Fireye InSight II 95DSS3 User manual

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
TYPE 95DSS3
Integrated Flame Scanner
II
SIL3
DESCRIPTION
The Fireye 95DSS3 InSight II is a family of versatile fully microprocessor based, integrated flame
scanners. The 95DSS3 holds multiple worldwide safety agency approvals (see Model Listings for
full details).
The InSight II scanners utilize advanced techniques for discrimination and integrate the flame detec-
tion, amplification, safety determination and flame switch functions into a single detection head. No
separate amplifier or flame switch module is therefore required to interface with the main burner
management system.
InSight II incorporates the superior detection and discrimination elements of the popular InSight
product with additional enhanced capability, features and benefits.
The scanner measures the amplitude of the modulations (the flame “flicker”) that occur within the
targeted flame. During the scanner set-up procedure, the modulation frequency that yields the best
flame ON/OFF discrimination is selected. The appropriate modulation frequency and sensor gain
can be either manually or automatically selected.
InSight II is a dual cell scanner utilizing UV and IR detector and various levels of housing type
including FM Class I Div 2 and ATEX ExdIIC (see Model Listing for full description of options).
Standard features include two independently adjustable Flame Relays that can be selected to operate
from the UV sensor, the IR sensor, or both sensors, 21 choices of modulation frequency, adjustable
sensor gain, adjustable flame relay ON/OFF thresholds, two 4-20 mA analog signal strength outputs
(one for FR1 and one for FR2), Fault Relay, four selectable programmable files (e.g. for different
fuels or firing rates), and Auto Config capability with manual override. Remote communication
capability is available via optional “Fireye Explorer” PC software (CU-109).
Ordered separately, a blank cover, or two different operator interfaces are available for the standard
(non-CEX) InSight II scanners enabling the user to view and change the operating parameters and
setpoints.
Model 95DISP-1 and 95DISP-1-SS are two-line by sixteen-character alpha-numeric VFD Displays
with five-pushbutton keypads. The 95DISP-1 is installed by the user onto the end of the scanners.
The 95DISP-1-SS is factory installed into the 95DSS3-1CEXSS and 95DSS3-1CEX-2 scanners.
Model 95WIDISP-2 is an Infrared Transmitter, installed by the user onto the end of the scanner
instead of a display. The 95WIDISP-2 transmitter provides wireless communications to a model
95WIHH-2 hand-held remote communications tool.
CU-113
OCTOBER 8, 2014

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Model 61-7347-1 is a Blank Cover installed by the user onto the end of the scanner to maintain envi-
ronmental ratings when neither the 95DISP-1 nor 95WIDISP-2 is installed. With the 61-7347-1
installed, the operator interface must either be via "Fireye Explorer" pc software, or by temporarily
installing a 95DISP-1 or 95WIDISP-2.
Model 95DSS3-1CEX includes the 95DISP-1 Display. Models 95DSS3-1CEXSS and 95DSS3-
1CEX-2 include the 95DISP-1-SS Display. Model 95DSS3-1WICEX includes the 95WIDISP-2
Infrared Transmitter. Model 95DSS3-1CEX-ND includes the 61-7347-1 Blank Cover.
See bulletin CU-116 for 95DISP-1, 95DISP-1-SS, 95WIDISP-2, and 61-7347-1 installation details.
All scanner models are powered by 24 VDC, and contain electronic self-checking (no mechanical
shutter required). Electrical connection is via quick-disconnects. Fiber optics are also available for
extended viewing applications.
Type 95DSS3-1 is the standard model and is provided with two cable quick-disconnects, one 8-pin
and one 12-pin, for use with the 59-546-xx and 59-547-xx prefabricated cable assemblies, ordered
separately.
Type 95DSS3-1WOC is similar to the model 95DSS3-1, but without the two cable quick-discon-
nects. Instead of quick-disconnects, the 95DSS3-1WOC has two threaded openings, one ½" NPT,
and one ¾" NPT, for the customer to install their own cable connectors or cable glands. Filler plugs
are installed at the factory. The customer will connect their cable(s) to two internal terminal blocks
located inside the scanner. Note: In order to maintain the NEMA 4X / IP66 rating, suitable NEMA 4X
/ IP66 connectors, fittings, or conduit must be used.
Type 95DSS3-1WINC is similar to the model 95DSS3-1, but is intended to retrofit into existing
InSight I installations where the customer is using one 59-497-xxx cable assembly. Instead of the two
cable quick-disconnects, the 95DSS3-WINC has one 12-pin InSight I style quick-disconnect, for use
with a 59-497-xxx prefabricated cable assembly. With the 95DSS3-WINC, only the first flame relay
(FR1) and its 4-20 ma output are accessible. The user does not have access to the second flame relay
(FR2) or to its 4-20 ma output. For backward compatibility with InSight I wiring, the Fault Relay
contacts are factory wired in series with the Flame Relay contacts.
Safety Information
When this equipment is fitted to an appliance, due regard must also be given to the requirements of
that appliance.
Before attempting to install, commission or operate this equipment, all relevant sections of this doc-
ument must be read and fully understood. If in doubt about any requirements consult Fireye.
Installation, commissioning or adjustment of this product MUST be carried out by suitably trained
engineers or personnel quilified by training and experience.
After installation or modifications to the installation all functions of the equipment MUST be
checked to ensure safe and reliable operation of the InSight II scanner.
The manufacturer of this equipment accepts no liability for any consequences resulting from inap-
propriate, negligent or incorrect installation, commissioning or adjustment of operating parameters
of the equipment. There are no user servicable parts.
Before attempting any work on this equipment or any equipment controlled by or connected to this
equipment, all related electrical supplies must be isolated.
Safety interlocks must not be removed or overridden. Any faults once detected must be corrected
before the control is operated.
WARNING
The equipment described in this manual is capable of causing property damage, severe injury, or death. It is the responsibility
of the owner or operator to ensure that the equipment described is installed, operated and commissioned in compliance with
the requirements of all national and local legislation, which may prevail.

