mount
H
D2(6)
4-in./DN 100
Alloy C-276
2-in./50 mm
H
D4(6)
4-in./DN 100
Alloy C-276
4-in./100 mm
H
D6(6)
4-in./DN 100
Alloy C-276
6-in./150 mm
H
E0
3-in./DN 80
Tantalum
Flush Mount Only
H
F0
4-in./DN 100
Tantalum
Flush Mount Only
H
Mounting flange size, rating, material (high side)
Size
Rating
Material
M
2-in.
ANSI/ASME B16.5 Class 150
CS
H
A
3-in.
ANSI/ASME B16.5 Class 150
CS
H
B
4-in.
ANSI/ASME B16.5 Class 150
CS
H
N
2-in.
ANSI/ASME B16.5 Class 300
CS
H
C
3-in.
ANSI/ASME B16.5 Class 300
CS
H
D
4-in.
ANSI/ASME B16.5 Class 300
CS
H
P
2-in.
ANSI/ASME B16.5 Class 600
CS
H
E
3-in.
ANSI/ASME B16.5 Class 600
CS
H
X(6)
2-in.
ANSI/ASME B16.5 Class 150
316 SST
H
F(6)
3-in.
ANSI/ASME B16.5 Class 150
316 SST
H
G(6)
4-in.
ANSI/ASME B16.5 Class 150
316 SST
H
Y(6)
2-in.
ANSI/ASME B16.5 Class 300
316 SST
H
H(6)
3-in.
ANSI/ASME B16.5 Class 300
316 SST
H
(6)
4-in.
ANSI/ASME B16.5 Class 300
316 SST
H
Z(6)
2-in.
ANSI/ASME B16.5 Class 600
316 SST
H
L(6)
3-in.
ANSI/ASME B16.5 Class 600
316 SST
H
Q
DN 50
PN 10-40 per EN 1092-1
CS
H
R
DN 80
PN 40 per EN 1092-1
CS
H
S
DN 100
PN 40 per EN 1092-1
CS
H
V
DN 100
PN 10/16 per EN 1092-1
CS
H
K(6)
DN 50
PN 10-40 per EN 1092-1
316 SST
H
T(6)
DN 80
PN 40 per EN 1092-1
316 SST
H
U(6)
DN 100
PN 40 per EN 1092-1
316 SST
H
J
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39
Rosemount 3051
September 2014
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Mounting flange size, rating, material (high side)
Size
Rating
Material
W(6)
DN 100
PN 10/16 per EN 1092-1
316 SST
H
7(6)
4 in.
ANSI/ASME B16.5 Class 600
316 SST
H
1
N/A
10K per JIS B2238
CS
2
N/A
20K per JIS B2238
CS
3
N/A
40K per JIS B2238
CS
4(6)
N/A
10K per JIS B2238
316 SST
5(6)
N/A
20K per JIS B2238
316 SST
(6)
N/A
40K per JIS B2238
316 SST
Seal fill fluid (high side)
Specific gravity
Temperature limits [ambient temperature of 70° F (21° C)]
D
Silicone 200
0.93
-49 to 401 °F (-45 to 205 °C)
H
F
Silicone 200 for
Vacuum
Applications
0.93
For use in vacuum applications below 14.7 psia (1 bar-a), refer to
vapor pressure curves in Rosemount DP Level Fill Fluid Specification
Technical Note (00840-2100-4016).
H
L
Silicone 704
1.07
32 to 401 °F (0 to 205 °C)
H
C
Silicone 704 for
Vacuum
Applications
1.07
For use in vacuum applications below 14.7 psia (1 bar-a), refer to
vapor pressure curves in Rosemount DP Level Fill Fluid Specification
Technical Note (00840-2100-4016).
H
R
Silicone 705
1.09
68 to 401 °F (20 to 205 °C)
H
V
Silicone 705 for
Vacuum
Applications
1.09
For use in vacuum applications below 14.7 psia (1 bar-a), refer to
vapor pressure curves in Rosemount DP Level Fill Fluid Specification
Technical Note (00840-2100-4016).
H
A
SYLTHERM™ XLT
0.85
-102 to 293 °F (-75 to 145 °C)
H
H
Inert (Halocarbon)
1.85
-49 to 320 °F (-45 to 160 °C)
H
G
Glycerine and Water
1.13
5 to 203 °F (-15 to 95 °C)
H
N
Neobee® M-20
0.92
5 to 401 °F (-15 to 205 °C)
H
P
Propylene Glycol and
Water
1.02
5 to 203 F (-15 to 95 °C)
H
6
Low pressure side
Configuration
Flange adapter Diaphragm material
Sensor fill fluid
11(6)
Gage
SST
316L SST
Silicone
H
21
Differential
SST
316L SST
Silicone
H
22(6)
Differential
SST
Alloy C-276
Silicone
H
2A(7)
Differential
SST
316L SST
Inert (Halocarbon)
H
2B
Differential
SST
Alloy C-276
Inert (Halocarbon)
H
31(6)
Tuned-System
Assembly with
Remote Seal
None
316L SST
Silicone
(requires Option Code S1)
H
(6)(7)
40
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September 2014
Rosemount 3051
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
O-ring
A
H
Glass-filled PTFE
Housing material
Conduit entry size
A
Aluminum
½–14 NPT
H
B
Aluminum
M20 × 1.5
H
J
SST
½–14 NPT
H
K
SST
M20 × 1.5
H
(8)
Engineered polymer
No conduit entries
H
D(9)
Aluminum
G½
M(9)
SST
G½
P
Wireless options (requires Wireless Output Code X and Engineered Polymer Housing Code P)
Wireless transmit rate, operating frequency, and protocol
WA3
User Configurable Transmit Rate, 2.4GHz WirelessHART
H
Antenna and SmartPower
WP5
Internal Antenna, Compatible with Green Power Module (I.S. Power Module Sold Separately)
H
HART Revision configuration (requires HART Protocol Output Code A)
HR5(2)
Configured for HART Revision 5
H
HR7(2)
Configured for HART Revision 7
H
Options (include with selected model number)
Extended product warranty
WR3
3-year limited warranty
H
WR5
5-year limited warranty
H
PlantWeb control functionality
A01(10)
FOUNDATION fieldbus Control Function Block Suite
H
PlantWeb diagnostic functionality
DA0(18)
D01
(10)
Power Advisory HART Diagnostic
H
FOUNDATION fieldbus Diagnostics Suite
H
Seal assemblies
S1(11)
Assembled to One Rosemount 1199 Seal
H
Product certifications
ATEX Flameproof and Dust Certification
H
ATEX Intrinsic Safety and Dust
H
IA
ATEX FISCO Intrinsic Safety; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
N1
ATEX Type n Certification and Dust
H
K8
ATEX Flameproof, Intrinsic Safety, Type n, Dust (combination of E8, I1 and N1)
H
E4(13)
TIIS Flameproof
H
E5
FM Explosion-proof, Dust Ignition-proof
H
I5(14)
FM Intrinsically Safe, Nonincendive
H
IE
FM FISCO Intrinsically Safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
K5
FM Explosion-proof, Dust Ignition-Proof, Intrinsically Safe, and Division 2
H
E8
I1
(12)
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41
Rosemount 3051
September 2014
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
C6
(8)
CSA Explosion-proof, Dust Ignition-proof, Intrinsically Safe, and Division 2
H
CSA Intrinsic Safety
H
K6
CSA and ATEX Explosion-proof, Intrinsically Safe, and Division 2 (combination of C6, E8, and I1)
H
E7
IECEx Flameproof, Dust Ignition-proof
H
I7
IECEx Intrinsic Safety
H
N7
IECEx Type n Certification
H
K7
IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n (combination of I7, N7 and E7)
H
E2
INMETRO Flameproof
H
I2
INMETRO Intrinsic Safety
H
IB
INMETRO FISCO intrinsically safe; for FOUNDATION fieldbus or PROFIBUS PA protocols only
H
K2
INMETRO Flameproof, Intrinsic Safety
H
E3
China Flameproof
H
I3
China Intrinsic Safety
H
N3
China Type n
H
EM
Technical Regulations Customs Union (EAC) Flameproof
H
IM
Technical Regulations Customs Union (EAC) Intrinsic Safety
H
KM
Technical Regulations Customs Union (EAC) Flameproof and Intrinsic Safety
H
KB
FM and CSA Explosion-proof, Dust Ignition Proof, Intrinsically Safe, and Division 2 (combination of K5 and C6)
H
KD
FM, CSA, and ATEX Explosion-proof, Intrinsically Safe (combination of K5, C6, I1, and E8)
H
I6
Shipboard approvals
SBS(7)
SBV(7)
American Bureau of Shipping
(15)
Bureau Veritas (BV)
SDN(7)
Det Norske Veritas
SLL(7)(15)
Lloyds Register (LR)
H
Bolting material
L4
Austenitic 316 SST Bolts
H
L5
ASTM A 193, Grade B7M bolts
H
L6
Alloy K-500 Bolts
H
L8
ASTM A 193 Class 2, Grade B8M Bolts
H
Display and interface options
M4(16)
LCD Display with Local Operator Interface
H
M5
LCD Display
H
Calibration certification
Q4
Calibration Certificate
H
QP
Calibration Certificate and tamper evident seal
H
QG(17)
Calibration Certificate and GOST Verification Certificate
H
Material traceability certification
Q8
Material Traceability Certification per EN 10204 3.1
H
Quality certification for safety
QS(18)
Prior-use certificate of FMEDA data
H
QT(18)
Safety certified to IEC 61508 with certificate of FMEDA
H
42
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September 2014
Rosemount 3051
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
Toolkit total system performance reports
QZ
H
Seal System Performance Calculation Report
Conduit electrical connector
GE(7)
M12, 4-pin, Male Connector (eurofast)
H
GM(7)
A size Mini, 4-pin, Male Connector (minifast)
H
Configuration buttons
D4(18)
Analog Zero and Span
H
DZ(19)
Digital Zero Trim
H
Transient protection
T1(7)(20)
H
Transient Protection
Software configuration
C1(19)
Custom Software Configuration (completed CDS 00806-0100-4007 for wired and 00806-0100-4100 for wireless
required with order)
H
Low power output
C2
0.8-3.2 Vdc Output with Digital Signal Based on HART Protocol (available with Output code M only)
Alarm levels
C4(18)
NAMUR alarm and saturation levels, high alarm
H
CN(18)
NAMUR alarm and saturation levels, low alarm
H
CR(18)
Custom alarm and saturation signal levels, high alarm (requires C1 and Configuration Data Sheet)
H
CS(18)
Custom alarm and saturation signal levels, low alarm (requires C1 and Configuration Data Sheet)
H
CT(18)
Rosemount Standard low alarm
H
Conduit plug
DO(7)
H
316 SST Conduit Plug
Ground screw
V5(7)(21)
H
External Ground Screw Assembly
Lower housing flushing connection options
Ring material
Number
Size (NPT)
F1
316 SST
1
1
/4-18 NPT
H
F2
316 SST
2
1/4-18 NPT
H
1
1
/4-18 NPT
H
F3
Alloy C-276
F4
Alloy C-276
2
1
/4-18 NPT
H
F7
316 SST
1
1/2-14 NPT
H
2
1
/2-14 NPT
H
F8
316 SST
F9
Alloy C-276
1
1
/2-14 NPT
H
F0
Alloy C-276
2
1/2-14 NPT
H
Lower housing intermediate gasket material
S0
No Gasket for lower housing
H
SY(22)
Thermo-Tork TN-9000
H
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Rosemount 3051
September 2014
Table 6. Rosemount 3051L Level Transmitter Ordering Information
H The Standard offering represents the most common options. The starred options (H) should be selected for best delivery.
__The Expanded offering is subject to additional delivery lead time.
NACE certificate
Q15(23)
(23)
Q25
Certificate of Compliance to NACE MR0175/ISO 15156 for wetted materials
H
Certificate of Compliance to NACE MR0103 for wetted materials
H
Typical model number: 3051L 2 A A0 D 21 A A F1
(1) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(2) Option HR5 configures the HART output to HART Revision 5. Option HR7 configures the HART output to HART Revision 7. The device can be field configured to
HART Revision 5 or 7 if desired. HART Revision 5 is the default HART output.
(3) Option code M4 - LCD Display with Local Operator Interface required for local addressing and configuration.
(4) Requires wireless options and engineered polymer housing. Available approvals are FM Intrinsically Safe, (option code I5), CSA Intrinsically Safe (option code I6),
ATEX Intrinsic Safety (option code I1), IECEx Intrinsic Safety (option code I7) and EAC Intrinsic Safety (option code IM).
(5) Only available with C6, E2, E5, I5, K5, KB and E8 approval. Not available with GE, GM, SBS, DA0, M4, D4, DZ, QT, HR5, HR7, CR, CS, CT.
(6) Materials of Construction comply with metallurgical requirements highlighted within NACE MR0175/ISO 15156 for sour oil field production environments.
Environmental limits apply to certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining
environments.
(7) Not available with Wireless output (output code X).
(8) Only available with Wireless output (output code X).
(9) Not available with Product certifications options E8, K8, E5, K5, C6, K6, E7, K7, E2, K2, E3, KB, KD.
(10) Only valid with FOUNDATION fieldbus output (output code F).
(11) “Assemble-to” items are specified separately and require a completed model number.
(12) Dust approval not applicable to output code X. See “IEC 62591 (WirelessHART Protocol)” on page 62 for wireless approvals.
(13) Only available with output codes A - 4-20mA HART, F - FOUNDATION fieldbus, and W - PROFIBUS PA. Also only available with G1/2 housing thread types.
(14) Nonincendive certification not provided with Wireless output option code (X).
(15) Only available with product certifications E7, E8, I1, I7, IA, K7, K8, KD, N1, N7.
(16) Not available with FOUNDATION fieldbus (Output Code F) or Wireless output (Output Code X) or Low Power (Output Code M).
(17) Contact an Emerson Process Management representative for availability.
(18) Only available with HART 4-20 mA output (output code A).
(19) Only available with 4-20 mA HART output (Output Code A) and Wireless output (Output Code X).
(20) The T1 option is not needed with FISCO Product Certifications; transient protection is included in the FISCO product certification codes IA, IB, and IE.
(21) The V5 option is not needed with the T1 option; external ground screw assembly is included with the T1 option.
(22) Gasket provided when lower housing is ordered.
(23) NACE compliant wetted materials are identified by Footnote 6.
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September 2014
Rosemount 3051
Specifications
Performance specifications
This product data sheet covers HART, Wireless, FOUNDATION fieldbus, and PROFIBUS PA protocols unless specified.
Conformance to specification [±3 (Sigma)]
Technology leadership, advanced manufacturing techniques, and statistical process control ensure specification conformance to at
least ±3.
Reference accuracy
Stated reference accuracy equations include terminal based linearity, hysteresis, and repeatability. For wireless, FOUNDATION fieldbus
and PROFIBUS PA devices, use calibrated range in place of span.
Models
3051C
Rosemount 3051and WirelessHART
+/-0.065% of span
 URL- % of Span
Range 5 For spans less than 10:1, accuracy =  0.015 + 0.005  -------------Span
Ranges 2-4 ± 0.04% of span(1)
URL 
- % of Span
For spans less than 10:1(2), accuracy =  0.015 + 0.005  -------------Span
Range 1 ± 0.10% of span
URL 
- % of Span
For spans less than 15:1, accuracy =  0.025 + 0.005  -------------Span
Range 0 (CD) ± 0.10% of span
For spans less than 2:1, accuracy = ± 0.05% of URL
3051CA
± 0.04% of span(1)
URL
Ranges 1-4 For spans less than 10:1, accuracy =  0.0075  --------------- % of Span
Span
3051T
± 0.04% of span(1)
 URL- % of Span
Ranges 1-4 For spans less than 10:1, accuracy =  0.0075  -------------Span
Range 5 ± 0.075% of span
URL 
- % of Span
For spans less than 10:1, accuracy =  0.0075  -------------Span
3051L
± 0.075% of span
URL 
- % of Span
Ranges 2-4 For spans less than 10:1, accuracy =  0.025 + 0.005  -------------Span
(1) For output code W and M, ±0.065% span.
(2) For output code F, for span less than 5:1.
Flow performance - flow reference accuracy(1)
3051CFA Annubar Flowmeter
Ranges 2-3
±1.80% of Flow Rate at 8:1 flow turndown
3051CFC_A Compact Annubar Flowmeter – Annubar Option A
Ranges 2-3
Uncalibrated
Calibrated
±2.10% of Flow Rate at 8:1 flow turndown
±1.80% of Flow Rate at 8:1 flow turndown
3051CFC_C Compact Orifice Flowmeter – Conditioning Option C
Ranges 2-3
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 = 0.4
 = 0.50, 0.65
±1.75% of Flow Rate at 8:1 flow turndown
±1.95% of Flow Rate at 8:1 flow turndown
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Rosemount 3051
September 2014
Flow performance - flow reference accuracy(1)
3051CFC_P Compact Orifice Flowmeter – orifice type option P(2)
Ranges 2-3
 = 0.4
 = 0.65
±2.00% of Flow Rate at 8:1 flow turndown
±2.00% of Flow Rate at 8:1 flow turndown
3051CFP Integral Orifice Flowmeter
Ranges 2-3
 <0.1
0.1<  <0.2
0.2<  <0.6
0.6<  <0.8
±3.00% of Flow Rate at 8:1 flow turndown
±1.95% of Flow Rate at 8:1 flow turndown
±1.75% of Flow Rate at 8:1 flow turndown
±2.15% of Flow Rate at 8:1 flow turndown
(1) Accuracy over range of use is always application dependent. Range 1 flowmeters may experience an additional uncertainty up to 0.9%.
Consult your Emerson Process Management Representative for exact specifications.
(2) Applicable to 2-in. to 12-in. line sizes. For smaller line sizes, see the Rosemount DP Flowmeters and Primary Elements PDS
(00813-0100-4485).
Total performance
Total performance is based on combined errors of reference accuracy, ambient temperature effect, and static pressure effect at
normal operating conditions (70% of span typical reading, 740 psi (51,02 bar) line pressure).
For ±50 °F (28 °C) temperature changes; 0-100% relative humidity, from 1:1 to 5:1 rangedown
Models
3051C
Ranges 2-5
3051T
Ranges 1-4
3051L
Total performance(1)
± 0.14% of span
± 0.14% of span
Use Instrument Toolkit™ or the QZ option to quantify the total
Ranges 2-4 performance of a remote seal assembly under operating conditions.
(1) For output code W, F and M, total performance is ±0.15% of span.
Long term stability
Models
Long term stability
3051C
Ranges 2-5
±0.2% of URL for 10 years
±50 °F (28 °C) temperature changes, and up to 1000 psi (68,95 bar) line pressure.
3051CD, 3051CG Low/Draft Range
±0.2% of URL for 1 year
Ranges 0-1
3051CA Low Range
±0.2% of URL for 10 years
Range 1 ±50 °F (28 °C) temperature changes, and up to 1000 psi (68,95 bar) line pressure.
3051T
Ranges 1-4
46
±0.2% of URL for 10 years
±50 °F (28 °C) temperature changes, and up to 1000 psi (68,95 bar) line pressure.
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September 2014
Rosemount 3051
Dynamic performance
4 - 20 mA HART(1)
FOUNDATION fieldbus
Typical HART transmitter response
and PROFIBUS PA
time
protocols(3)
Total Response Time (Td + Tc)(2):
3051C
Ranges 2-5
Range 1
Range 0
3051T
3051L
100 ms
255 ms
700 ms
100 ms
See Instrument Toolkit
152 ms
307 ms
N/A
152 ms
See Instrument Toolkit
Transmitter Output vs. Time
Pressure
10
Dead Time (Td)
45 ms (nominal)
97 ms
Update Rate(4)
22 times per second
22 times per second
(1) Dead time and update rate apply to all models and ranges; analog output only.
Td
Tc
Td = Dead Time
Tc = Time Constant
Response Time = Td +Tc
63.2% of Total
Step Change
36.
0%
Time
(2) Nominal total response time at 75 °F (24 °C) reference conditions.
(3) Transducer block response time, Analog Input block execution time not included.
(4) Does not apply to wireless (output Code X). See “Wireless (output code X)” on page 52
for wireless update rate.
Line pressure effect per 1000 psi (68,95 bar)
For line pressures above 2000 psi (137,90 bar) and Ranges 4-5, see user manual
(Document number 00809-0100-4007 for HART, 00809-0100-4100 for WirelessHART, 00809-0100-4774 for
FOUNDATION fieldbus, and 00809-0100-4797 for PROFIBUS PA).
Models
Line pressure effect
3051CD, 3051CF
Zero Error
Ranges 2-3 ±0.05% of URL/1000 psi (68,95 bar) for line pressures from 0 to 2000 psi (0 to 137,90 bar)
Range 1 ±0.25% of URL/1000 psi (68,95 bar) for line pressures from 0 to 2000 psi (0 to 137,90 bar)
Range 0 ±0.125% of URL/100 psi (6,89 bar) for line pressures from 0 to 750 psi (0 to 51,71 bar)
Span Error
Ranges 2-3 ±0.1% of reading/1000 psi (68,95 bar)
Range 1 ±0.4% of reading/1000 psi (68,95 bar)
Range 0 ±0.15% of reading/100 psi (68,95 bar)
Ambient temperature effect per 50 °F (28 °C)
Models
Ambient temperature effect
3051C
Ranges 2-5
Range 1
Range 0
3051CA
Ranges 1-4
3051T
Range 2-4
Range 1
Range 5
3051L
www.rosemount.com
±(0.0125% URL + 0.0625% span) from 1:1 to 5:1
±(0.025% URL + 0.125% span) from 5:1 to 150:1
±(0.1% URL + 0.25% span) from 1:1 to 30:1
±(0.14% URL + 0.15% span) from 30:1 to 50:1
±(0.25% URL + 0.05% span) from 1:1 to 30:1
±(0.025% URL + 0.125% span) from 1:1 to 30:1
±(0.035% URL + 0.125% span) from 30:1 to 150:1
±(0.025% URL + 0.125% span) from 1:1 to 30:1
±(0.035% URL + 0.125% span) from 30:1 to 150:1
±(0.025% URL + 0.125% span) from 1:1 to 10:1
±(0.05% URL + 0.125% span) from 10:1 to 100:1
±(0.1% URL + 0.15% span) from 1:1 to 5:1
See Instrument Toolkit software.
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Rosemount 3051
September 2014
Mounting position effects
Models
Mounting position effects
3051C
3051CA, 3051T
Zero shifts up to ±1.25 inH2O (3,11 mbar), which can be calibrated out. No span effect.
Zero shifts up to ±2.5 inH2O (6,22 mbar), which can be calibrated out. No span effect.
With liquid level diaphragm in vertical plane, zero shift of up to ±1 inH2O (2,49 mbar). With
diaphragm in horizontal plane, zero shift of up to ±5 inH2O (12,43 mbar) plus extension length on
extended units. All zero shifts can be calibrated out. No span effect.
3051L
Vibration effect
Less than ±0.1% of URL when tested per the requirements of IEC60770-1: 1999 field or pipeline with high vibration level
(10-60 Hz 0.21 mm displacement peak amplitude / 60-2000 Hz 3g).
Power supply effect
Less than ±0.005% of calibrated span per volt change.
Electromagnetic compatibility (EMC)
Meets all relevant requirements of EN61326-1:2006 and Namur NE-21.(1)
(1)
NAMUR NE-21 does not apply to wireless output code X.
Transient protection (option code T1)
Tested in accordance with IEEE C62.41.2-2002, Location Category B
6 kV crest (0.5 s - 100 kHz)
3 kA crest (8 × 20 s)
6 kV crest (1.2 × 50 s)
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September 2014
Rosemount 3051
Functional specifications
Range and sensor limits
Table 7. 3051CD, 3051CG, 3051CF, and 3051L Range and Sensor Limits
Range(1)
Minimum span
0
1
2
3
4
5
Range and sensor limits
Lower (LRL)
3051CD,
3051CG,
3051CF,
3051L(2)
0.10 inH2O
(0,24 mbar)
0.50 inH2O
(1,24 mbar)
1.67 inH2O
(4,15 mbar)
6.67 inH2O
(16,58 mbar)
2.00 psi
(137,89 mbar)
13.33 psi
(919,01 mbar)
Upper
(URL)
3051CD
differential
3051CF
Flowmeters
3.00 inH2O
(7,45 mbar)
25.00 inH2O
(62,16 mbar)
250.00 inH2O
(621,60 mbar)
1000.00 inH2O
(2,48 bar)
300.00 psi
(20,68 bar)
2000.00 psi
(137,89 bar)
-3.00 inH2O
(-7,45 mbar)
-25.00 inH2O
(-62,16 mbar)
-250.00 inH2O
(-621,60 mbar)
-1000.00 inH2O
(-2,48 bar)
-300.00 psi
(-20,68 bar)
- 2000.00 psi
(-137,89 bar)
3051CG
gage(3)
3051L
differential
3051L gage(3)
N/A
N/A
N/A
-25.00 inH2O
N/A
(-62,16 mbar)
-250.00 inH2O -250.00 inH2O
(-621,60 mbar) (-621,60 mbar)
0.50 psia
-1000.00 inH2O
(34,47 mbar)
(-2,48 bar)
0.50 psia
-300.00 psi
(34,47 mbar)
(-20,68 bar)
0.50 psia
N/A
(34,47 mbar)
N/A
-250.00 inH2O
(-621,60 mbar)
0.50 psia
(34,47 mbar)
0.50 psia
(34,47 mbar)
N/A
(1) Range 0 only available with 3051CD. Range 1 only available with 3051CD, 3051CG, or 3051CF. inH2O referenced at 68 degrees Fahrenheit.
(2) For outputs options W and M, minimum span are: range 1 - 0.50 inH2O (1,24 mbar), range 2 - 2.50 inH2O (6,21 mbar), range 3 - 10.00 inH2O
(24,86 mbar), range 4 - 3.00 psi (0,21 bar), range 5 - 20.00 psi (1,38 bar).
(3) Assumes atmospheric pressure of 14.7 psig.
Table 8. 3051CA and 3051T Range and Sensor Limits
1
2
3
4
5
3051T
Upper
(URL)
Lower
(LRL)
0.30 psi
(20,68 mbar)
1.00 psi
(68,94 mbar)
5.33 psi
(367,49 mbar)
26.67 psi
(1,83 bar)
30 psia
(2,06 bar)
150 psia
(10,34 bar)
800 psia
(55,15 bar)
4000 psia
(275,79 bar)
0 psia
(0 bar)
0 psia
(0 bar)
0 psia
(0 bar)
0 psia
(0 bar)
N/A
N/A
N/A
Range
Range
3051CA
Minimum span(1) Range and sensor limits
1
2
3
4
5
Minimum span(1)
Range and sensor limits
Upper
(URL)
0.30 psi
(20,68 mbar)
1.00 psi
(68,94 mbar)
5.33 psi
(367,49 mbar)
26.67 psi
(1,83 bar)
2000.00 psi
(137,89 bar)
30.00 psi
(2,06 bar)
150.00 psi
(10,34 bar)
800.00 psi
(55,15 bar)
4000.00 psi
(275,79 bar)
10000.00 psi
(689,47 bar)
Lower(2)
Lower
(LRL) (gage)
(LRL)
(absolute)
0 psia
(0 bar)
0 psia
(0 bar)
0 psia
(0 bar)
0 psia
(0 bar)
0 psia
(0 bar)
-14.70 psig
(-1,01 bar)
-14.70 psig
(-1,01 bar)
-14.70 psig
(-1,01 bar)
-14.70 psig
(-1,01 bar)
-14.70 psig
(-1,01 bar)
(1) For output options W and M, minimum span are: range 2 - 1.50 psi(0,10 bar), range 3 - 8.00 psi (0,55 bar), range 4 - 40.00 psi (2,75 bar), range 5 for 3051T
- 2000.00 psi (137,89 bar)
(2) Assumes atmospheric pressure of 14.7 psig.
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Rosemount 3051
September 2014
Service
External power supply required. Standard transmitter (4-20mA)
operates on 10.5-42.4 Vdc with no load
Local operator interface
The LOI utilizes a 2 button menu with internal and external
configuration buttons. Internal buttons are always
configured for Local Operator Interface. External Buttons can
be configured for either LOI (option code M4), Analog Zero
and Span (option code D4) or Digital Zero Trim (option code
DZ). See Rosemount 3051 product manual
(00809-0100-4007) for LOI configuration menu.
Load limitations
FOUNDATION fieldbus (output code F)
Maximum loop resistance is determined by the voltage level of
the external power supply described by:
Power supply
Liquid, gas, and vapor applications
4-20 mA HART (output code A)
Power supply
Max. Loop Resistance = 43.5 (Power Supply Voltage – 10.5)
Load (s)
1387
External power supply required; transmitters operate on 9.0 to
32.0 V dc transmitter terminal voltage. FISCO transmitters
operate on 9.0 to 17.5 V dc.
Current draw
17.5 mA for all configurations (including LCD display option)
1000
500
Indication
Operating
Region
Optional two line LCD display
0
10.5
20
30
Voltage (Vdc)
FOUNDATION fieldbus block execution times
42.4(1)
Block
Execution time
Resource
N/A
Sensor and SPM Transducer
N/A
LCD Display
N/A
Analog Input 1, 2
20 milliseconds
PID
25 milliseconds
Configuration buttons need to be specified:
Digital Zero trim (option code DZ) changes digital value of the
transmitter and is used for performing a sensor zero trim.
Analog Zero Span (option code D4) changes analog value and
can be used to rerange the transmitter with an applied pressure.
Input Selector
20 milliseconds
Arithmetic
20 milliseconds
Signal Characterizer
20 milliseconds
Integrator
20 milliseconds
Output
Output Splitter
20 milliseconds
Two-wire 4-20mA, user selectable for linear or square root
output. Digital process variable superimposed on 4-20 mA
signal, available to any host that conforms to HART protocol.
The 3051 comes with Selectable HART Revisions. Digital
communications based on HART Revision 5 (default) or Revision
7 (option code HR7) protocol can be selected. The HART revision
can be switched in the field using any HART based configuration
tool or the optional local operator interface (M4).
Control Selector
20 milliseconds
Communication requires a minimum
loop resistance of 250 ohms.
(1) For CSA approval, power supply must not exceed 42.4 V.
Indication
Optional two line LCD/LOI Display
Optional configuration buttons
Power advisory diagnostics
Power Advisory Diagnostics pro-actively detect and notify
you of degraded electrical loop integrity before it can affect
your process operation. Example loop problems that can be
detected include water in the terminal compartment,
corrosion of terminals, improper grounding, and unstable
power supplies.
The Device Dashboard presents the diagnostics in a
graphical, task-based interface that provides single-click
access to critical process/device information and descriptive
graphical troubleshooting.
50
FOUNDATION fieldbus parameters
Links
25 (max.)
Virtual Communications Relationships (VCR)
20 (max.)
FOUNDATION fieldbus function blocks (option A01)
Resource block
The resource block contains diagnostic, hardware, and
electronics information. There are no linkable inputs or
outputs to the Resource Block.
Sensor transducer block
The sensor transducer block contains sensor information
and the ability to calibrate the pressure sensor or recall
factory calibration.
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September 2014
LCD transducer block
The LCD transducer block is used to configure the LCD
display meter.
Analog input block
The analog input (AI) function block processes the
measurements from the sensor and makes them available
to other function blocks. The output value from the AI
block is in engineering units and contains a status
indicating the quality of the measurement. The AI Block is
widely used for scaling functionality.
Input selector block
The input selector (ISEL) function block can be used to
select the first good, hot backup, maximum, minimum,
or average of as many as eight input values and place it at
the output. The block supports signal status propagation.
Integrator block
The integrator (INT) function block integrates one or two
variables over time. The block compares the integrated or
accumulated value to pre-trip and trip limits and
generates discrete output signals when the limits are
reached.
The Integrator Block is used as a totalizer. This block will
accept up to two inputs, has six options how to totalize
the inputs, and two trip outputs.
Arithmetic block
The arithmetic (ARTH) function block provides the ability
to configure a range extension function for a primary
input. It can also be used to compute nine different
arithmetic functions including flow with partial density
compensation, electronic remote seals, hydrostatic tank
gaging, ratio control, and others.
Signal characterizer block
The signal characterizer (SGCR) function block
characterizes or approximates any function that defines
an input/output relationship. The function is defined by
configuring as many as twenty X,Y coordinates. The block
interpolates an output value for a given input value using
the curve defined by the configured coordinates. Two
separate analog input signals can be processed
simultaneously to give two corresponding separate
output values using the same defined curve.
PID block
The PID function block combines all of the necessary logic
to perform proportional/integral/derivative (PID) control.
The block supports mode control, signal scaling and
limiting, feed forward control, override tracking, alarm
limit detection, and signal status propagation.
Control selector block
The control selector function block selects one of two or
three inputs to be the output. The inputs are normally
connected to the outputs of PID or other function blocks.
One of the inputs would be considered normal and the
other two overrides.
Rosemount 3051
Output splitter block
The output splitter function block provides the capability
to drive two control outputs from a single input. It takes
the output of one PID or other control block to control
two valves or other actuators.
Backup Link Active Scheduler (LAS)
The transmitter can function as a Link Active Scheduler if the
current link master device fails or is removed from the
segment.
FOUNDATION fieldbus Diagnostics Suite
(option code D01)
The 3051C FOUNDATION fieldbus Diagnostics Suite features
SPM technology to detect changes in the process, process
equipment, or installation conditions (such as plugged
impulse lines) of the transmitter. This is done by modeling the
process noise signature (using the statistical values of mean
and standard deviation) under normal conditions and then
comparing the baseline values to current values over time. If a
significant change in the current values is detected, the
transmitter can generate an alert.
PROFIBUS PA (output code W)
Profile version
3.02
Power supply
External power supply required; transmitters operate on 9.0
to 32.0 V dc transmitter terminal voltage. FISCO transmitters
operate on 9.0 to 17.5 V dc.
Current draw
17.5 mA for all configurations (including LCD display option)
Output update rate
Four times per second
Standard function blocks
Analog input (AI block)
The AI function block processes the measurements and
makes them available to the host device. The output
value from the AI block is in engineering units and
contains a status indicating the quality of the
measurement.
Physical block
The physical block defines the physical resources of the
device including type of memory, hardware, electronics
and diagnostic information.
Transducer block
Contains actual sensor measurement data including the
sensor diagnostics and the ability to trim the pressure
sensor or recall factory defaults.
Indication
Optional 2-line LCD display
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51
Rosemount 3051
September 2014
Local operator interface
Minimum load impedance
The LOI utilizes a 2 button menu with external configuration
buttons.
100 k  (Vout wiring)
Wireless (output code X)
Optional 5-digit LCD display
Output
Overpressure limits
IEC 62591 (WirelessHART), 2.4 GHz DSSS
Wireless radio (internal antenna, WP5 option)
Indication
Rosemount 3051CD/CG/CF
•
Range 0: 750 psi (51,71 bar)
Frequency: 2.400 - 2.485 GHz
•
Range 1: 2000 psig (137,90 bar)
•
Channels: 15
•
•
Modulation: IEEE 802.15.4 compliant DSSS
Ranges 2-5: 3626 psig (250,00 bar)
4500 psig (310,26 bar) for option code P9
•
Transmission: Maximum of 10 dBm EIRP
•
Rosemount 3051CA
Local display
•
Range 1: 750 psia (51,71 bar)
The optional 3-line, 7-digit LCD display can display
user-selectable information such as primary variable in
engineering units, scaled variable, percent of range, sensor
module temperature, and electronics temperature. The display
updates based on the wireless update rate.
•
Range 2: 1500 psia (103,42 bar)
•
Range 3: 1600 psia (110,32 bar)
•
Range 4: 6000 psia (413,69 bar)
Rosemount 3051TG/TA
•
Range 1: 750 psi (51,71 bar)
Digital zero trim
•
Range 2: 1500 psi (103,42 bar)
Digital Zero trim (option DZ) is an offset adjustment to
compensate for mounting position effects, up to 5% of URL.
•
Range 3: 1600 psi (110,32 bar)
•
Range 4: 6000 psi (413,69 bar)
Update rate
•
Range 5: 15000 psi (1034,21 bar)
User selectable 1 sec. to 60 min.
Wireless sensor module for in-line transmitters
The 3051 Wireless transmitter requires the engineered polymer
housing to be selected. The standard sensor module will come
with aluminum material. If stainless steel is required, the option
WSM must be selected.
Power module
Field replaceable, keyed connection eliminates the risk of
incorrect installation, Intrinsically Safe Lithium-thionyl chloride
Power Module with PBT/PC enclosure. Ten-year life at one
minute update rate.(1)
(1)
Reference conditions are 70 °F (21 °C), and routing data for three
additional network devices.
Note: Continuous exposure to ambient temperature limits of -40 °F or
185 °F (-40 °C or 85 °C) may reduce specified life by less than 20
percent.
Low power output
1-5 Vdc HART Low Power (output code M)
Output
Three-wire 1-5 Vdc (option code C2) user-selectable output.
Also user selectable for linear or square root output
configuration. Digital process variable superimposed on voltage
signal, available to any host conforming to the HART protocol.
Low-power transmitter operates on 6-12 Vdc with no load.
Power consumption
3.0 mA, 18-36 mW
For 3051L or Level Flange Option Codes FA, FB, FC, FD, FP, and
FQ, limit is 0 psia to the flange rating or sensor rating, whichever
is lower.
Table 9. 3051L and Level Flange Rating Limits
Standard
Type
CS rating SST rating
ANSI/ASME
Class 150
285 psig
275 psig
ANSI/ASME
Class 300
740 psig
720 psig
ANSI/ASME
Class 600
1480 psig
1440 psig
At 100 °F (38 °C), the rating decreases
with increasing temperature, per ANSI/ASME B16.5.
DIN
PN 10-40
40 bar
40 bar
DIN
PN 10/16
16 bar
16 bar
DIN
PN 25/40
40 bar
40 bar
At 248 °F (120 °C), the rating decreases
with increasing temperature, per DIN 2401.
Static pressure limit
Rosemount 3051CD only
Operates within specifications between static line pressures of
0.5 psia and 3626 psig (4500 psig (310, 26 bar) for Option Code
P9).
Range 0: 0.5 psia and 750 psig (0,03 bar and 51,71 bar)
Range 1: 0.5 psia and 2000 psig (0,03 bar and 137, 90 bar)
Burst pressure limits
3051C, 3051CF Coplanar or
traditional process flange
10081 psig (695,06 bar)
52
www.rosemount.com
September 2014
Rosemount 3051
3051T In-Line
Process
Ranges 1-4: 11016 psi (759,53 bar)
Range 5: 26016 psig (1793,74 bar)
At atmospheric pressures and above. See Table 10.
Table 10. 3051 Process Temperature Limits
Failure mode alarm
3051CD, 3051CG, 3051CF, 3051CA
HART 4-20 mA (output option code A)
If self-diagnostics detect a sensor or microprocessor failure, the
analog signal is driven either high or low to alert the user. High or
low failure mode is user-selectable with a jumper/switch on the
transmitter. The values to which the transmitter drives its
output in failure mode depend on whether it is configured to
standard, NAMUR-compliant, or custom levels (see Alarm
Configuration below). The values for each are as follows:
High alarm
Default
NAMUR compliant(1)
Custom levels(2)
Low alarm
21.75 mA
3.75 mA
22.5 mA
3.6 mA
20.2 - 23.0 mA 3.4 - 3.8 mA
Silicone Fill Sensor(1)
with Coplanar Flange
with Traditional Flange
with Level Flange
with 305 Integral
Manifold
Inert Fill Sensor(1)(4)
–40 to 250 °F (–40 to 121 °C)(2)
–40 to 300 °F (–40 to 149 °C)(2)(3)
–40 to 300 °F (–40 to 149 °C)(2)
–40 to 300 °F (–40 to 149 °C)(2)
–40 to 185 °F (–40 to 85 °C)(5)(6)
3051T (process fill fluid)
Silicone Fill Sensor(1)
Inert Fill Sensor(1)
–40 to 250 °F (–40 to 121 °C)(2)
–22 to 250 °F (–30 to 121 °C)(2)
3051L low-side
temperature limits
(1)
Analog output levels are compliant with NAMUR
recommendation NE 43, see option codes C4 or C5.