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TABLE OF CONTENTS
DESCRIPTION..............................................1
OPERATION...............................................4
APPLICATION..............................................4
DIMENSIONS ..............................................5
MODELLISTING............................................8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INSTALLATIONNOTES........................................10
INSTALLATIONPROCEDURE....................................10
MECHANICAL ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SCANNERWIRING..........................................18
REMOTE FILE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIRINGFORREMOTECOMMUNICATIONS...........................24
GROUNDING AND SHIELDING TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PROGRAMMINGTHEINSIGHTIISCANNER...........................26
INSIGHTIIMENUSTRUCTURE...................................27
THEMAINSTATUSMENU......................................29
THEERRORHISTORYMENU....................................33
THEPASSWORDMENU.......................................36
THECONFIGMENU .........................................38
THEAUTOCONFIGMENU .....................................42
THEFILECOPYMENU........................................45
THE4/20mAMENU..........................................47
THEDATE/TIMEMENU .......................................49
THECOMMSMENU .........................................51
THEMANUALCONFIGMENU...................................53
THE IR and UV SETTINGS MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
MANUALSET-UPINMANUALCONFIGFR1&FR2MENUS..................56
INSIGHT II REPLACEMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ORDERINGINFORMATION.....................................62

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OPERATION
The InSight II has numerous adjustment options available. It can be tuned either automatically or
manually to achieve the optimum level of sensitivity to the target flame balanced with superior dis-
crimination of background radiation.
The InSight II scanner measures the amplitude of the modulations (the flame “flicker”) that occur
within the targeted flame. The two sensors within the scanner measure these amplitudes seen within
the ultraviolet (UV) and infrared (IR) spectral ranges across a wide range of flicker frequency bands.
In addition the scanner has two independent flame relays (FR1 and FR2) that can be tied to the sen-
sors in logical configurations. It is possible to set up each flame relay to operate from the UV sensor,
the IR sensor, or both UV and IR sensors.
During the scanner set up procedure, the logical operation for the two flame relays is selected for the
desired sensors. In addition the operation and settings relative to user gain, required (flicker) fre-
quency band and switching thresholds for the relays are selected (refer to commissioning procedure
for more details on set up procedures)
The current Flame Signal Strength (FS) of the selected sensors can be viewed on the scanner display
via the main menu. This displayed value is the measure of amplitude within the selected modulation
(flicker) frequency band, for example:
FS 1: 850 2: 999 (Flame signal for selected sensors 0 to 999)
1: IR&UV 2: UV (Relay Logic operation = FR1 tied to IR & UV; FR2 tied to UV Only)
The scanner set-up procedure, the operation and settings relative to the sensor signals and each of the
two flame relays are chosen either in Auto Config or Manual Config mode to provide the optimum
flame ON/OFF discrimination.
The flame relays (FR1 and FR2) energize (and their normally open contacts close) when the flame
quality is at or above the programmed flame ON threshold for each relay and remain on until the
flame quality is at or below the programmed flame OFF threshold. Each relay operates with totally
independent settings meaning that the signal strength used can be at different gains and different fre-
quency bands. Each relay can also have independent timings and thresholds associated with it.
IMPORTANT NOTE - The FAULT RELAY is energized when the scanner is powered (24 vdc) and
when the scanner had successfully passed all internal self-checking routines. The Fault relay is de-
energized if there is a power interruption to the scanner or if the scanner has detected an internal
fault.
APPLICATION
The InSight II is best suited to multi-fuel applications that require the highest level of sophistication
and flexibility (addition choices of modulation frequencies, and the time-saving Auto Config func-
tion), and remote modbus communications capability (e.g. larger multi-burner boilers and furnaces).
The InSight II scanner contains both the infrared and ultraviolet flame sensors described below.
The infrared flame sensor, responds to infrared radiation from 700 to 1700 nanometers wavelength.
The ultraviolet flame sensor, responds to ultraviolet radiation from 295 to 320 nanometers wave-
length.
Warning - Fireye recommends that the FAULT RELAY contacts MUST be wired in series
with the Flame relay contacts for maximum safety applications.