Silicone Fill Sensor(1)
Inert Fill Sensor(1)
(2)
Low alarm must be 0.1 mA less than low saturation and high
alarm must be 0.1 mA greater than high saturation.
3051L high-side temperature limits (process fill fluid)
Output code M
If self-diagnostics detect a gross transmitter failure, the analog
signal will be driven either below 0.94 V or above 5.4 V to alert
the user (below 0.75 V or above 4.4 V for Option C2). High or low
alarm signal is user-selectable by internal jumper.
Output code F, W, and X
If self-diagnostics detect a gross transmitter failure, that
information gets passed as an alert and a status along with the
process variable.
SYLTHERM XLT
D.C. Silicone 704®
D.C. Silicone 200
Inert
Glycerin and Water
Neobee M-20
Propylene Glycol and
Water
–40 to 250 °F (–40 to 121 °C)(2)
-40 to 185 °F (–40 to 85 °C)(5)
–102 to 293 °F (–75 to 145 °C)
32 to 401 °F (0 to 205 °C)
–49 to 401 °F (–45 to 205 °C)
–49 to 320 °F (–45 to 160 °C)
5 to 203 °F (–15 to 95 °C)
5 to 401 °F (–15 to 205 °C)
5 to 203 °F (–15 to 95 °C)
(1) Process temperatures above 185 °F (85 °C) require derating the ambient
limits by a 1.5:1 ratio.
Temperature limits
Ambient
(2) 220 °F (104 °C) limit in vacuum service; 130 °F (54 °C) for pressures
below 0.5 psia.
-40 to 185 °F (-40 to 85 °C)
With LCD display(1)(2): -40 to 176 °F (-40 to 80 °C)
(3) 3051CD0 process temperature limits are –40 to 212 °F (–40 to 100 °C).
(1)
For the output code M and W, LCD display may not be readable and
LCD display updates will be slower at temperatures below -22 °F
(-30 °C).
(2)
Wireless LCD display may not be readable and LCD display updates
will be slower at temperature below -4 °F (-20 °C).
(4)
Inert fill with traditional flange on Range 0: limits are 32 to 185°F
(0 to 85°C).
(5) 160 °F (71 °C) limit in vacuum service.
(6) Not available for 3051CA.
Humidity limits
Storage(1)
0–100% relative humidity
-50 to 230 °F (-46 to 110 °C)
With LCD display: -40 to 185 °F (-40 to 85 °C)
With Wireless Output: -40 °F to 185 °F (-40 °C to 85 °C)
Turn-on time
(1)
If storage temperature is above 85°C, perform a sensor trim prior to
installation.
Performance within specifications less than 2.0 seconds
(20.0 seconds for PROFIBUS PA and FOUNDATION fieldbus
protocols) after power is applied to the transmitter.(1)
(1)
Does not apply to wireless option code X.
Volumetric displacement
Less than 0.005 in3 (0,08 cm3)
www.rosemount.com
53
Rosemount 3051
Damping
4-20 mA HART
September 2014
For 3051CFC, see 00813-0100-4485 Rosemount 405 Compact
Orifice Plate
For 3051CFP, see 00813-0100-4485 Rosemount 1195 Integral
Orifice
Analog output response to a step input change is user-enterable
from 0.0 to 60 seconds for one time constant. This software
damping is in addition to sensor module response time.
Process-wetted parts
FOUNDATION fieldbus
Drain/vent valves
Transducer block: User configurable
AI Block: User configurable
316 SST, Alloy C-276, or Alloy 400 material (Alloy 400 not
available with 3051L)
PROFIBUS PA
Process flanges and adapters
AI Block only: User configurable
Physical specifications
Plated carbon steel
SST: CF-8M (Cast 316 SST) per ASTM A743
Cast C-276: CW-12MW per ASTM A494
Cast Alloy 400: M-30C per ASTM A494
Material selection
Wetted O-rings
Emerson provides a variety of Rosemount products with various
product options and configurations including materials of
construction that can be expected to perform well in a wide
range of applications. The Rosemount product information
presented is intended as a guide for the purchaser to make an
appropriate selection for the application. It is the purchaser’s
sole responsibility to make a careful analysis of all process
parameters (such as all chemical components, temperature,
pressure, flow rate, abrasives, contaminants, etc.), when
specifying product materials, options, and components for the
particular application. Emerson Process Management is not in a
position to evaluate or guarantee the compatibility of the
process fluid or other process parameters with the product
options, configuration, or materials of construction selected.
Glass-filled PTFE or Graphite-filled PTFE
Electrical connections
1
/2–14 NPT, G1/2, and M20 × 1.5 conduit. The polymer housing
(housing code P) has no conduit entries. HART interface
connections fixed to terminal block for output code A and to
701P Power Module for Output Code X.
Process connections
Rosemount 3051C
1
/4–18 NPT on 21/8-in. centers
1
/2–14 NPT on 2-, 21/8-, or 21/4-in. centers
Rosemount 3051L
High pressure side: 2-, 3-, or 4-in., ASME B 16.5 (ANSI) Class 150,
300 or 600 flange; 50, 80 or 100 mm, PN 40 or 10/16 flange
Low pressure side: 1/4–18 NPT on flange 1/2–14 NPT on adapter
Rosemount 3051T
Isolating diaphragm material
3051CD
3051CG
3051T
3051CA
Process isolating diaphragms
316L SST (UNS S31603)
Alloy C-276 (UNS N10276)
Alloy 400 (UNS N04400)
Tantalum (UNS R05440)
Gold-plated Alloy 400
Gold-plated 316L SST
•
•
•
•
•
•
•
•
•
•
•
•
•
Rosemount 3051L process wetted parts
Flanged process connection (transmitter high side)
Process diaphragms, including process gasket surface
316L SST, Alloy C-276, or Tantalum
Extension
CF-3M (Cast version of 316L SST, material per ASTM-A743),
or Alloy C-276. Fits schedule 40 and 80 pipe.
Mounting flange
Zinc-cobalt plated CS or SST
Reference process connection (transmitter low side)
Isolating diaphragms
316L SST or Alloy C-276
Reference flange and adapter
CF-8M (Cast version of 316 SST, material per ASTM-A743)
Non-wetted parts
1
/2–14 NPT female.
G1/2 A DIN 16288 Male (Range 1–4 only)
Autoclave type F-250-C (Pressure relieved 9/16–18 gland thread;
1
/4 OD high pressure tube 60° cone; available in SST for Range 5
transmitters only).
Electronics housing
Low-copper aluminum or CF-8M (Cast version of 316 SST).
Enclosure Type 4X, IP 65, IP 66, IP 68
Housing Material Code P: PBT/PC with NEMA 4X and IP66/67/68
Rosemount 3051CF
Coplanar sensor module housing
For 3051CFA, see 00813-0100-4485 Rosemount 485 Annubar
SST: CF-3M (Cast 316L SST)
54
www.rosemount.com
September 2014
Rosemount 3051
Table 12. 3051L Weights without Options
Bolts
Plated carbon steel per ASTM A449, Type 1
Austenitic 316 SST per ASTM F593
ASTM A193, Grade B7M alloy steel
Alloy K-500
Flange
DN 80/PN
40
DN 100/
PN 10/16
DN 100/
PN 40
Sensor module fill fluid
Coplanar: silicone or Inert Halocarbon
In-line: silicone or Fluorinert™ FC-43
Flush
lb. (kg)
2-in. Ext. 4-in. Ext. 6-in. Ext.
lb. (kg)
lb. (kg)
lb. (kg)
19.5 (8,8)
21.5 (9,7)
22.5
(10,2)
23.5
(10,6)
17.8 (8,1)
19.8 (9,0)
20.8 (9,5)
21.8 (9,9)
23.2
(10,5)
25.2
(11,5)
26.2
(11,9)
27.2
(12,3)
Process fill fluid (3051L only)
SYLTHERM XLT, D.C. Silicone 704, D.C. Silicone 200, inert,
glycerin and water, Neobee M-20, or propylene glycol and water
Paint
Polyurethane
Cover O-rings
Buna-N
Silicone (for wireless option code X)
Power module
Field replaceable, keyed connection eliminates the risk of
incorrect installation, Intrinsically Safe Lithium-thionyl chloride
Power Module with PBT enclosure.
Shipping weights
Table 11. Transmitter Weights without Options(1)
Transmitter
Rosemount 3051 In
Wireless In lb. (kg)
lb. (kg)
3051C
3051T
3051L
6.0 (2,7)
3.0 (1,4)
Table 12
3.9 (1,8)
1.9 (0,86)
Table 12
(1) Transmitter weights include the sensor module and housing only
(aluminum for Rosemount 3051 and polymer for wireless).
Table 12. 3051L Weights without Options
Flange
2-in., 150
3-in., 150
4-in., 150
2-in., 300
3-in., 300
4-in., 300
2-in., 600
3-in., 600
DN 50/PN
40
Flush
lb. (kg)
2-in. Ext. 4-in. Ext. 6-in. Ext.
lb. (kg)
lb. (kg)
lb. (kg)
12.5 (5,7)
17.5 (7,9)
23.5
(10,7)
17.5 (7,9)
22.5
(10,2)
32.5
(14,7)
15.3 (6,9)
25.2
(11,4)
N/A
19.5 (8,8)
26.5
(12,0)
N/A
24.5
(11,1)
35.5
(16,1)
N/A
27.2
(12,3)
N/A
20.5 (9,3)
28.5
(12,9)
N/A
25.5
(11,6)
37.5
(17,0)
N/A
28.2
(12,8)
N/A
21.5 (9,7)
30.5
(13,8)
N/A
26.5
(12,0)
39.5
(17,9)
N/A
29.2
(13,2)
13.8 (6,2)
N/A
N/A
N/A
www.rosemount.com
Table 13. Transmitter Option Weights
Add
lb. (kg)
Code
Option
J, K, L, M
J, K, L, M
M4/M5
M5
Stainless Steel Housing (T)
Stainless Steel Housing (C, L, H, P)
LCD display for wired transmitter
LCD Display for Wireless Output
SST Mounting Bracket for Coplanar
Flange
3.9 (1,8)
3.1 (1,4)
0.5 (0,2)
0.1 (0,04)
Mounting Bracket for Traditional Flange
2.3 (1,0)
Mounting Bracket for Traditional Flange
2.3 (1,0)
SST Bracket for Traditional Flange
Traditional Flange
Traditional Flange
Traditional Flange
Traditional Flange
Level Flange—3 in., 150
Level Flange—3 in., 300
Level Flange—2 in., 150
Level Flange—2 in., 300
DIN Level Flange, SST, DN 50, PN 40
DIN Level Flange, SST, DN 80, PN 40
SST Sensor Module
Power Module (701PGNKF)
2.3 (1,0)
2.4 (1,1)
2.7 (1,2)
2.6 (1,2)
2.5 (1,1)
10.8 (4,9)
14.3 (6,5)
10.7 (4,8)
14.0 (6,3)
8.3 (3,8)
13.7 (6,2)
1.0 (0,45)
0.4 (0,18)
B4
B1, B2,
B3
B7, B8,
B9
BA, BC
H2
H3
H4
H7
FC
FD
FA
FB
FP
FQ
WSM
1.0 (0,5)
55
Rosemount 3051
September 2014
3051 Product Certifications
European Directive Information
A copy of the EC Declaration of Conformity can be found at the
end of the Quick Start Guide. The most recent revision of the EC
Declaration of Conformity can be found at
www.rosemount.com.
Ordinary Location Certification for FM Approvals
As standard, the transmitter has been examined and tested to
determine that the design meets the basic electrical,
mechanical, and fire protection requirements by FM
Approvals, a nationally recognized test laboratory (NRTL) as
accredited by the Federal Occupational Safety and Health
Administration (OSHA).
Special Conditions for Safe Use (X):
1. The Model 3051 transmitter housing contains aluminum
and is considered a potential risk of ignition by impact or
friction. Care must be taken into account during
installation and use to prevent impact and friction.
2. The Model 3051 transmitter with the transient terminal
block (Option code T1) will not pass the 500Vrms
dielectric strength test and this must be taken into
account during installation.
C6
Standards: ANSI/ISA 12.27.01-2003, CSA Std. C22.2 No. 30
-M1986, CSA Std. C22.2 No.142-M1987, CSA
Std. C22.2. No.157-92, CSA Std. C22.2 No. 213
- M1987, CAN/CSA C22.2 No. 0-10, CSA Std
C22.2 No. 25-1966, CAN/CSA-C22.2 No.
94-M91, CAN/CSA-E60079-0-07,
CAN/CSA-E60079-1-07
North America
E5
FM Explosionproof (XP) and Dust-Ignitionproof (DIP)
Certificate: 0T2H0.AE
Standards: FM Class 3600 – 1998, FM Class 3615 – 2006,
FM Class 3810 – 2005, ANSI/NEMA 250 – 2003
Markings: Explosionproof for Class I, Division 1, Groups B,
C and D; Suitable for Class I, Zone 1, Group
IIB+H2, T5; Dust-Ignitionproof Class II, Division
1, Groups E, F, G; Class III Division 1; Intrinsically
Safe Class I, Division 1 Groups A, B, C, D when
connected in accordance with Rosemount
drawing 03031-1024, Temperature Code T3C;
Suitable for Class I, Zone 0; Class I Division 2
Groups A, B, C and D, T5; Suitable for Class I
Zone 2, Group IIC; Type 4X; Factory Sealed;
Single Seal (See drawing 03031-1053)
Markings: XP CL I, DIV 1, GP B, C, D; DIP CL II, DIV 1, GP E, F,
G; CL III; T5(-50°C  Ta  +85°C); Factory Sealed;
Type 4X
I5
FM Intrinsic Safety (IS) and Nonincendive (NI)
Certificate: 1Q4A4.AX
Standards: FM Class 3600 – 2011, FM Class 3610 – 2010,
FM Class 3611 – 2004, FM Class 3810 – 2005
Markings: IS CL I, DIV 1, GP A, B, C, D; CL II, DIV 1, GP E, F, G;
Class III; DIV 1 when connected per Rosemount
drawing 03031-1019; NI CL 1, DIV 2, GP A, B, C,
D; T4(-50°C  Ta  +70°C) [HART], T5(-50°C  Ta
 +40°C) [HART]; T4(-50°C  Ta  +60°C)
[Fieldbus/PROFIBUS]; Type 4x
Special Conditions for Safe Use (X):
1. The Model 3051 transmitter housing contains aluminum
and is considered a potential risk of ignition by impact or
friction. Care must be taken into account during
installation and use to prevent impact and friction.
2. The Model 3051 transmitter with the transient terminal
block (Option code T1) will not pass the 500Vrms
dielectric strength test and this must be taken into
account during installation.
IE
FM FISCO
Certificate: 1Q4A4.AX
CSA Explosionproof, Dust-Ignitionproof, Intrinsic Safety
and Nonincendive
Certificate: 1053834
E6
CSA Explosionproof, Dust-Ignitionproof and Division 2
Certificate: 1053834
Standards: ANSI/ISA 12.27.01-2003, CSA Std. C22.2 No. 30
-M1986, CSA Std. C22.2 No.142-M1987, CSA
Std. C22.2 No. 213 - M1987, CAN/CSA C22.2
No. 0-10, CSA Std C22.2 No. 25-1966,
CAN/CSA-C22.2 No. 94-M91, CAN/CSA-C22.2
No. 157-92, CAN/CSA-E60079-0-07,
CAN/CSA-E60079-1-07
Markings: Explosionproof Class I, Division 1, Groups B, C
and D; Suitable for Class I, Zone 1, Group
IIB+H2, T5; Dust-Ignitionproof for Class II and
Class III, Division 1, Groups E, F and G; Class I,
Division 2, Groups A, B, C and D; Suitable for
Class I Zone 2, Group IIC; Type 4X; Factory
Sealed; Single Seal (See drawing 03031-1053)
Standards: FM Class 3600 – 2011, FM Class 3610 – 2010,
FM Class 3611 – 2004, FM Class 3810 – 2005
Markings: IS CL I, DIV 1, GP A, B, C, D when connected per
Rosemount drawing 03031-1019 (-50°C  Ta 
+60°C); Type 4x
56
www.rosemount.com
September 2014
Rosemount 3051
Europe
E8
Special Conditions for Safe Use (X):
1. The apparatus is not capable of withstanding the 500 V
insulation test required by EN60079-11. This must be
taken into account when installing the apparatus.
ATEX Flameproof and Dust
Certificate: KEMA00ATEX2013X; Baseefa11ATEX0275X
2. The enclosure may be made of aluminum alloy and given a
protective polyurethane paint finish; however care should
be taken to protect it from impact or abrasion if located in
Zone 0.
Standards Used: EN60079-0:2012, EN60079-1:2007,
EN60079-26:2007, EN60079-31:2009
Markings: II 1/2 G, Ex d IIC T6/T5 Ga/Gb, T6(-50°C  Ta 
+65°C), T5(-50°C  Ta  +80°C);
II 1 D Ex ta IIIC T95°C T500 105°C Da (-20°C  Ta  +85°C)
3. Some variants of the equipment have reduced markings
on the nameplate. Refer to the Certificate for full
equipment marking.
Process Temperature
IA
Temperature class
Process temperature
T6
-50°C to +65°C
T5
-50°C to +80°C
ATEX FISCO
Certificate: BAS97ATEX1089X
Standards: EN60079-0:2012, EN60079-11:2009
Markings:
II 1 G Ex ia IIC Ga T4(-60°C  Ta  +60°C)
Special Conditions for Safe Use (X):
Input parameters
1. This device contains a thin wall diaphragm. Installation,
maintenance and use shall take into account the
environmental conditions to which the diaphragm will be
subjected. The manufacturer’s instructions for installation
and maintenance shall be followed in detail to assure
safety during its expected lifetime.
I1
FISCO
Voltage Ui
17.5 V
Current Ii
380 mA
2. For information on the dimensions of the flameproof joints
the manufacturer shall be contacted.
Power Pi
5.32 W
3. Some variants of the equipment have reduced markings
on the nameplate. Refer to the Certificate for full
equipment marking.
Capacitance Ci
<5 nF
Inductance Li
<10 μH
ATEX Intrinsic Safety and Dust
Special Conditions for Safe Use (X):
Certificate: BAS97ATEX1089X; Baseefa11ATEX0275X
Standards: EN60079-0:2012, EN60079-11:2012,
EN60079-31:2009
Markings: HART:
II 1 G Ex ia IIC T5/T4 Ga T5(-60°C  Ta 
+40°C), T4(-60°C  Ta  +70°C)
Fieldbus/PROFIBUS:
II 1 G Ex ia IIC Ga
T4(-60°C  Ta  +60°C)
DUST:
II 1 D Ex ta IIIC T95°C T500105°C Da
(-20°C  Ta  +85°C)
Input parameters
HART
Fieldbus/PROFIBUS
Voltage Ui
30 V
30 V
Current Ii
200 mA
300 mA
Power Pi
0.9 W
1.3 W
Capacitance Ci
0.012 μF
0 μF
Inductance Li
0 mH
0 mH
1. The apparatus is not capable of withstanding the 500 V
insulation test required by EN60079-11. This must be
taken into account when installing the apparatus.
2. The enclosure may be made of aluminum alloy and given a
protective polyurethane paint finish; however care should
be taken to protect it from impact or abrasion if located in
Zone 0.
N1
ATEX Type n and Dust
Certificate: BAS00ATEX3105X; Baseefa11ATEX0275X
Standards: EN60079-0:2012, EN60079-15:2010,
EN60079-31:2009
Markings:
II 3 G Ex nA IIC T5 Gc (-40°C  Ta  +70°C);
II 1 D Ex ta IIIC T95°C T500105°C Da (-20°C 
Ta  +85°C)
Special Conditions for Safe Use (X):
1. This apparatus is not capable of withstanding the 500V
insulation test that is required by EN60079-15. This must
be taken into account when installing the apparatus.
2. Some variants of the equipment have reduced markings
on the nameplate. Refer to the Certificate for full
equipment marking.
www.rosemount.com
57
Rosemount 3051
September 2014
International
E7
Special Conditions for Safe Use (X):
IECEx Flameproof and Dust
Certificate: IECEx KEM 09.0034X; IECEx BAS 10.0034X
Standards: IEC60079-0:2011, IEC60079-1:2007-04,
IEC60079-26:2006, IEC60079-31:2008
Markings: Ex d IIC T6/T5 Ga/Gb, T6(-50°C  Ta  +65°C),
T5(-50°C  Ta  +80°C);
Ex ta IIIC T95°C T500105°C Da (-20°C  Ta 
+85°C)
1. If the apparatus is fitted with an optional 90V transient
suppressor, it is not capable of withstanding the 500V
insulation test required by IEC 60079-11. This must be
taken into account when installing the apparatus.
2. The enclosure may be made of aluminum alloy and given a
protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in
Zone 0.
IECEx Mining (Special A0259)
Certificate: IECEx TSA 14.0001X
Process Temperature
Standards: IEC60079-0:2011, IEC60079-11:2011
Temperature class
Process temperature
T6
-50°C to +65°C
T5
-50°C to +80°C
Markings: Ex ia I Ma (-60°C  Ta  +70°C)
Input parameters
Special Conditions for Safe Use (X):
1. This device contains a thin wall diaphragm. Installation,
maintenance and use shall take into account the
environmental conditions to which the diaphragm will be
subjected. The manufacturer’s instructions for installation
and maintenance shall be followed in detail to assure
safety during its expected lifetime.
2. For information on the dimensions of the flameproof joints
the manufacturer shall be contacted.
3. Some variants of the equipment have reduced markings
on the nameplate. Refer to the Certificate for full
equipment marking.
I7
IECEx Intrinsic Safety
Certificate: IECEx BAS 09.0076X
Standards: IEC60079-0:2011, IEC60079-11:2011
Markings: HART: Ex ia IIC T5/T4 Ga, T5(-60°C  Ta  +40°C),
T4(-60°C  Ta  +70°C)
Fieldbus/PROFIBUS: Ex ia IIC Ga T4(-60°C  Ta 
+60°C)
Input parameters
58
HART
Fieldbus/PROFIBUS
Voltage Ui
30 V
30 V
Current Ii
200 mA
300 mA
Power Pi
0.9 W
1.3 W
Capacitance Ci
0.012 μF
0 μF
Inductance Li
0 mH
0 mH
HART
Fieldbus/PROFIBUS
FISCO
Voltage Ui
30 V
30 V
17.5 V
Current Ii
200 mA
300 mA
380 mA
Power Pi
0.9 W
1.3 W
5.32 W
Capacitance Ci
0.012 μF
0 μF
<5 nF
Inductance Li
0 mH
0 mH
<10 μH
Special Conditions for Safe Use (X):
1. If the apparatus is fitted with optional 90V transient
suppressor, it is not capable of withstanding the 500V
insulation test required by IEC60079-11. This must be
taken into account when installing the apparatus.
2. It is a condition of safe use that the above input
parameters shall be taken into account during installation.
3. It is a condition of manufacture that only the apparatus
fitted with housing, covers and sensor module housing
made out of stainless steel are used in Group I
applications.
N7
IECEx Type n
Certificate: IECEx BAS 09.0077X
Standards: IEC60079-0:2011, IEC60079-15:2010
Markings: Ex nA IIC T5 Gc (-40°C  Ta  +70°C)
Special Condition for Safe Use (X):
1. The apparatus is not capable of withstanding the 500V
insulation test required by IEC60079-15. This must be
taken into account when installing the apparatus.
www.rosemount.com
September 2014
Rosemount 3051
Brazil
Certificate: UL-BR 13.0584X
E2
INMETRO Flameproof
Standards: ABNT NBR IEC60079-0:2008 + Errata 1:2011,
ABNT NBR IEC60079-11:2009
Certificate: UL-BR 13.0643X
Markings: Ex ia IIC T4 Ga (-60°C  Ta  +60°C)
Standards: ABNT NBR IEC60079-0:2008 + Errata 1:2011,
ABNT NBR IEC60079-1:2009 + Errata 1:2011,
ABNT NBR IEC60079-26:2008 + Errata 1:2008
Input parameters
FISCO
Markings: Ex d IIC T6/T5 Ga/Gb, T6(-50°C  Ta  +65°C),
T5(-50°C  Ta  +80°C)
Special Conditions for Safe Use (X):
1. This device contains a thin wall diaphragm. Installation,
maintenance and use shall take into account the
environmental conditions to which the diaphragm will be
subjected. The manufacturer’s instructions for installation
and maintenance shall be followed in detail to assure
safety during its expected lifetime.
2. In case of repair, contact the manufacturer for information
on the dimensions of the flameproof joints.
3. The capacitance of the wrap around label, being 1.6nF,
exceeds the limit in Table 9 of ABNT NBR IEC 60079-0. The
user shall determine suitability for the specific application.
I2
INMETRO Intrinsic Safety
Certificate: UL-BR 13.0584X
Standards: ABNT NBR IEC60079-0:2008 + Errata 1:2011,
ABNT NBR IEC60079-11:2009
Markings: HART: Ex ia IIC T5/T4 Ga, T5(-60°C  Ta  +40°C),
T4(-60°C  Ta  +70°C)
Fieldbus/PROFIBUS: Ex ia IIC T4 Ga (-60°C  Ta 
+60°C)
Input parameters
HART
Fieldbus/PROFIBUS
Voltage Ui
30 V
30 V
Current Ii
200 mA
300 mA
Power Pi
0.9 W
1.3 W
Capacitance Ci
0.012 μF
0 μF
Inductance Li
0 mH
0 mH
Special Conditions for Safe Use (X):
1. If the equipment is fitted with an optional 90V transient
suppressor, it is not capable of withstanding the 500V
insulation test required by ABNT NBR IRC 60079-11:2008.
This must be taken into account when installing the
equipment.
2. The enclosure may be made of aluminum alloy and given a
protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in
Zone 0.
IB
INMETRO FISCO
www.rosemount.com
Voltage Ui
17.5 V
Current Ii
380 mA
Power Pi
5.32 W
Capacitance Ci
<5 nF
Inductance Li
<10 μH
Special Conditions for Safe Use (X):
1. If the equipment is fitted with an optional 90V transient
suppressor, it is not capable of withstanding the 500V
insulation test required by ABNT NBR IRC 60079-11:2008.
This must be taken into account when installing the
equipment.
2. The enclosure may be made of aluminum alloy and given a
protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in
Zone 0.
China
E3
China Flameproof
Certificate: GYJ14.1041X; GYJ10.1313X [Flowmeters]
Standards: GB3836.1-2000, GB3836.2-2010,
GB12476-2000
Markings: Ex d IIC T6/T5, T6(-50°C  Ta  +65°C), T5(-50°C 
Ta  +80°C)
Special Conditions for Safe Use (X):
1. The relation between ambient temperature arrange and
temperature class is as follows:
Ta
Temperature class
-50°C~+80°C
T5
-50°C~+65°C
T6
When used in a combustible dust environment, the
maximum ambient temperature is 80°C.
2. The earth connection facility in the enclosure should be
connected reliably.
3. Cable entry certified by notified body with type of
protection Ex d IIC in accordance with GB3836.1-2000 and
GB3836.2-2000, should be applied when installed in a
59
Rosemount 3051
September 2014
hazardous location. When used in combustible dust
environment, cable entry in accordance with IP66 or
higher level should be applied.
3. Intrinsically Safe parameters:
Input parameters
HART
Fieldbus/PROFIBUS
FISCO
Voltage Ui
30 V
30 V
17.5 V
Current Ii
200 mA
300 mA
380 mA
Power Pi
0.9 W
1.3 W
5.32 W
Capacitance Ci
0.012 μF
0 μF
<5 nF
Inductance Li
0 mH
0 mH
<10 μH
4. Obey the warning “Keep tight when the circuit is alive.”
5. End users are not permitted to change any internal
components.
6. During installation, use and maintenance of this product,
observe the following standards:
GB3836.13-1997 “Electrical apparatus for explosive gas
atmospheres Part 13: Repair and overhaul for apparatus
used in explosive gas atmospheres”
GB3836.15-2000 “Electrical apparatus for explosive gas
atmospheres Part 15: Electrical installations in hazardous
area (other than mines)”
GB3836.16-2006 “Electrical apparatus for explosive gas
atmospheres Part 16: Inspection and maintenance of
electrical installation (other than mines)”
GB50257-1996 “Code for construction and acceptance of
electric device for explosion atmospheres and fire hazard
electrical equipment installation engineering”.
GB12476.2-2006 “Electrical apparatus for use in the
presence of combustible dust Part 1-2: Electrical apparatus
protected by enclosures and surface temperature
limitation-Selection, installation and maintenance”
GB15577-2007 “Safety regulations for dust explosion
prevention and protection”
I3
China Intrinsic Safety
Certificate: GYJ13.1362X; GYJ101312X [Flowmeters]
Standards: GB3836.1-2010, GB3836.4-2010,
GB3836.20-2010, GB12476.1-2000
Markings: Ex ia IIC Ga T4/T5
Special Conditions for Safe Use (X):
1. Symbol “X” is used to denote specific conditions of use:
a.If the apparatus is fitted with an optional 90V transient
suppressor, it is not capable of withstanding the 500V
insulation test for 1 minute. This must be taken into
account when installing the apparatus.
b.The enclosure may be made of aluminum alloy and
given a protective polyurethane paint finish; however,
care should be taken to protect it from impact or
abrasion if located in Zone 0.
2. The relation between T code and ambient temperature
range is:
60
Model
T
code
Temperature
range
HART
T5
-60°C  Ta  +40°C
HART
T4
-60°C  Ta  +70°C
Fieldbus/PROFIBUS/FISCO
T4
-60°C  Ta  +60°C
Flowmeter with 644 Temp
Housing
T4
-40°C  Ta  +60°C
Note 1: FISCO parameters apply to both Group IIC and IIB.
Note 2: [For Flowmeters] When 644 Temperature
Transmitter is used, it should be used with Ex-certified
associated apparatus to establish explosion protection
system that can be used in explosive gas atmospheres.
Wiring and terminals should comply with the instruction
manual of both 644 Temperature Transmitter and
associated apparatus. The cables between 644
Temperatures Transmitter and associated apparatus
should be shielded cables (the cables must have insulated
shield). The shielded cable has to be grounded reliably in a
non-hazardous area.
4. Transmitters comply with the requirements for FISCO field
devices specified in IEC60079-27:2008. For the connection
of an intrinsically safe circuit in accordance with FISCO
Model, FISCO parameters are listed in the table above.
5. The product should be used with Ex-certified associated
apparatus to establish explosion protection system that
can be used in explosive gas atmospheres. Wiring and
terminals should comply with the instruction manual of
the product and associated apparatus.
6. The cables between this product and associated apparatus
should be shielded cables (the cables must have insulated
shield). The shielded cable has to be grounded reliably in a
non-hazardous area.
7. End users are not permitted to change any intern
components but to settle the problem in conjunction with
the manufacturer to avoid damage to the product.
8. During installation, use and maintenance of this product,
observe the following standards:
GB3836.13-1997 “Electrical apparatus for explosive gas
atmospheres Part 13: Repair and overhaul for apparatus
used in explosive gas atmospheres”
GB3836.15-2000 “Electrical apparatus for explosive gas
atmospheres Part 15: Electrical installations in hazardous
area (other than mines)”
GB3836.16-2006 “Electrical apparatus for explosive gas
atmospheres Part 16: Inspection and maintenance of
electrical installation (other than mines)”
GB50257-1996 “Code for construction and acceptance of
electric device for explosion atmospheres and fire hazard
electrical equipment installation engineering”.
GB12476.2-2006 “Electrical apparatus for use in the
presence of combustible dust Part 1-2: Electrical apparatus
protected by enclosures and surface temperature
www.rosemount.com
September 2014
N3
Rosemount 3051
limitation-Selection, installation and maintenance”
GB15577-2007 “Safety regulations for dust explosion
prevention and protection”
Technical Regulations Customs Union
(EAC)
China Type n
EM, IM, KM
Certificate: GYJ101111X
Standards: GB3836.1-2000, GB3836.8-2003
Markings: Ex nA IIC T5 (-40°C  Ta  +70°C)
Special Conditions for Safe Use (X):
1. Symbol “X” is used to denote specific conditions of use:
The apparatus is not capable of withstanding the 500V test
to earth for one minute. The must be taken into
consideration during installation.
2. The ambient temperature range is -40°C  Ta  +70°C.
3. Maximum input voltage: 55V.
4. Cable glands, conduit or blanking plugs, certified by NEPSI
with Ex e or Ex n protection type and IP66 degree of
protection provided by enclosure, should be used on
external connections and redundant cable entries.
5. Maintenance should be done in non-hazardous location.
6. End users are not permitted to change any internal
components but to settle the problem in conjunction with
manufacturer to avoid damage to the product.
7. During installation, use and maintenance of this product,
observe the following standards:
GB3836.13-1997 “Electrical apparatus for explosive gas
atmospheres Part 13: Repair and overhaul for apparatus
used in explosive gas atmospheres”
GB3836.15-2000 “Electrical apparatus for explosive gas
atmospheres Part 15: Electrical installations in hazardous
area (other than mines)”
GB3836.16-2006 “Electrical apparatus for explosive gas
atmospheres Part 16: Inspection and maintenance of
electrical installation (other than mines)”
GB50257-1996 “Code for construction and acceptance of
electric device for explosion atmospheres and fire hazard
electrical equipment installation engineering”
Contact an Emerson Process Management
representative for further information.
Combinations
K2
Combination of E2 and I2
K5
Combination of E5 and I5
K6
Combination of C6, E8, and I1
K7
Combination of E7, I7, and N7
K8
combination of E8, I1, and N1
KB
Combination of E5, I5, and C6
KD
Combination of E8, I1, E5, I5, and C6
Conduit Plugs and Adapters
IECEx Flameproof and Increased Safety
Certificate: IECEx FMG 13.0032X
Standards: IEC60079-0:2011, IEC60079-1:2007,
IEC60079-7:2006-2007
Markings: Ex de IIC Gb
ATEX Flameproof and Increased Safety
Certificate: FM13ATEX0076X
Standards: EN60079-0:2012, EN60079-1:2007,
IEC60079-7:2007
Markings:
II 2 G Ex de IIC Gb
Conduit Plug Thread Sizes
Thread
Identification mark
Japan
M20 x 1.5
M20
E4
1/2 - 14 NPT
1/2 NPT
G1/2A
G1/2
Japan Flameproof
Certificate: TC20577, TC20578, TC20583, TC20584
[HART]; TC20579, TC20580, TC20581,
TC20582 [Fieldbus]
Markings: Ex d IIC T5
www.rosemount.com
61
Rosemount 3051
September 2014
Application:
Thread Adapter Thread Sizes
Male thread
Identification mark
M20 x 1.5 – 6H
M20
1/2 - 14 NPT
1/2 – 14 NPT
3/4 - 14 NPT
3/4 – 14 NPT
Female thread
Identification mark
M20 x 1.5 – 6H
M20
1/2 - 14 NPT
1/2 – 14 NPT
PG 13.5
PG 13.5
Location classes
2. The blanking plug shall not be used with an adapter.
3. Blanking Plug and Threaded Adapter shall be either NPT or
Metric thread forms. G½ and PG 13.5 thread forms are
only acceptable for existing (legacy) equipment
installations.
3051
Temperature
D
Humidity
B
Vibration
A
EMC
B
Enclosure
D
SLL Lloyds Register (LR) Type Approval
Certificate: 11/60002
Special Conditions for Safe Use (X):
1. When the thread adapter or blanking plug is used with an
enclosure in type of protection increased safety “e” the
entry thread shall be suitably sealed in order to maintain
the ingress protection rating (IP) of the enclosure.
Type
Application: Environmental categories ENV1, ENV2, ENV3
and ENV5
C5
Custody Transfer - Measurement Canada Accuracy
Approval
Certificate: AG-0226; AG-0454; AG-0477
IEC 62591 (WirelessHART Protocol)
Additional Certifications
Approved Manufacturing Locations
SBS American Bureau of Shipping (ABS) Type Approval
Rosemount Inc. — Chanhassen, Minnesota USA
Fisher-Rosemount GmbH & Co. — Wessling, Germany
Emerson Process Management Asia Pacific Private Limited —
Singapore
Beijing Rosemount Far East Instrument Co., LTD — Beijing, China
Certificate: 09-HS446883A-PDA
Intended Use: Measure gauge or absolute pressure of
liquid, gas or vapor applications on ABS classed
vessels, marine, and offshore installations.
ABS Rules: 2014 Steel Vessels Rules 1-1-4/7.7, 4-8-3/13.1,
1-1-A3, 4-8-3/1.7, 4-8-3/1.11.1
SBV Bureau Veritas (BV) Type Approval
European Directive Information
The most recent revision of the EC declaration of conformity can
be found at www.rosemount.com.
Certificate: 23155/A3 BV
Telecommunication Compliance
Requirements: Bureau Veritas Rules for the Classification of
Steel Ships
All wireless devices require certification to ensure that they
adhere to regulations regarding the use of the RF spectrum.
Nearly every country requires this type of product certification.
Emerson is working with governmental agencies around the
world to supply fully compliant products and remove the risk of
violating country directives or laws governing wireless device
usage.
Application: Class notations: AUT-UMS, AUT-CCS,
AUT-PORT and AUT-IMS; Pressure transmitter
type 3051 cannot be installed on diesel engines
SDN Det Norske Veritas (DNV) Type Approval
Certificate: A-13245
Intended Use: Det Norske Veritas’ Rules for Classification of
Ships, High Speed & Light Craft and Det Norske
Veritas’ Offshore Standards
62
www.rosemount.com
September 2014
Rosemount 3051
FCC and IC
CSA - Canadian Standards Association
This device complies with Part 15 of the FCC Rules. Operation is
subject to the following conditions: This device may not cause
harmful interference. This device must accept any interference
received, including interference that may cause undesired
operation. This device must be installed to ensure a minimum
antenna separation distance of 20 cm from all persons.
I6
Ordinary Location Certification for FM
As standard, the transmitter has been examined and tested to
determine that the design meets basic electrical, mechanical,
and fire protection requirements by FM, a nationally recognized
testing laboratory (NRTL) as accredited by the Federal
Occupational Safety and Health Administration (OSHA).
European Certifications
I1
North American Certifications
Factory Mutual (FM) approvals
I5
FM Intrinsically Safe
Certificate No: 3046325
Applicable Standards: Class 3600:2011, Class 3610:2010,
Class 3810: 2005, ANSI/ISA 60079-0 2009,ANSI/ISA
60079-11:2009&#10;ANSI/NEMA 250:2003, ANSI/IEC
60529:2004
Markings: Intrinsically Safe for Class I, Division I, Groups A,
B, C, D
Zone Marking: Class I Zone 0, AEx ia IIC
T4 (-40 °C to 70 °C)
Intrinsically Safe when installed according to Rosemount
Drawing 03031-1062
Enclosure Type 4X/IP66/IP68/IP67
CSA Intrinsically Safe
Certificate No: 2526009
Applicable Standards: CSA C22.2 No. 0-M91, CSA C22.2
No. 94-M91, CSA C22.2 No. 142-M1987, CSA C22.2 No.
157-92, CSA C22.2 No. 60529-05
Markings: Intrinsically Safe For Class I, Division I, Groups A,
B, C, D
T4 (-40 °C to 70 °C)
Intrinsically safe when installed according to Rosemount
drawing 03031-1063
Enclosure Type 4X/IP66/IP68
ATEX Intrinsic Safety
Certificate No: Baseefa12ATEX0228X
Applicable Standards: EN60079-11:2012,
EN60079-0:2012
Markings: Ex ia IIC T4 Ga (-40 °C Ta 70 °C)
II 1G
IP66/68
1180
Special Conditions for Safe Use (X):
1. The plastic enclosure may constitute a potential
electrostatic ignition risk and must not be rubbed or
cleaned with a dry cloth.
I7
IECEx Intrinsic Safety
Certificate No: IECEx BAS 12.0124X
Applicable Standards: IEC60079-11:2011,
IEC60079-0:2011
Markings: Ex ia IIC T4 Ga (-40 °C Ta 70 °C)
IP66/68
Special Conditions for Safe Use (X):
1. The inline pressure sensor may contain more than 10%
aluminum and is considered a potential risk of ignition by
impact or friction. Care must be taken into account during
installation and use to prevent impact and friction.
2. The surface resistivity of the transmitter is greater than
one gigaohm. To avoid electrostatic charge build-up, it
must not be rubbed or cleaned with solvents or a dry cloth.
3. The Model 3051 Wireless Pressure Transmitter shall only
be used with the 701PGNKF Rosemount SmartPower
Battery Pack.
www.rosemount.com
Special Conditions for Safe Use (X):
1. The plastic enclosure may constitute a potential
electrostatic ignition risk and must not be rubbed or
cleaned with a dry cloth.
2. The Model 701PGNKF Power Module may be replaced in a
hazardous area. The Power Module has a surface resistivity
greater than 1G  and must be properly installed in the
wireless device enclosure. Care must be taken during
transportation to and from the point of installation to
prevent electrostatic charge build-up.
63
Rosemount 3051
September 2014
Pipe I.D. Range Codes
For pipes with an Inner Diameter (I.D.) Range/Pipe Wall Thickness not found in this table or with a line size greater than 12-in. (300
mm), choose option code Z and specify the exact pipe dimensions (I.D. and Pipe Wall Thickness) on the Configuration Data Sheet
(see document number 00806-0100-4010). The Emerson Process Management sizing program will determine this code, based on
the application piping.
Line size
Nominal
2-in.
(50 mm)
21/2-in.
(63.5 mm)
3-in.
(80 mm)
31/2-in.
(89 mm)
4-in.
(100 mm)
5-in.
(125 mm)
64
Max. O.D.
2.625-in.
(66.68 mm)
3.188-in.
(80.98 mm)
3.75-in.
(95.25 mm)
4.25-in.
(107.95 mm)
5.032-in.
(127.81 mm)
6.094-in.
(154.79 mm)
Pipe wall thickness
Option I.D. range
code
020
025
030
035
040
050
1.784 to 1.841-in.
(45.31 to 46.76 mm)
1.842 to 1.938-in.
(46.79 to 49.23 mm)
1.939 to 2.067-in.
(49.25 to 52.50 mm)
2.068 to 2.206-in.
(52.53 to 56.03 mm)
2.207 to 2.322-in.
(56.06 to 58.98 mm)
2.323 to 2.469-in.
(59.00 to 62.71 mm)
2.470 to 2.598-in.
(62.74 to 65.99 mm)
2.599 to 2.647-in.
(66.01 to 67.23 mm)
2.648 to 2.751-in.
(67.26 to 69.88 mm)
2.752 to 2.899-in.
(69.90 to 73.63 mm)
2.900 to 3.068-in.
(73.66 to 77.93 mm)
3.069 to 3.228-in.
(77.95 to 81.99 mm)
3.229 to 3.333-in.
(82.02 to 84.66 mm)
3.334 to 3.548-in.
(84.68 to 90.12 mm)
3.549 to 3.734-in.
(90.14 to 94.84 mm)
3.735 to 3.825-in.
(94.87 to 97.16 mm)
3.826 to 4.026-in.
(97.18 to 102.26 mm)
4.027 to 4.237-in.
(102.29 to 107.62 mm)
4.238 to 4.437-in.
(107.65 to 112.70 mm)
4.438 to 4.571-in.
(112.73 to 116.10 mm)
4.572 to 4.812-in.
(116.13 to 122.22 mm)
4.813 to 5.047-in.
(122.25 to 128.19 mm)
5.048 to 5.249-in.
(128.22 to 133.32 mm)
ANSI pipes
0.065 to 0.545-in.
(1.7 to 13.8 mm)
0.083 to 0.563-in.
(2.1 to 14.3 mm)
0.083 to 0.563-in.
(2.1 to 14.3 mm)
0.120 to 0.600-in.
(3.0 to 15.2 mm)
0.120 to 0.600-in.
(3.0 to 15.2 mm)
0.134 to 0.614-in.
(3.4 to 15.6 mm)
Non-ANSI pipes
0.065 to 0.488-in.
(1.7 to 12.4 mm)
0.065 to 0.449-in.
(1.7 to 11.4 mm)
0.065 to 0.417-in.
(1.7 to 10.6 mm)
0.065 to 0.407-in.
(1.7 to 10.3 mm)
0.083 to 0.448-in.
(2.1 to 11.4 mm)
0.083 to 0.417-in.
(2.1 to 10.6 mm)
0.083 to 0.435-in.
(2.1 to 11.0 mm)
0.083 to 0.515-in.
(2.1 to 13.1 mm)
0.083 to 0.460-in.
(2.1 to 11.7 mm)
0.083 to 0.416-in.
(2.1 to 10.6 mm)
0.083 to 0.395-in.
(2.1 to 10.0 mm)
0.083 to 0.404-in
(2.1 to 10.3 mm)
0.120 to 0.496-in.
(3.0 to 12.6 mm)
0.120 to 0.386-in.
(3.0 to 9.8 mm)
0.120 to 0.415-in.
(3.0 to 10.5 mm)
0.120 to 0.510-in.
(3.0 to 13.0 mm)
0.120 to 0.400-in.
(3.0 to 10.2 mm)
0.120 to 0.390-in.
(3.0 to 9.9 mm)
0.120 to 0.401-in.
(3.0 to 10.2 mm)
0.134 to 0.481-in.
(3.4 to 12.2 mm)
0.134 to 0.374-in.
(3.4 to 9.5 mm)
0.134 to 0.380-in.
(3.4 to 9.7 mm)
0.134 to 0.413-in.
(3.4 to 10.5 mm)
I.D.
range
code
A
B
C
D
B
C
D
E
A
B
C
D
B
C
D
B
C
D
E
A
B
C
D
www.rosemount.com
Sensor
Size 2
Sensor
Size 1
Sensor
Z2
Sensor
Size 1
Sensor
Size 2
Sensor
Size 1
September 2014
6-in.
(150 mm)
6-in.
(150 mm)
7-in.
(180 mm)
7-in.
(180 mm)
8-in.
(200 mm)
8-in.
(200 mm)
10-in.
(250 mm)
12-in.
(300 mm)
Rosemount 3051
6.93-in.
(176.02 mm)
6.93-in.
(176.02 mm)
7.93-in.
(201.42 mm)
7.93-in.
(201.42 mm)
9.688-in.
(246.08 mm)
9.688-in.
(246.08 mm)
11.75-in.
(298.45 mm)
13.0375-in.
(331.15 mm)
www.rosemount.com
060
060
070
070
080
080
100
120
5.250 to 5.472-in.
(133.35 to 138.99 mm)
5.473 to 5.760-in.
(139.01 to 146.30 mm)
5.761 to 6.065-in.
(146.33 to 154.05 mm)
6.066 to 6.383-in.
(154.08 to 162.13 mm)
5.250 to 5.472-in.
(133.35 to 139.99 mm)
5.473 to 5.760-in.
(139.01 to 146.30 mm)
5.761 to 6.065-in.
(146.33 to 154.05 mm)
6.066 to 6.383-in.
(154.08 to 162.13 mm)
6.384 to 6.624-in.
(162.15 to 168.25 mm)
6.625 to 7.023-in.
(168.28 to 178.38 mm)
7.024 to 7.392-in.
(178.41 to 187.76 mm)
6.384 to 6.624-in.
(162.15 to 168.25 mm)
6.625 to 7.023-in.
(168.28 to 178.38 mm)
7.024 to 7.392-in.
(178.41 to 187.76 mm)
7.393 to 7.624-in.
(187.78 to 193.65 mm)
7.625 to 7.981-in.
(193.68 to 202.72 mm)
7.982 to 8.400-in.
(202.74 to 213.36 mm)
8.401 to 8.766-in.
(213.39 to 222.66 mm)
7.393 to 7.624-in.
(187.78 to 193.65 mm)
7.625 to 7.981-in.
(193.68 to 202.72 mm)
7.982 to 8.400-in.
(202.74 to 213.36 mm)
8.401 to 8.766-in.
(213.39 to 222.66 mm)
8.767 to 9.172-in.
(222.68 to 232.97 mm)
9.173 to 9.561-in.
(232.99 to 242.85 mm)
9.562 to 10.020-in.
(242.87 to 254.51 mm)
10.021 to 10.546-in.
(254.53 to 267.87 mm)
10.547 to 10.999-in.
(267.89 to 279.37 mm)
11.000 to 11.373-in.
(279.40 to 288.87 mm)
11.374 to 11.938-in.
(288.90 to 303.23 mm)
11.939 to 12.250-in.
(303.25 to 311.15 mm)
0.134 to 0.614-in.
(3.4 to 15.6 mm)
0.134 to 1.354-in.
(3.4 to 34.4 mm)
0.134 to 0.614-in.
(3.4 to 15.6 mm)
0.134 to 1.354-in.
(3.4 to 34.4 mm)
0.250 to 0.73-in.
(6.4 to 18.5 mm)
0.250 to 1.47-in.
(6.4 to 37.3 mm)
0.250 to 1.470-in.
(6.4 to 37.3 mm)
0.250 to 1.470-in.
(6.4 to 37.3 mm)
0.134 to 0.3919-in.
(3.4 to 9.9 mm)
0.134 to 0.327-in.
(3.4 to 8.3 mm)
0.134 to 0.31-in.
(3.4 to 7.9 mm)
0.134 to 0.297-in.
(3.4 to 7.5 mm)
0.134 to 1.132-in.
(3.4 to 28.7 mm)
0.134 to 1.067-in.
(3.4 to 27.1 mm)
0.134 to 1.05-in.
(3.4 to 26.7 mm)
0.134 to 1.037-in.
(3.4 to 26.3 mm)
0.134 to 0.374-in.
(3.4 to 9.5 mm)
0.134 to 0.216-in.
(3.4 to 5.5 mm)
0.134 to 0.246-in.
(3.4 to 6.2 mm)
0.134 to 1.114-in.
(3.4 to 28.3 mm)
0.134 to 0.956-in.
(3.4 to 24.3 mm)
0.134 to 0.986-in.
(3.4 to 25.0 mm)
0.250 to 0.499-in.
(6.4 to 12.6 mm)
0.250 to 0.374-in.
(6.4 to 9.5 mm)
0.250 to 0.312-in.
(6.4 to 7.9 mm)
0.250 to 0.364-in.
(6.4 to 9.2 mm)
0.250 to 1.239-in.
(6.4 to 31.4 mm)
0.250 to 1.114-in.
(6.4 to 28.3 mm)
0.250 to 1.052-in.
(6.4 to 26.7 mm)
0.250 to 1.104-in.
(6.4 to 28.0 mm)
0.250 to 1.065-in.
(6.4 to 27.1 mm)
0.250 to 1.082-in.
(6.4 to 27.5 mm)
0.250 to 1.012-in.
(6.4 to 25.7 mm)
0.250 to 0.945-in.
(6.4 to 24.0 mm)
0.250 to 1.018-in.
(6.4 to 25.9 mm)
0.250 to 1.097-in.
(6.4 to 27.9 mm)
0.250 to 0.906-in.
(6.4 to 23.0 mm)
0.250 to 1.159-in.
(6.4 to 29.4 mm)
A
B
C
D
A
B
C
D
B
C
D
B
C
D
B
C
D
E
B
C
D
E
A
B
C
D
E
B
C
D
65
Rosemount 3051
September 2014
Rosemount 3051 Dimensional Drawings(1)
Figure 1. Rosemount 3051C Exploded View
F
E
D
C
B
A
G
H
I
J
K
N
L
O
M
P
Q
A. Cover
B. Cover O-ring
C. Terminal Block
D. Electronics Housing
E. Configuration Buttons Cover
F. Local Configuration Buttons
(1)
66
G. Electronics Board
H. Name Plate
I. Housing Rotation Set Screw (180 degree maximum
rotation without further disassembly)
J. Sensor Module
K. Coplanar Flange
L. Drain/Vent Valve
M. Flange Adapters
N. Process O-Ring
O. Flange Adapter O-Ring
P. Flange Alignment Screw (not pressure retaining)
Q. Flange Bolts
This section contains dimensional drawings for output codes A, F and X. For output codes W and M, visit
http://www2.emersonprocess.com/en-US/brands/rosemount/Documentation-and-Drawings/Type-1-Drawings/Pages/index.aspx
www.rosemount.com
September 2014
Rosemount 3051
Figure 2. Rosemount 3051C Coplanar Flange
4.29
(109)
4.09
(104)
7.12
(181)
6.55
(166)
Dimensions are in inches (millimeters).
Figure 3. 3051 Wireless Housing with Coplanar Flange
4.196
(106.6)
5.49
(139)
7.41
(188)
Dimensions are in inches (millimeters).
www.rosemount.com
67
Rosemount 3051
September 2014
Figure 4. Rosemount 3051C Coplanar Flange with Rosemount 305RC3 3-Valve Coplanar Integral Manifold
6.75
(171)
5.50 (140)
Max Open
9.20 (234)
Max Open
Dimensions are in inches (millimeters).
68
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September 2014
Rosemount 3051
Figure 5. Coplanar Flange Mounting Configurations with Optional Bracket (B4) for 2-in. Pipe or Panel Mounting
A
2.81
(71)
B
PANEL
MOUNTING
3.35
(85)
6.20
(157)
2.81
(71)
4.73
(120)
C
D
PIPE
MOUNTING
3.35
(85)
6.25
(159)
3.50
(89)
A. 5/16 - 18 Bolts (not supplied)
B. 3/8–16 Bolts
Dimensions are in inches (millimeters).
www.rosemount.com
C. 2-inch U-Bolt
D. 3/8–16 Bolts
69
Rosemount 3051
September 2014
Figure 6. Rosemount 3051C Coplanar with Traditional Flange
4.09
(104)
1.63
(41)
2.13
(54)
A
1.16
(29)
3.40
(86)
1.10
(28)
A. Flange Adapters (optional)
Dimensions are in inches (millimeters).
Figure 7. Rosemount 3051C Coplanar with Rosemount 305RT3 3-Valve Traditional Integral Manifold
6.28
(159)
A
3.63
(92)
0.91
(23)
3.50
(89)
1.10
(28)
6.38
(162)
2.13
(54)
2.52
(64)
A. 1/2–14 NPT Flange Adapter (optional)
Dimensions are in inches (millimeters).
70
www.rosemount.com
September 2014
Rosemount 3051
Figure 8. Traditional Flange Mounting Configurations with Optional Brackets for 2-in. Pipe or Panel Mounting
Panel mounting bracket (option B2/B8)
2.62
(67)
2-in. pipe mounting bracket (option B1/B7/BA)
9.27
(235)
2.62
(67)
A
6.65
(169)
0.93
(24)
4.12
(105)
2.81
(71)
2-in. pipe mounting bracket (option B3/B9/BC)
6.65
(169)
4.85
(123)
1.10
(28)
3.40
(86)
1.75
(44)
A. 5/16-18 Bolts (not supplied)
Dimensions are in inches (millimeters).
www.rosemount.com
71
Rosemount 3051
September 2014
Figure 9. Rosemount 3051T Dimensional Drawings
4.09
(104)
4.29
(109)
R1-4: 7.22 (183)
R5: 7.32 (186)
Dimensions are in inches (millimeters).
Figure 10. 3051T Wireless Housing Dimensional Drawings
4.20
(107)
5.49
(139)
R1-4: 7.56 (192)
R5: 7.66 (195)
A
A. U-Bolt Bracket
Dimensions are in inches (millimeters).
72
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September 2014
Rosemount 3051
Figure 11. Rosemount 3051T with Rosemount 306 2-Valve I Integral Manifold
4.13
(105)
4.88
(124)
6.25 (159)
Max Open
Dimensions are in inches (millimeters).
Figure 12. Rosemount 3051T Typical Mounting Configurations with Optional Mounting Bracket
Pipe mounting
Panel mounting
6.15
(156)
3.49
(89)
6.15
(156)
2.81
(71)
4.78
(121)
Dimensions are in inches (millimeters).
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73
Rosemount 3051
September 2014
Figure 13. Rosemount 3051CFA Pak-Lok Annubar Flowmeter(1)
Front view
Side view
Top view
D
C
B
A
Table 14. Rosemount 3051CFA Pak-Lok Annubar Flowmeter Dimensional Data (Maximum Dimensions)
Sensor size
A
B
C
D
1
8.50 (215.9)
15.60 (396.9)
9.00 (228.6)
6.00 (152.4)
2
11.00 (279.4)
18.10 (460.4)
9.00 (228.6)
6.00 (152.4)
3
12.00 (304.8)
19.10 (485.8)
9.00 (228.6)
6.00 (152.4)
Dimensions are in inches (millimeters).
(1)
74
The Pak-Lok Annubar model is available up to 600# ANSI [1440 psig at 100 °F (99 bar at 38 °C)].
www.rosemount.com
September 2014
Rosemount 3051
Figure 14. Rosemount 3051CFC Compact Orifice Flowmeter
Orifice plate front view
Orifice plate top view
Conditioning orifice plate
(Primary element type code C)
Compact orifice plate
(Primary element type code P)
Orifice plate side view
Primary element type
Type P and C
A
B
5.62 (143) Transmitter Height + A
Transmitter height
C
D
6.27 (159)
7.75 (197) - closed
8.25 (210) - open
6.00 (152) - closed
6.25 (159) - open
Dimensions are in inches (millimeters).
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75
Rosemount 3051
September 2014
Figure 15. Rosemount 3051CFP Integral Orifice Flowmeter
Side view
Bottom view
Front view
8.80
(223.46)
10.30
(261.81)
6.30
(160.55)
A
5.30
(134.51)
K
Downstream
J
Upstream
A. B.D. (Bore Diameter)
Dimensions are in inches (millimeters).
Line size
Dimension
J (Beveled/Threaded pipe ends)
J (RF slip-on, RTJ slip-on, RF-DIN slip on)
J (RF 150#, weld neck)
J (RF 300#, weld neck)
J (RF 600#, weld neck)
K (Beveled/Threaded pipe ends)
K (RF slip-on, RTJ slip-on, RF-DIN slip on)(1)
K (RF 150#, weld neck)
K (RF 300#, weld neck)
K (RF 600#, weld neck)
B.D. (Bore Diameter)
1
/2-in. (15 mm)
1-in. (25 mm)
11/2-in. (40 mm)
12.54 (318.4)
12.62 (320.4)
14.37 (364.9)
14.56 (369.8)
14.81 (376.0)
5.74 (145.7)
5.82 (147.8)
7.57 (192.3)
7.76 (197.1)
8.01 (203.4)
0.664 (16.87)
20.24 (514.0)
20.32 (516.0)
22.37 (568.1)
22.63 (574.7)
22.88 (581.0)
8.75 (222.2)
8.83 (224.2)
10.88 (276.3)
11.14 (282.9)
11.39 (289.2)
1.097 (27.86)
28.44 (722.4)
28.52 (724.4)
30.82 (782.9)
31.06 (789.0)
31.38 (797.1)
11.91 (302.6)
11.99 (304.6)
14.29 (363.1)
14.53 (369.2)
14.85 (377.2)
1.567 (39.80)
Dimensions are in inches (millimeters).
(1) Downstream length shown here includes plate thickness of 0.162-in. (4.11 mm).
76
www.rosemount.com
September 2014
Rosemount 3051
Figure 16. Rosemount 3051L Dimensional Drawings
2-in. flange configuration (flush mount only)
3- and 4-in. flange configuration
4.09
(104)
4.09
(104)
D
C
A
A
E
B
A. Flange Thickness
B. See Table 15.
C. Extension Diameter
B
D. O.D. Gasket Surface
E. 2-in., 4-in., or 6-in. extension (only available with 3-in. and 4-in., DN80,
and DN100 flange configurations)
Optional flushing connection ring (lower housing)
Diaphragm assembly and mounting flange
E
G
I
F
D
H
D. O.D. Gasket Surface
E. Lower Housing
F. Process Side
G. Bolt Circle Diameter
H. Flushing Connection
I. Outside Diameter
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77
Rosemount 3051
September 2014
Diaphragm assembly and mounting flange
5.13
(130)
4.29
(109)
6.80
(173)
7.10
(181)
8.20
(209)
Dimensions are in inches (millimeters).
78
www.rosemount.com
September 2014
Rosemount 3051
Table 15. 3051L Dimensional Specifications
Class(1)
ASME B16.5 (ANSI)
150
ASME B16.5 (ANSI)
300
ASME B16.5 (ANSI)
600
DIN 2501 PN
10–40
DIN 2501 PN 25/40
DIN 2501 PN 10/16
Pipe
size
Flange
thickness A
Extension
Bolt circle Outside
No. of Bolt hole
diameter(1)
diameter H diameter J bolts diameter
D
O.D.
gasket
surface E
2 (51)
0.69 (18)
4.75 (121)
6.0 (152)
4
0.75 (19)
N/A
3.6 (92)
3 (76)
0.88 (22)
6.0 (152)
7.5 (191)
4
0.75 (19)
2.58 (66)
5.0 (127)
4 (102)
0.88 (22)
7.5 (191)
9.0 (229)
8
0.75 (19)
3.5 (89)
6.2 (158)
2 (51)
0.82 (21)
5.0 (127)
6.5 (165)
8
0.75 (19)
N/A
3.6 (92)
3 (76)
1.06 (27)
6.62 (168)
8.25 (210)
8
0.88 (22)
2.58 (66)
5.0 (127)
4 (102)
1.19 (30)
7.88 (200)
10.0 (254)
8
0.88 (22)
3.5 (89)
6.2 (158)
2 (51)
1.00 (25)
5.0 (127)
6.5 (165)
8
0.75 (19)
N/A
3.6 (92)
3 (76)
1.25 (32)
6.62 (168)
8.25 (210)
8
0.88 (22)
2.58 (66)
5.0 (127)
DN 50
20 mm
125 mm
165 mm
4
18 mm
N/A
4.0 (102)
DN 80
24 mm
160 mm
200 mm
8
18 mm
66 mm
5.4 (138)
DN 100
24 mm
190 mm
235 mm
8
22 mm
89 mm
6.2 (158)
DN 100
20 mm
180 mm
220 mm
8
18 mm
89 mm
6.2 (158)
Dimensions are in inches (millimeters).
(1) Tolerances are 0.040 (1.02), - 0.020 (0.51).
Class(1)
ASME B16.5 (ANSI) 150
ASME B16.5 (ANSI) 300
ASME B16.5 (ANSI) 600
DIN 2501 PN 10–40
DIN 2501 PN 25/40
DIN 2501 PN 10/16
Lower housing F
Pipe
size
Process
side G
2 (51)
2.12 (54)
0.97 (25)
1.31 (33)
5.65 (143)
3 (76)
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
4 (102)
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
2 (51)
2.12 (54)
0.97 (25)
1.31 (33)
5.65 (143)
3 (76)
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
4 (102)
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
2 (51)
2.12 (54)
0.97 (25)
1.31 (33)
7.65 (194)
3 (76)
3.60 (91)
0.97 (25)
1.31 (33)
7.65 (194)
DN 50
2.40 (61)
0.97 (25)
1.31 (33)
5.65 (143)
DN 80
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
DN 100
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
DN 100
3.60 (91)
0.97 (25)
1.31 (33)
5.65 (143)
C
1
/4-in. NPT
1
/2 -in. NPT
(1) Tolerances are 0.040 (1.02), - 0.020 (0.51).
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79
Rosemount 3051
September 2014
Options
Standard configuration
Custom configuration(1)
Unless otherwise specified, transmitter is shipped
as follows:
If Option Code C1 is ordered, the customer may specify the
following data in addition to the standard configuration
parameters.
ENGINEERING UNITS
Differential/Gage:
inH2O (Range 0, 1, 2, and 3)
psi (Range 4 and 5)
Absolute/3051TA/3051TG:
psi (all ranges)
4 mA(1)
0 (engineering units above)
 Output Information
 Transmitter Information
 LCD Display Configuration
 Hardware Selectable Information
 Signal Selection
(1):
20 mA
Upper range limit
 Wireless Information
Output:
Linear
External buttons:
None
Flange type:
Specified model code option
 and more
Flange material:
Specified model code option
O-ring material:
Specified model code option
Drain/vent:
Specified model code option
Refer to the “Rosemount 3051 Configuration Data Sheet”
document number 00806-0100-4007 for Rosemount 3051 HART
protocol.
LCD Display:
None
Alarm(1):
High
Software tag:
(Blank)
Damping:
0.4 seconds(2)
(1) Not applicable to FOUNDATION fieldbus, PROFIBUS PA, or wireless.
 Scaled Variable
For Wireless refer to the “Rosemount 3051 Wireless
Configuration Data Sheet” (document number
00806-0100-4100).(1)
Tagging (3 options available)
 Standard SST hardware tag is wired to the transmitter. Tag
character height is 0.125 in. (3,18 mm), 56 characters
maximum.
(2) For fieldbus protocols, default damping is 1 second.
 Tag may be permanently stamped on transmitter nameplate
upon request, 56 characters maximum.
 Tag may be stored in transmitter memory. Character limit is
dependent on protocol.
(1)
80
•
HART Revision 5: 8 characters
•
HART Revision 7 and Wireless: 32 characters
•
FOUNDATION fieldbus: 32 characters
•
PROFIBUS PA: 32 characters
Not applicable to FOUNDATION fieldbus or PROFIBUS PA protocols.
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September 2014
Rosemount 3051
Commissioning tag(1)
M5 Digital Display
A temporary commissioning tag is attached to all transmitters.
The tag indicates the device ID and allows an area for writing the
location.
Optional Rosemount 304, 305 or 306 Integral
Manifolds
Factory assembled to 3051C and 3051T transmitters. Refer to
the following Product Data Sheet (document number
00813-0100-4839 for Rosemount 304 and 00813-0100-4733
for Rosemount 305 and 306) for additional information.
•
2-Line, 5-Digit LCD display for low power output
•
2-Line, 8-Digit LCD display for 4-20 mA HART, FOUNDATION
fieldbus and PROFIBUS PA
•
3-Line, 7-Digit LCD display for Wireless
•
Direct reading of digital data for higher accuracy
•
Displays user-defined flow, level, volume, or pressure units
•
Displays diagnostic messages for local troubleshooting
•
90-degree rotation capability for easy viewing
Configuration buttons
Other seals
Rosemount 3051 will ship with no buttons unless option D4
(Analog Zero and Span), DZ (Digital Zero), or M4 (LOI) for local
configuration buttons are specified.
Refer to Product Data Sheet 00813-0100-4016 for additional
information.
The Rosemount 3051 Wireless Transmitter is available with a
Digital Zero button installed with or without the LCD display
digital display.
Output information
Transient protection (option code T1)
Output range points must be the same unit of measure.
Available units of measure include:
Tested in accordance with IEEE C62.41.2-2002, Location
Category B
6 kV crest (0.5 s - 100 kHz)
3 kA crest (8 × 20 s)
6 kV crest (1.2 × 50 s)
Pressure
atm
inH2O@4 °C(2)
g/cm2
psi
mbar
mmH2O
kg/cm2
torr
bar
mmHg
Pa
cmH2O
@4 °C(1)(2)
inH20
mmH2O
@4 °C(2)
kPa
mH2O
@4 °C(1)(2)
inHg
ftH20
MPa(2)
ftH2O
@60 °F(1)(2)
hPa(1)(2)
inH2O@60 °F(2)
kg/m2(1)(2)
cmHg
@0 °C(1)(2)
mHg
@0 °C(1)(2)
psf(1)(2)
ftH2O
@4 °C(1)(2)
Bolts for flanges and adapters
 Options permit bolts for flanges and adapters to be obtained
in various materials
 Standard material is plated carbon steel per ASTM A449, Type
1
L4 Austenitic 316 Stainless Steel Bolts
L5 ASTM A 193, Grade B7M Bolts
L6 Alloy K-500 Bolts
Conduit plug
(1) Field configurable only, not available for factory calibration or custom
configuration (option code C1 “Software configuration”).
DO 316 SST Conduit Plug
Single 316 SST conduit plug replaces carbon steel plug
(2) Not available with Low Power (output option code M) or PROFIBUS PA
(output option code W).
Rosemount 3051C Coplanar Flange and 3051T
Bracket Option
Display and interface options
M4 Digital Display with Local Operator Interface (LOI)
•
(1)
Available for 4-20 mA HART and PROFIBUS PA
B4
Bracket for 2-in. Pipe or Panel Mounting
•
For use with the standard coplanar flange configuration
•
Bracket for mounting of transmitter on 2-in. pipe or panel
•
Stainless steel construction with stainless steel bolts
Only applicable to FOUNDATION fieldbus.
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81
Rosemount 3051
September 2014
Rosemount 3051C Traditional Flange Bracket
Options
B1
Bracket for 2-in. Pipe Mounting
•
B2
Bracket for mounting on 2-in. pipe
•
Carbon steel construction with carbon steel bolts
•
Coated with polyurethane paint
Bracket for Panel Mounting
•
B3
Bracket for mounting transmitter on wall or panel
•
Carbon steel construction with carbon steel bolts
•
Coated with polyurethane paint
Flat Bracket for 2-in. Pipe Mounting
Bracket for vertical mounting of transmitter on 2-in. pipe
•
Carbon steel construction with carbon steel bolts
•
Coated with polyurethane paint
B1 Bracket with SST Bolts
B1 bracket in stainless steel with Series 300 stainless steel
bolts
Stainless Steel B3 Bracket with SST Bolts
•
82
Same bracket as the B3 option with Series 300 stainless steel
bolts
Stainless Steel B1 Bracket with SST Bolts
•
BC
Same bracket as the B2 option with Series 300 stainless steel
bolts
B3 Bracket with SST Bolts
•
BA
Same bracket as the B1 option with Series 300 stainless steel
bolts
B2 Bracket with SST Bolts
•
B9
For use with the traditional flange option
•
•
B8
For use with the traditional flange option
•
•
B7
For use with the traditional flange option
•
B3 bracket in stainless steel with Series 300 stainless steel
bolts
www.rosemount.com
September 2014
www.rosemount.com
Rosemount 3051
83
Rosemount 3051
Product Data Sheet
00813-0100-4001, Rev SA
September 2014
Emerson Process Management
Rosemount Inc.
8200 Market Boulevard
Chanhassen, MN 55317 USA
T (U.S.) 1-800-999-9307
T (International) (952) 906-8888
F (952) 906 8889
www.rosemount.com
Emerson Process Management
Latin America
1300 Concord Terrace, Suite 400
Sunrise Florida 33323 USA
Tel + 1 954 846 5030
www.rosemount.com
Emerson Process Management Asia
Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
Tel +65 6777 8211
Fax +65 6777 0947
Service Support Hotline : +65 6770 8711
Email : Enquiries@AP.EmersonProcess.com
www.rosemount.com
Emerson Process Management
Blegistrasse 23
P.O. Box 1046
CH 6341 Baar
Switzerland
Tel +41 (0) 41 768 6111
Fax +41 (0) 41 768 6300
www.rosemount.com
Emerson FZE
P.O. Box 17033
Jebel Ali Free Zone
Dubai UAE
Tel +971 4 811 8100
Fax +971 4 886 5465
www.rosemount.com
Standard Terms and Conditions of Sale can be found at www.rosemount.com\terms_of_sale
The Emerson logo is a trade mark and service mark of Emerson Electric Co.
Tuned System, Coplanar, SmartPower, Annubar, Instrument Toolkit, Rosemount, and the Rosemount logotype are registered trademarks of
Rosemount Inc.
PlantWeb is a registered trademark of one of the Emerson Process Management group of companies.
HART and WirelessHART are registered trademarks of the HART Communication Foundation.
FOUNDATION fieldbus is a trademark of the Fieldbus Foundation.
PROFIBUS is a registered trademark of PROFINET International (PI).
Fluorinert is a trademark of 3M.
Neobee is a registered trademark of Stepan Speciality Products, LLC.
SYLTHERM is a trademark of Dow Corning Corporation.
eurofast and minifast are registered trademarks of TURCK.
All other marks are the property of their respective owners.
© 2014 Rosemount Inc. All rights reserved.
LA-2400 Series
Installation Manual
Linear Actuators
Established Leaders in Actuation Technology
Instruction Manual
IM-0443
LA-2400 Series
Linear Actuator
Table of Contents
General Information .............................................. 2-3
Introduction ....................................................... 2
Receiving/Inspection ......................................... 2
Storage ............................................................... 2
Equipment Return .............................................. 2
Identification Label ............................................ 3
Abbreviations Used in This Manual ................... 3
General Actuator Description ............................. 3
Basic Models ...................................................... 3
Product Specifications .............................................. 4
Installation ................................................................ 5
Typical Wiring Diagrams ...................................... 6-7
Start-up/Calibration ............................................... 8-9
Start-up/Calibration for Units with Amplifier.... 10-13
Amplifier Specifications .................................... 10
Amplifier Start-up ............................................. 11
Amplifier Parts Identification ............................ 12
Amplifier DIP Switch Chart .............................. 12
Typical Amplifier Wiring Diagram .................... 13
Amplifier Troubleshooting Chart ....................... 13
Troubleshooting Guide ...................................... 14-15
Component Location Drawing .......................... 16-17
Maintenance, Gear and Drive Nut Selection .... 18-19
Parts List and Recommended Spares ................ 20-22
Major Dimensions ............................................. 22-23
Due to wide variations in the terminal numbering
of actuator products, actual wiring of this device
should follow the print supplied with the unit.
GENERAL INFORMATION
INTRODUCTION
WARNING - ELECTROSTATIC DISCHARGE
Rotork Process Controls, designs, manufactures, and
tests its products to meet many national and
international standards. For these products to operate
within their normal specifications, they must be properly
installed and maintained. The following instructions
must be followed and integrated with your safety program when installing, using and maintaining Rotork
Process Controls products:
This electronic control is static-sensitive. To protect
the internal components from damage, never touch
the printed circuit cards without using electrostatic
discharge (ESD) control procedures.
•
Read and save all instructions prior to installing,
operating and servicing this product.
•
If you do not understand any of the instructions,
contact your Rotork Process Controls representative
for clarification.
•
Follow all warnings, cautions and instructions
marked on, and supplied with, the product.
RECEIVING/INSPECTION
Carefully inspect for shipping damage. Damage to the
shipping carton is usually a good indication that it has
received rough handling. Report all damage immediately
to the freight carrier and Rotork Process Controls
Unpack the product and information packet—taking
care to save the shipping carton and any packing
material should return be necessary. Verify that the
items on the packing list or bill of lading agree with
your own.
STORAGE
•
Inform and educate personnel in the proper
installation, operation and maintenance of the
product.
•
If the product will not be installed immediately, it
should be stored in a clean, dry area where the ambient
temperature is not less than -20° F. The actuator
should be stored in a non-corrosive environment. The
actuator is not sealed to NEMA 4 until the conduit
entries are properly connected.
Install equipment as specified in Rotork Process
Controls installation instructions and per applicable
local and national codes. Connect all products to the
proper electrical sources.
EQUIPMENT RETURN
•
To ensure proper performance, use qualified
personnel to install, operate, update, tune and
maintain the product.
•
When replacement parts are required, ensure that
the qualified service technician uses replacement
parts specified by Rotork Process Controls.
Substitutions may result in fire, electrical shock,
other hazards, or improper equipment operation.
•
A Returned Goods authorization (RG) number is
required to return any equipment for repair. This
must be obtained from Rotork Process Controls.
(Telephone:
414/461-9200) The equipment must be shipped,
freight prepaid, to the following address after the RG
number is issued:
Rotork Process Controls
5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Attn: Service Department
Keep all product protective covers in place (except
when installing, or when maintenance is being
performed by qualified personnel), to prevent
electrical shock, personal injury or damage to the
actuator.
To facilitate quick return and handling of your
equipment, include:
• RG Number on outside of box
• Company Name, Contact Person, Phone/Fax No.
• Address
• Repair Purchase Order Number
• Brief description of the problem
WARNING
Before installing the actuator, make sure that it is
suitable for the intended application. If you are unsure
of the suitability of this equipment for your installation,
consult Rotork Process Controls prior to proceeding.
WARNING - SHOCK HAZARD
Installation and servicing must be performed only
by qualified personnel.
2
GENERAL INFORMATION
GENERAL ACTUATOR DESCRIPTION
IDENTIFICATION LABEL
The LA-2400 series actuators are electrically operated,
bi-directional linear devices. They are designed for
strokes to 24 inches (610 mm) and thrusts to 1,500 lbf
(6672 N) and include a non-clutchable manual override handwheel. The drive motor may be single or
three phase ac, or dc.
LA-2410
1627 C 01
120 / 50-60 / 1 / 1
95C 036051 - 1
Options Include:
LA-2410
• Up to four independently adjustable limit switches
• Contactless position feedback
• Linear potentiometer position feedback
• Thermostatically controlled anti-condensation heater
• Integral or remote servo-amplifiers
• Trunnion mounting
• 4 to 20mA position feedback
• Shaft bellows
• Paint/coatings
MODEL NUMBER: LA24 10 Series
SERIAL NUMBER: 1627 C 01
Sequential Number
Year Built
Month Built
The LA-2400 series include 120/240 Vac single phase
models, 240/380/480 Vac three phase models and 24
Vdc models. These actuators are controlled by
“switched” power inputs or by a remotely installed
servo-amplifier.
ABBREVIATIONS USED IN THIS MANUAL
A or Amps
Ampere
AC
Alternating Current
°C
Degrees Celsius
CW
Clockwise
CCW
Counterclockwise
DC
Direct Current
°F
Degrees Fahrenheit
G
Earth Ground
Hz
Hertz
kg
Kilogram
L
Line (power supply)
lbs.
Pounds
lbf.
Lbs. Force
LVDT
Linear Variable Differential Transformer
mA
Milliamp
mfd
Microfarad
mm
Millimeters
N
Newton (force)
NEMA National Electrical Manufacturing Association
Nm
Newton Meter
NPT
National Pipe Thread
Ph
Phase
PL
Position Limit Switch
RPM
Revolutions per Minute
sec.
Second
TL
Thrust Limit Switch
Vac
Volts ac
Vdc
Volts dc
VR
Variable Resistance
W
Watt
The LA-2400 series is also available with an internal
servo-amplifier. They require 120 or 240 Vac (depending on model) unswitched, single phase line voltage
input and a dc analog command signal for a complete,
closed-loop positioning system in a compact enclosure.
BASIC MODELS
LA-2410, LA-2420, LA-2450 and LA-2490 are all single
phase ac, three wire, plug reversible models. They are
compatible with Jordan Controls remotely located
AD-8240 Series servo amplifiers, or any bi-directional
contact type control.
These actuators may also be equipped with an internal
servo amplifier that features loss of signal detection for
current command signal inputs and can be calibrated to
allow the actuator to lock-in-place or drive to a preset
position should the command signal drop below
3.8mA. Also included is a dynamic brake circuit to
increase positioning accuracy.
The LA-2415 is a three phase ac, plug reversible model
compatible with Jordan Controls remotely located AD8900 servo amplifier or any bi-directional contact type
control. The LA-2440 is a dc plug reversible model and
is compatible with Jordan Controls remotely located
model AD-7530 servo amplifier or other compatible
control device.
-3-
LA-2400 SERIES PRODUCT SPECIFICATIONS
GENERAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
Speed / Thrust:
Power Requirements:
in. per sec. / lbf.
(mm per sec. / N)
Model
LA-2410
LA-2415
LA-2450
LA-2420
LA-2490
LA-2440
Model
0.1/800
(2.5/3558)
0.2/800
(5.1/3558)
0.4/200
(10.2/890)
0.7/200
(17.8/890)
0.1/1500 *
(2.5/6672)
0.2/1500 *
(5.1/6672)
0.4/550
(10.2/2446)
0.7/450
(17.8/2002)
0.2/550
(5.1/2446)
0.25/550
(6.4/2446)
0.6/150
(15.2/667)
1/150
(25.4/667)
LA-2410
LA-2415
LA-2415
LA-2420
LA-2440
LA-2450
LA-2490
Input Power
Volts/PH/Hz
120/1/50-60
240/480/3/50-60
380/3/50
120/1/50-60
24 Vdc
240/1/50-60
240/1/50-60
Current (Amps)
Run
Stall
0.9
1.2
0.4/0.2
1.3/0.65
0.3
0.9
2.5
2.9
1.7
7.5
0.45
0.5
1.1
1.6
*1500 lbf. available in 6 in. stroke only.
Voltage Tolerance: +/-10%
Stroke: 6 to 24 in. (152 to 610 mm)
Lubrication & Type:
Conduit Entry: Two, 3/4 NPT.
Permanently lubricated, AmocoAmolith Rykon All-Weather
Premium Grease #2.
Field Wiring: To barrier terminal blocks.
Gearing: Hardened steel spur gear train, self-locking.
OPTIONS
Temperature: -40° F to 150° F. (-40° C to 65° C)
Anti-condensation Heater: 120/240 Vac, 30W
Environment Rating: Dust ignition-proof for Class II,
Division I, Groups E, F and G,
and Type 4 (IP65) indoor and
outdoor.
Two auxiliary position limit switches: 10A SPDT,
120/240 Vac
Enclosure Material: Cast Aluminum Alloy.
Contactless Feedback: Hall Effect
Approximate Weight: 40 lbs. (18kg)
4-20mA Feedback Transmitter:
Isolated, loop-powered 12-36 Vdc at 25 mA.
1000 ohm Feedback Potentiometer: 2 Watt Max. dc
Mounting: Clevis mount in any position.
Trunnion (not available with 6 in. stroke).
When mounted vertically with the ram
extending up, option D056 (vertical
moisture shield) must be used for wet
applications.
Maximum Load (ohms) = Power Supply Voltage - 8
0.020A
Servo-Amplifier Model AD-8130: 120/240 Vac. (For
more information
see Jordan Controls
IM-0523).
Manual Handcrank: Permits local operation.
Thrust Limiting: Bi-directional
(factory set and not adjustable).
Accuracy: +/-1.0% of full rated travel
Modulating Rate: (1% position changes)
LA-2415, 1200 starts/hour.
All others, 2000 starts/hour.
Hysteresis: 0.5% of full rated travel
Repeatibility: 0.5% of full rated travel
Linearity: +/-1.0% of full rated travel
Input Deadband: Adjustable
Duty Cycle:
Modulating: LA-2410, LA-2415, LA-2440, LA-2450.
20%: LA-2420, LA-2490.
Loss of Signal: Stays in place or runs to pre-set on current command signals dropping below 3.8 mA (field
selectable)
Clevis: Non-rotating.
Command Signal Inputs: Field selectable
4 to 20 mA (200 ohm impedance)
0 to 5 or 0 to 10 Vdc (100,000 ohm impedance)
High and Low Trim: Adjustable
-4-
INSTALLATION
MOUNTING
WIRING
Refer to installation dimensions on the installation print
sent with the actuator. The rear cover (opposite the
ram) must have clearance so it can be removed for
adjustments and interconnect wiring.
The wiring diagram on page 6 shows the fundamental
connections for standard three-wire reversible singlephase ac motor, standard permanent magnet dc motor,
and three phase AC models.
The actuator is mounted with pins through the rear and
front clevises. The rear clevis is normally the stationary
end. The device to be positioned must be such that it
will allow retraction and extension. Side loading must
be avoided. Side loading will lead to excessive operating thrust which will cause premature bearing failure.
The device to be positioned must not require greater
thrust than the rating of the actuator. Mount the rear
clevis to the stationary actuator support device first,
then move the traveling portion of the device to the
front clevis and mount it.
The wiring diagram on page 7 shows the fundamental
connections for single phase AC actuators with an
integral AD-8130 servo-amplifier, along with other
options.
A barrier type terminal strip is located under the rear
enclosure cover at the rear clevis end of the actuator.
Two ¾ inch NPT conduit entries are available for field
use. See the installation dimension drawing on the last
page of this manual for their location.
CAUTION: On standard single-phase wiring, the
position limit switches and the thrust switches are
wired directly in the motor circuit and protect it at
the extremes of travel or at thrust cutout. Three
phase AC or DC units must have these thrust and
position limit switches wired into the controlling
device to cause end of travel or thrust shutdown.
Care must be taken in wiring these to the controlling
device so that the appropriate direction of control is
turned off when that direction’s limit switch is
actuated. If care is not taken in phasing the equipment, damage may occur to the actuator or driven
load.
The front clevis is non-rotating. The installation should
place no torque upon the clevis or premature failure of
the actuator will result.
As an option, trunnion mounting is available on
actuators with 12 inch (305 mm) or greater strokes.
Dimensional details of this style of mounting is shown
on page 18 of this manual.
When mounted vertically with the ram extending
up, option D056 (vertical moisture shield) must be
used for wet applications.
• All wiring must be done in accordance with prevailing codes by qualified personnel.
• Typical wiring diagrams are shown on pages 6-7.
Actual wiring should follow the wiring diagram
supplied with the actuator.
• Fusing must be installed in line power, and should be
of the slow blow type.
• Wiring must be routed to the actuator through the
two conduit openings. Generally, one conduit will
contain input power and earth ground wires. The
other conduit would then contain low level input and
output signal wiring.
• It is required that all low level signal wiring be a
shielded type with the shield grounded at source
common.
• After installation, it is recommended that all conduits
be sealed to prevent water damage and to maintain
NEMA 4 enclosure rating.
• Remote mounted servo amplifiers must maintain a
maximum of 50 feet of wire run to the actuator.
-5-
TYPICAL WIRING DIAGRAMS
ACTUATOR WITHOUT A BUILT-IN AMPLIFIER
LA-2410, LA-2420 (120 Vac)
LA-2450, LA-2490 (240 Vac)
Actuator
Action
Viewing Actuator Ram
LA-2440 (24 Vdc)
AC Power Applied to Terminals
1&2
1&3
Extend
Retract
DC Power Applied to Terminals
1(+) & 2(-)
1(-) & 2(+)
Extend
Retract
LA-2415 SERIES ACTUATOR
Due to wide variations
in terminal numbering
of actuator products, actual
wiring should follow the print
supplied with the actuator.
Notes: 1. The thrust limit switches (TL1 & TL2) are factory set to trip if the thrust exceeds the actuator rating.
2. Shielded wire is required for command and position feedback signal wiring.
-6-
TYPICAL WIRING DIAGRAM
LA-2400 SERIES ACTUATORS WITH A BUILT-IN AD-8130 AMPLIFIER
(120/240 Vac, Single Phase, 50-60 Hz)
Due to wide variations
in terminal numbering
of actuator products, actual
wiring should follow the print
supplied with the actuator.
Notes:
1. All references to actuator ram movement are as viewed facing the front clevis.
2. An increasing command signal will result in ram extension.
3. The thrust limit switches are factory set to trip if the thrust exceeds the actuator rating.
4. Shielded wire is required for command and position feedback signal wiring.
5. Comand signal input:
4 to 20 mA into a 200 ohm impedance
0 to 5 or 0 to 10 Vdc into a 100,000 ohm impedance
6. Refer to amplifier instruction manual for proper DIP switch settings and amplifier setup.
-7-
START UP & CALIBRATION
A. LIMIT SWITCH ADJUSTMENT PROCEDURE
(see Figure 1)
The limit switch assembly features up to four independently adjustable position limit switches. The setting of
one switch does not affect the setting of the other.
Limit switch #1 (PL1) is set to stop the actuator at the
actuator fully extended position. Limit switch #2 (PL2)
is always set to stop the actuator at the actuator fully
retracted position. Each limit switch is activated by an
aluminum cam with a detent. When the cam roller falls
into this detent, the limit switch goes to its normal state.
To readjust the limit switches for the required actuator
stroke, the following methods are recommended:
1K ohm potentiometer
Fiqure 1
FOR ACTUATOR WITHOUT A POSITION
FEEDBACK DEVICE
1. With no power applied to the circuits, manually turn
the manual handwheel until there is a slight gap
(1/32”) between the front clevis and the outer
support tube with the clevis hole in the required
mounting plate.
Note:
1K ohm potentiometer
and #3 and #4 limit
switches are options.
CAUTION: Do not energize the actuator while
manual positioning or attempt to engage the
manual handwheel while the unit is running.
Rotation of the manual handwheel by the motor
could inflict personal injury.
4. The end of travel position limits PL1 and PL2 are
now set for full stroke of the actuator.
2. Loosen both set screws in PL2 cam (set screws are
120° apart). Rotate PL2 cam until the indent of the
cam and the roller begin to mate and the limit
switch activates (when you hear a “click”). Tighten
the set screws.
5. Apply electrical power and run the actuator through
its range to check for proper limit switch adjustment.
FOR ACTUATOR WITH A POSITION
FEEDBACK DEVICE
3. Energize the motor and run front clevis to the fully
extended position. Loosen both the set screws of
PL1 cam and manually rotate the cam until the
indent of the cam and the roller begin to mate and
the limit switch activates (when you hear a “click”).
Tighten the set screws.
1. With no power applied to the circuits, connect an
ohm meter across the potentiometer wiper arm and
the “zero” (retract) end of the pot.
2. Follow steps 1 through 5 in the previous section.
-8-
START UP & CALIBRATION
C. 4 to 20mA TRANSMITTER ADJUSTMENT
A. POSITION FEEDBACK ALIGNMENT
(Potentiometer)
The ST-4130 (1000 ohm-input, 4 to 20mA output) two
wire transmitter modulates the current on a direct
current supply proportional to the input resistance. It is
powered by a 12.0 to 36.0 Vdc unregulated power
supply line which is modulated from 4 to 20mA
proportional to the resistance of the input.
Position feedback is provided through the use of a
potentiometer attached to the limit switch assembly. As
the switches are driven by the actuator gearing, the
potentiometer is simutaneously driven to provide
position feedback.
1. Establish if full extend or full retract is to be used for
zero indication. On slide gate installations, zero
indication is normally used when the actuator is fully
extended and the gate closed.
2. Make sure end of travel limit switches are correctly
set for proper stroke length.
800 ohm maximum load when power supply is 24 Vdc
3. Use an ohmmeter to monitor the position of the
feedback potentiometer wiper to determine which
end of the pot gives a low ohm resistance indication.
For the unit to function properly the 4mA end of the
feedback potentiometer must be preset to 50 ohms.
1. Position the actuator to the desired 4mA setting.
Resistance of the potentiometer must be measured
without the ST-4130 connected.
4. If the reading is greater than 50 ohms, see Position
Limit Switch Adjustment Procedure for actuators
with a potentiometer.
2. With potentiometer resistance at 50 ohms, adjust
ELEVATION for 4.0mA output.
5. Run the actuator through its stroke range to ensure
the potentiometer is tracking through its electrical
range. (Generally 60 to 90% of 1,000 ohms).
3. Position the actuator to the desired 20mA setting.
4. Adjust RANGE for 20mA output.
NOTE: On tandem potentiometer assembly, set the
bottom potentiometer to approximately 50 ohms.
5. Repeat steps 1 through 4 until no further adjustment
is necessary.
6. To reverse the 4 and 20mA output, interchange the
BLUE and YELLOW wires at the terminal block and
return to step 1.
B. POSITION FEEDBACK ALIGNMENT
(Contactless)
Position feedback can also be provided through the use
of a contactless feedback device attached to the limit
switch assembly. As the switches are driven by the
actuator gearing, the feedback device is simutaneously
driven to provide position feedback.
-9-
START UP & CALIBRATION FOR UNITS WITH AMPLIFIERS
Switch and feedback device alignment is accomplished
in the same manner as actuator without amplifiers,
except motor power is supplied from the amplifier.
Varying the command signal input to the amplifier will
allow you to reverse the extension or retraction of the
shaft to run to the minimum/maximum switch settings.
If the actuator does not run to the limit switch but stops
short and both red lights are off on the amplifier board,
the amplifier has nulled and adjustments of span,
elevation, loss of signal, or feedback potentiometer
may be required.
Amplifier Specifications
Field Wiring Terminations: Plugable terminal block,
wire size range 26-14
AWG.
Standard Line Voltage: 120/240Vac, ±10%,
50/60 Hz (Slide switch select)
(Voltage input MUST match
the actuator motor voltage
rating).
Command Signal Monitor: The amplifier’s loss-ofsignal circuitry monitors
the command signal
input. If the command
signal drops below or
above the rating, the
actuator will either lock
in place or run to a
preset position (user
selectable).
Power Consumption: Less than 20 watts for amplifier
functions only.
Voltage Output: Identical to voltage input.
Current Output: 10 amps max. at 120 or 240 Vac.
Fuse protection: Customer supplied. Size based on
actuator controlled and local codes.
Null output (AD-8240): Rated 2 ampers
@120/240Vac, 50/60Hz.
Limit Signals: Internal: Part of servo control.
Output Shaft Motion: All models can go either
direction on an increasing
command signal. This is
determined by the ZERO and
SPAN settings.
Command Signal Inputs:
• 4-20mA, 4-12mA, 12-20mA into a 200Ω shunt
resistor
• 0-5Vdc into 100,000Ω impedance
• 0-10Vdc into 100,000Ω impedance
Temperature Limits: -40° to 150° F (-40° to 65° C).
Position Feedback Signal: 1000Ω potentiometer
4-20mA
Duty Cycle: Unrestricted modulating duty.
(Cont. duty).
Position Output Signal: Isolated 4-20mA, loop
powered with 12-36Vdc
external power supply.
Position Accuracy: 1% of full range.
Deadband: Factory preset to 1%. Field adjustable.
-10-
Amplifier Start-Up
5) Transmitter. This adjustment sets the endpoints of
the 4-20 mA transmitter to account for variations in
accuracy of the input command.
1) Power. Before applying AC power to TB2 set slide
switch to the correct voltage (120/240Vac)
A) Set command signal to low level, normally 4 mA.
2) Command Calibration. This procedure calibrates
the minimum and maximum command to the unit.
B) Depress ZERO pushbutton (S1) and LOS
pushbutton (S4) until the SPARE LED illuminates.
B) Depress ZERO pushbutton (S1) and LOS
pushbutton (S4) until the SPARE LED illuminates.
While depressing pushbuttons, turn adjusting
knob CW to increase the 4 mA point, or CCW to
decrease the 4 mA point.
C) Set command signal to high level, normally
20 mA.
C) Set command signal to high level, normally
20 mA.
D) Depress SPAN pushbutton (S2) and LOS
pushbutton (S4) until the SPARE LED illuminates.
D) Depress SPAN pushbutton (S2) and LOS
pushbutton (S4) until the SPARE LED illuminates.
While depressing pushbuttons, turn adjusting
knob CW to increase the 20 mA point, or CCW
to decrease the 20 mA point.
A) Set command signal to low level, normally 4 mA.
3) Auto/Manual (Option). If the unit has the Auto/
Manual switch option, place it in the auto position.
4) Setpoints. These are the end of travel extremes
corresponding to the actuator output shaft positions
for low (4mA) and high (20mA) command signal
levels. They are set by the ZERO and SPAN
pushbuttons and adjusting knob. All settings require
the holding of a push button and the turning of the
adjusting knob.
6) Deadband. This adjustment establishes the actuator
servo sensitivity. It is factory set at 1% and should not
be field adjusted. If the actuator begins to oscillate
(Green and Yellow LEDs turn on and off rapidly),
decrease the sensitivity by holding deadband push
button (S3) and turning adjusting knob CW until
oscillation stops. Release button.
A) Set the command signal to lowest level,
normally 4mA.
7) Loss of Signal Preset. This adjustment establishes
the position to which the actuator will travel upon a
loss of command signal condition. To activate this
setting, SW3 must be OFF. Adjust the setting by
holding the LOS push button (S4) and turning the
adjusting knob to set the preset position. Turn the
adjusting knob CW to extend the ouput shaft for
linear actuators, or rotate the output shaft CW for
rotary actuators. Turn the adjusting knob CCW to
retract the ouput shaft for linear actuators, or rotate
the output shaft CCW for rotary actuators.
B) Adjust LO setpoint (ZERO) by holding ZERO
push button (S1) and turning adjusting knob to
move actuator output shaft to desired position.
Turn the adjusting knob CW to extend the ouput
shaft. Turn the adjusting knob CCW to retract
the ouput shaft. Release button.
C) Set the command signal to highest level,
normally 20mA.
D) Adjust HI setpoint (SPAN) by holding SPAN push
button (S2) and turning adjusting knob to move
actuator output shaft to desired position. Turn
the adjusting knob CW to extend the ouput
shaft. Turn the adjusting knob CCW to retract
the ouput shaft. Release button.
8) Verify all settings by running the actuator through its
travel range several times.
-11-
Amplifier Parts Identification
Amplifier DIP Switch Chart
DIP Switch Configurations SW2
Switch
1
2
3
4
Switch Position
Function
ON (Up)
Current Command
OFF (Down)
0-5V / 0-10V Voltage Command
ON (Up)
0-5V Voltage Command
OFF (Down)
Current / 0-10V Command
ON (Up)
LOS Lock-in-Place
OFF (Down)
LOS Preset Position
ON (Up)
Dynamic Brake On
OFF (Down)
Dynamic Brake Off
-12-
Typical Amplifier Wiring Diagram
AD-8140
Due to wide variations
in terminal numbering
of actuator products, actual
wiring should follow the print
supplied with the unit.
Troubleshooting
For visual troubleshooting, LEDs are provided to display the status of the actuator.
These are located on the same side of the lower board as SW1.
The identification of these LEDs are shown in the table below.
LE D
MICRO OK
Functi on
This LED flashes when the microprocessor is running. If this is not on, verify
power to the board.
INC.
This LED is on when the actuator is extending the ouput shaft for linear
actuators, or rotating the output shaft CW for rotary actuators.
DEC.
This LED is on when the actuator is retracting the ouput shaft for linear
actuators, or rotating the output shaft CCW for rotary actuators.
1 Flash - Indicates loss of 4-20 mA ignal (LOS).
L.O.S.
2 Flashes - Indicates loss of the feedback signal.
3 Flashes - Indicates indicates a stall condition.
-13-
TROUBLESHOOTING GUIDE
TROUBLE
Motor won’t operate
Ram positions in wrong
direction for extend and
retract input power
Motor hums,
but does not run
POSSIBLE CAUSE
REMEDY
a. No power to actuator
a. Check source, fuses, wiring
b. Motor overheated and internal thermal switch tripped
(single phase AC motors only)
b. Let motor cool and determine why overheating occurred
(such as, excessive duty cycle or ambient temperature)
c. Motor defective
c. Replace motor and determine cause of failure
d. Both end of travel position limit switches open or one
open and one defective
d. Adjust switch settings or replace defective switch
e. Actuator ram stalled (mechanically jammed)
e. Check drive load for mechanical jam and correct cause
f. Defective motor run capacitor
(single phase ac motors only)
f. Replace capacitor
g. Load exceeds actuator thrust rating
g. Reduce load or replace actuator with one with
appropriate thrust rating
h. Power applied to extend & retract at same time
h. Correct power input problem
i. Amplifier defective
i. Replace amplifier
j. Amplifier is in Loss of Signal
j. Check command signal to verify signal greater than
3.8 mA is present
k. Amplifier deadband is too wide
k. Reduce deadband setting
a. Wiring to actuator incorrect
a. Correct field wiring
b. Wiring from motor to terminals or switches is reversed
b. Correct internal actuator wiring
a. Power applied to extend & retract at the same time
a. Correct power input problem
b. Damaged power gearing
b. Repair gearing
c. Defective motor run capacitor
(single phase ac motors only)
c. Replace capacitor
d. Damaged servo amplifier
d. Replace servo amplifier
a. Defective power gearing
a. Repair gearing
b. Screw drive nut stripped or pulled out of tube
b. Repair or replace screw drive nut
a. Switch wired wrong or is defective
a. Correct wiring or replace switch
b. Switches are not aligned
b. Align switches
Motor runs,
but ram does not move
Motor does not shut off
at limit switch
-14-
TROUBLESHOOTING GUIDE
TROUBLE
POSSIBLE CAUSE
REMEDY
a. Thrust limit sw itch not properly w ired to control circuit
a. Correct w iring per diagram
b. Thrust limit sw itch collars loose or not properly adjusted b. Adjust and tighten collars as required
Thrust limit sw itch
operation
c. Thrust limit sw itch defective
c. Replace
d. Thrust limit sw itch bent and binding
d. Replace shaft
e. Thrust limit sw itch mounting or bushing is bent or
damaged
e. Replace as required
f. Thrust limit sw itch mounting block not aligned or secured f. Align and secure blocks as required
Motor runs,
but only one way
g. The actuator is overloaded
g. Remove overload
a. Power not applied for other direction
a. Correct power problem
b. Power always applied to one direction and electrically
stalls when applied for opposite direction
b. Correct power problem
c. Open limit switch for other direction
c. Adjust or replace limit switch as required
d. Actuator is in thrust overload
d. Determine obstruction and correct
e. Motor has an open winding
e. Replace motor
f. Motor and feedback potentiometer are out of phase
f. Reverse potentiometer end leads
g. Amplifier is defective
g. Replace amplifier
a. Amplifier deadband is too wide
a. Reduce deadband setting
Poor response to command b. Amplifier is defective
signal changes
Actuator oscillates
at setpoint
Pot feedback signal not
always present during
actuator ram movement
Pot signal does not change
as actuator operates
Pot signal is reversed
for output ram direction
b. Replace amplifier
c. Excessive noise on command signal
c. Reduce noise. Also ensure that command signal wiring
is shielded with shield grounded at source common only
a. Amplifier deadband is too narrow
a. Increase deadband setting
b. Amplifier is defective
b. Replace amplifier
c. Excessive noise on command signal
c. Reduce noise. Also ensure that command signal wiring
is shielded with shield grounded at source common only
a. Pot not aligned with end of travel extremes and is being
driven through its dead region
a. Align pot to range of actuator
b. Pot signal is erratic or nonexistent
b. Replace pot
a. Defective pot
a. Replace pot
b. Feedback gear not turning pot shaft
b. Check gearing engagement and set screw in gear hub
a. Pot is wired wrong
a. Reverse wiring from ends of pot at actuator terminal block
a. Condensation caused by temperature variations and
humidity
a. Add heater and thermostat circuit and ensure that existing
circuit is continuously energized Check conduit entry and
seal to prevent water from entering via the conduit
b. Water entering actuator
b. Ensure rear cover gasket is in place and replace if
defective. Also ensure all cover bolts are in place and
tightened. Check conduit entry and seal to prevent
water from entering via the conduit. Order optional
bellows kit if needed
Water droplets inside
motor area of actuator
Note: For actuators controlled by servo-amplifiers, refer to that servo-amplifier’s instruction manual for additional troubleshooting information.
-15-
COMPONENT IDENTIFICATION
1.
Actuator Housing
20. Feedback Assembly
2.
Feedback Housing
21. Thrust Limit Switch (2)
3.
Motor Cover
22. Motor Pinion
4.
Feedback Cover
23. Power Idler Gear Assembly
5.
Outer Tube
24. Feedback Idler Gear Assembly
6.
Inner Tube Assembly
25. Limit Switch Gear
7.
Clevis, Stationary
26. Drive Screw Gear
8.
Clevis, Tube
27. Drive Screw
9.
Housing Gasket
28. Handcrank Gear
10. Cover Gasket
29. Handcrank
11. O’ Ring, Stationary Clevis
30. Spring Pack Assembly
12. O’ Ring, Tube Clevis
31. Drive Screw Guide
13. Seal, Handcrank
36. Tube Clevis Roll Pin
14. Tube Scraper
41. Limit Switch Gear Set Screws
15. Tube Seals
42. Limit Switch Assembly Mounting Screws
16. Tube Spacer
43. Tube Bearing and Seal Retaining Ring
17. Tube Bearing
44. Drive Screw Guide Retaining Ring
18. Motor
49. Drive Nut
19. Motor Top (1phase ac only)
50. Potentiometer
51. Noncontact Feedback Module
Optional
noncontact
feedback
device and
4 limit switches.
-16-
COMPONENT IDENTIFICATION
DC Motor Side
Feedback Side with Amp
AC Motor Side (1 phase)
Feedback Side
18. Motor
37. Housing Bolts
19. Motor Top (1 phase ac only)
38. Motor Cover Bolts
20. Feedback Assembly
39. Feedback Cover Bolts
21. Thrust Limit Switch Assembly
40. Motor Mounting Bolts
32. AC Motor Capacitor (1 phase ac only)
45. AD-8130 Amplifier
33. AC Motor Resistor (1 phase ac only)
46. Heater
34. ST-4130 Loop Powered 4-20 mA
Transmitter or EC-10883 analog conversion module for contactless feedback
47. Ground Screw
48. Thermo Switch
35. Terminal Strip
-17-
MAINTENANCE
To Remove Multi-turn Feedback Assembly 20:
A. Separate housings.
B. Loosen set screws 41 and remove gear 25.
C. Remove screws 42.
D. Remove feedback assembly 20.
Under normal service conditions, the motor, gearing,
bearings, and parts do not require periodic maintenance. If for any reason the unit is disassembled in the
field, all Oilite bushings should be saturated with S.A.E.
20 or 30 non-detergent oil and all gearing heavily
coated with Amoco-Amolith Rykon all weather premium grease #2 or equal.
To Remove Single-turn Feedback Assembly 20:
A. Separate housings.
B. Loosen set screws 41 and remove gear 25.
C. Remove screws 42.
D. Remove feedback assembly 20.
Care should be taken to ensure that no foreign material
is in the grease, which could cause premature failure.
The screw shaft must be lubricated with Allex EP1L
grease. DO NOT SUBSTITUTE.
To Change Tube Bearing 17 or Seals 15:
A. Separate housings.
B. Remove outer retaining ring 43.
C. Remove scraper 14, spacer 16, seals 15 and tube
bearing 17.
Refer to Pages 16 and 17 for component locations.
To Separate Housings:
A. Disconnect motor wires which run through housing.
B. Extend front clevis to obtain access to roll pin 36.
C. Remove roll pin 36 and front clevis 8.
D. Remove housing screws 37, 38 and 39.
E. Separate housing assemblies and remove gears 23
and 24.
To Remove Inner Tube Assembly 6:
A. Separate housings.
B. Remove retaining ring 44 and guide 31.
C. Hold screw shaft gear 26 and turn tube 6 to unscrew
from shaft.
To Remove Motor 18:
A. Separate housings.
B. If gear 22 is held to motor shaft with a retaining ring,
remove the ring and gear 22.
C. Remove screws 40.
D. Remove motor top 19. (ac motor only).
E. Remove motor stator and rotor 18.
POWER GEARING SELECTION CHART
(All Stroke Lengths)
Actuator Voltage
120 or 240 Vac
240/380/480 Vac 3 phase
24 Vdc
Stroke Speed
0.1" + 0.2"/sec.
0.4" + 0.7"/sec.
0.2" + 0.25"/sec.
0.6" + 1.0"/sec.
Motor Pinion Gear
16A-017896-001
16A-017895-001
16A-017896-001
16A-017895-001
-18-
Power Idler Gear Assembly
65A-016334-002
65A-016334-001
65A-016334-002
65A-016334-001
Single Turn Feedback Gearing & Drive Nut Selection Charts
LA-2410, LA-2415, LA-2420, LA-2450, LA-2490 (0.1”/sec. & 0.4”/sec.); LA-2440 (0.2”/sec. & 0.6”/sec.)
Stroke
3"
4"
5"
6"
7"
9"
12"
15"
18"
24"
1st Stage Gear
65B-025344-004
65B-025344-009
65B-025344-001
65A-017619-001
65A-017619-001
65A-017619-001
65A-017619-001
65A-017619-001
65A-017619-001
65A-017619-001
2nd Stage Gear
N/A
N/A
N/A
65A-025339-001
65A-021042-001
65A-017620-003
65A-017620-003
65A-021042-004
65A-021042-005
65A-021042-006
Feedback Gear
16B-003803-133
16B-003803-151
16B-003803-109
16B-003803-130
16A-021043-001
16B-003803-042
16B-003803-131
16B-003803-042
16B-003803-133
16B-003803-132
Drive Nut (3/4 - 10)
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
61A-039553-003
LA-2410, LA-2415, LA-2420, LA-2450, LA-2490 (0.2”/sec. & 0.7”/sec.); LA-2440 (0.25”/sec. & 1.0”/sec.)
Stroke
3"
4"
5"
6"
7"
9"
12"
15"
18"
24"
1st Stage Gear
65B-025344-003
65B-025344-007
65B-025344-004
65B-025344-002
65B-025344-008
65B-025344-001
65A-017619-001
65A-017619-001
65A-017619-001
65A-017619-001
2nd Stage Gear
N/A
N/A
N/A
N/A
N/A
N/A
65A-021042-001
65A-017620-003
65A-017620-002
65A-021042-002
Feedback Gear
16B-003803-131
16B-003803-149
16B-003803-133
16B-003803-132
16B-003803-150
16B-003803-109
16A-021043-001
16B-003803-042
16B-003803-112
16B-003803-050
Drive Nut (3/4 - 6)
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
61A-039553-002
Multi Turn Feedback Gearing & Drive Nut Selection Charts
LA-2410, LA-2415, LA-2420, LA-2450, LA-2490 (0.1”/sec. & 0.4”/sec.); LA-2440 (0.2”/sec. & 0.6”/sec.)
Stroke
6"
12"
18"
24"
1st Stage Gear
65B-025344-004
65A-017619-001
65A-017619-001
65A-017619-001
2nd Stage Gear
N/A
65A-025339-001
65A-017620-003
65A-021042-003
Limit Switch Gear
16B-003803-133
16B-003803-130
16B-003803-042
16B-003803-131
Drive Nut (3/4 - 10)
61A-016350-001
61A-016350-001
61A-016350-001
61A-039553-003
LA-2410, LA-2415, LA-2420, LA-2450, LA-2490 (0.2”/sec. & 0.7”/sec.); LA-2440 (0.25”/sec. & 1.0”/sec.)
Stroke
6"
12"
18"
24"
1st Stage Gear
65B-025344-003
65B-025344-002
65B-025344-001
65B-017619-001
2nd Stage Gear
N/A
N/A
N/A
65A-021042-001
-19-
Limit Switch Gear
16B-003803-131
16B-003803-132
16B-003803-109
16A-021043-001
Drive Nut (3/4 - 6)
14A-016378-001
14A-016378-001
14A-016378-001
61A-039553-002
PARTS LIST
Recommended Spare Parts Indicated in Bold
ID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Description
Motor Housing - ac Units
Motor Housing - dc Units
Feedback Housing w/o Amp
Feedback Housing with Amp
Motor Cover
Feedback Cover w/o Amp
Feedback Cover with Amp
(or with 21P option)
Outer Tube, 6" stroke
Outer Tube, 12" stroke
Outer Tube, 18" stroke
Outer Tube, 24" stroke
Inner Tube, 6" stroke
Inner Tube, 12" stroke
Inner Tube, 18" stroke
Inner Tube, 24" stroke
Tube Bearing
Retaining Ring
Washer
Retaining Ring
Key
Shim Spacer
Rear Clevis
Front Clevis
Gasket, Main Housing
Gasket, Cover
O Ring, Rear Clevis
O Ring, Front Clevis
Seal, Handwheel Shaft
Scraper
Tube Seal
Tube Spacer
Tube Bearing
Motor, LA-2410, 0.1" or 0.2" / sec.
Motor, LA-2410, 0.4" or 0.7" / sec.
Motor, LA-2415, 0.1" or 0.2" / sec.
Motor, LA-2415, 0.4" or 0.7" / sec.
Motor, LA-2420, 0.1" or 0.2" / sec.
Motor, LA-2420, 0.4" or 0.7" / sec.
Motor, LA-2440, 0.2" or 0.25" / sec.
Motor, LA-2440, 0.6" or 1.0" / sec.
Motor, LA-2450, 0.1" or 0.2" / sec.
Motor, LA-2450, 0.4" or 0.7" / sec.
Motor, LA-2490, 0.1" or 0.2" / sec.
Motor, LA-2490, 0.4" or 0.7" / sec.
Motor Top (1 phase ac units only)
Belleville Washers (1 phase ac units only)
-20-
Part Number
60D-042926-002
60D-042926-003
60D-023767-001
60D-023767-001
60C-016326-001
60C-016328-001
60C-016326-001
Quantity
1
1
1
1
1
1
1
61B-040118-001
61B-040118-002
61B-040118-003
61B-040118-004
61B-039536-001
61B-039536-002
61B-039536-003
61B-039536-004
61A-016376-001
58B-014184-102
74A-016377-001
58B-019899-016
61A-012228-001
13A-014549-006
60B-016330-001
60A-016346-001
13C-016366-001
13B-016367-001
74B-010957-133
74B-010957-020
19B-003815-021
13A-012877-001
19A-012878-000
61A-012876-001
61A-016348-001
61B-042938-002
61B-042933-005
23B-037613-001
23B-0037614-001
61B-0042938-006
61B-042933-001
61B-026405-001
61B-026404-001
61B-042938-003
61B-042500-001
61B-042938-005
61B-042933-004
60C-042348-001
56A-005478-001
1
1
1
1
1
1
1
1
1
2
2
2
1
A/R
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
PARTS LIST
Recommended Spare Parts Indicated in Bold
ID
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Description
Single Turn Feedback:
Position Limit Switch, SPDT
Position Limit Switch, DPDT
1K Potentiometer
1K/1K Potentiometer
Hall Effect Sensor
Multi Turn Feedback:
Travel Nut
Position Limit Switch, SPDT
Position Limit Switch, DPDT
1K Potentiometer
1K/1K 10 Turn Potentiometer
Thrust Limit Switch
Motor Pinion Gear
Power Idler Gear Assembly
Feedback Gearing
Feedback Gear
Screw Gear
Drive Screw:
6 inch, 3/4 - 10
12 inch, 3/4 - 10
18 inch, 3/4 - 10
24 inch, 3/4 - 10
6 inch, 3/4 - 6
12 inch, 3/4 - 6
18 inch, 3/4 - 6
24 inch, 3/4 - 6
Handwheel Gear Assembly
Handwheel
Thrust Spring Pack Assembly
Drive Screw Guide
Capacitor:
12.5 mfd, LA-2410, .1", .2", .4", .7" / sec.
35 mfd, LA-2420
5 mfd, LA-2450
7.5 mfd, LA-2490
Resistor, LA-2410, LA-2450
Resistor, LA-2420, LA-2490
ST-4130 Transmitter
Terminal Block
Roll Pin
Cap Screw
Cap Screw
Cap Screw
Screw, LA-2410
Screw, LA-2420, LA-2490
Screw, LA-2450
-21-
Part Number
Quantity
46B-004053-405
46B-004053-414
34B-0033104-001
34B-003956-160
70B-039960-002
2
2
1
1
1
14B-008602-001
46B-004053-409
46B-004053-414
34B-100033-001
34B-100033-007
46B-004053-405
See Selection Chart
See Selection Chart
See Selection Chart
See Selection Chart
16B-023764-001
1
2
2
1
1
2
1
1
1
1
1
62C-016356-001
62C-016356-002
62C-016356-003
62C-016356-004
62C-016355-001
62C-016355-002
62C-016355-003
62C-016355-004
68A-018955-001
61A-016343-001
Consult Factory
14A-012868-001
1
1
1
1
1
1
1
1
1
1
1
1
24B-029812-027
24B-029812-026
24B-029812-028
24B-029812-030
33B-003852-205
33B-003852-305
70A-019948-001
43B-003888-107
57A-015215-125
54A-015070-175
54A-015070-200
54A-015070-100
54A-015044-375
54A-015044-500
54A-015044-450
1
1
1
1
1
1
1
2
1
2
4
8
3
3
3
PARTS LIST
Recommended Spare Parts Indicated in Bold
ID
41
42
43
44
45
46
47
48
49
50
Description
Set Screw
Screw, Truss Head
Retaining Ring
Retaining Ring
AD-8140 Amplifier
Heater, 120 Vac
Heater, 240 Vac
Ground Screw
Thermoswitch
Drive Nut
Screw Shaft Grease
Part Number
54A-015037-019
54A-015032-025
58B-014185-162
58B-014183-050
68C-041180-001
74A-016946-001
74A-031965-001
58B-024244-152
74A-023565-001
See Selection Chart
73A-032878-001
INSTALLATION DIMENSIONS
(Trunnion Mount)
-22-
Quantity
2
3
2
1
1
1
1
1
1
1
1
LA-2400 MAJOR DIMENSIONS
D
Stroke
in. (mm)
A
B
2 (51)
to 6 (152)
16.16
(410)
4.01
(102)
Without Amp
13.1
(333)
With amp
15.73
(400)
Without Amp
3.81
(97)
With amp
6.44
(164)
6.01 (153)
to 12 (305)
22.61
(574)
10.01
(254)
13.1
(333)
15.73
(400)
3.81
(97)
6.44
(164)
12.01 (305)
to 18 (457)
28.61
(727)
16.01
(407)
13.1
(333)
15.73
(400)
3.81
(97)
6.44
(164)
18.01 (457)
to 24 (610)
34.61
(879)
22.01
(559)
13.1
(333)
15.73
(400)
3.81
(97)
6.44
(164)
C
These dimensions are subject to change without notice and should not be used for preparation of drawings
or fabrication of installation mounting. Current installation dimension drawings are available upon request.
-23-
Electric Actuators and Control Systems
Fluid Power Actuators and Control Systems
Gearboxes and Gear Operators
Projects, Services and Retrofit
UK
Rotork plc
tel
+44 (0)1225 733200
fax
+44 (0)1225 333467
email mail@rotork.com
USA
Rotork Process Controls
tel
+1 (414) 461 9200
fax
+1 (414) 461 1024
email rpcinfo@rotork.com
A full listing of our worldwide sales and
service network is available on our website.
www.rotork.com
PUB045-003-00
Issue 08/11
As part of a process of on-going product development, Rotork reserves the right to amend and
change specifications without prior notice. Published data may be subject to change. For the
very latest version release, visit our website at www.rotork.com
The name Rotork is a registered trademark. Rotork recognizes all registered trademarks.
Published and produced in the UK by Rotork Controls Limited. POWSH0811