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InSight II SCANNER FEATURES
DIMENSIONS
FIGURE 1. SCANNER TYPE 95DSS3-1, 95DSS3-1WOC, 95DSS3-1WINC
Features Basic Models Flame-Proof Hazardous Area Models
95DSS3-1
95DSS3-1WOC
95DSS3-1WINC
95DSS3-1CEX
95DSS3-1CEX-2
95DSS3-1WICEX 95DSS3-1CEX-ND 95DSS3-1CEXSS
Infrared Sensor 11 1 1 1
Ultraviolet Sensor 11 1 1 1
Flame Relay 22 2 2 2
Fault Relay 11 1 1 1
4-20 mA Output YES YES YES YES YES
Modulation Frequency
Selections 21 21 21 21 21
Memory Files 44 4 4 4
Communications YES YES YES YES YES
Auto Config YES YES YES YES YES
Alphanumeric VFD Display (order separately) YES N/A N/A YES
Infrared Transmitter (order separately) N/A YES N/A N/A
Blank Cover (order separately) N/A N/A YES N/A
Housing Material Aluminum Aluminum Aluminum Aluminum 316 Stainless Steel
12 PIN
ELECTRICAL
CONNECTOR
8 PIN
ELECTRICAL
CONNECTOR
12.57
319.2
75°
PURGE AIR CONNECTION
3/8 NPT OR
3/8 BSP
LOCKING RING
5.75
146
5.06
128.4
1"NPT OR
1" BSP SIGHT PIPE
CONNECTION
1 23/32 HEX
[43.7]
MATERIAL
: ALUMINUM ALLOY A 380
FINISH:
BODY AND CAP ARE GREY POWDER COAT,
LOCK RINGS ARE BLACK POWDER COAT
Shown with optional display p/n 95DISP-1
Mounting Flange
95DISP-1
Display
60-2919-1 (NPT)
60-2919-2 (BSP)
(Ordered
separately)
(Ordered
separately)
Quick disconnect
right side
Quick disconnect
left side
Scanner Type Quick-Disconnect Right Side Quick-Disconnect Left Side
95DSS3-1 12-pin male (for 59-547-xx cable) 8-pin male (for 59-546-xx cable)
95DSS3-1WOC none (3/4” NPT filler plug) none (1/2” NPT filler plug)
95DSS3-1WINC 12-pin male (for 59-497-xxx cable) none (1/2” NPT filler plug)

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FIGURE 2. TYPE 95DSS3-1CEX, -1WICEX, -1CEX-ND SCANNERS, STANDARD FLAME-PROOF HAZARDOUS AREA HOUSING
•Window joints are cemented using Aremco bond 568 high temperature epoxy with a Temperature
Rating of -65°C to +204°C.
•Window material is fused silica with a temperature rating of +950°C.
•O-rings are made of BUNA-N with a temperature rating of +121°C.
•Suitably rated blanking elements must be used on all unused openings.
•Supply connection wiring shall have a temperature rating of at least +105°C
Note: The above items are suitable for the InSight II scanners rated environment and conditions of use.
13.37
339.7
75°
PURGE AIR CONNECTION
3/8 NPT OR
3/8 BSP
LOCKING RING
5.75
146
5.06
128.4
FLAME PROOF FITTINGS
1"NPT OR
1" BSP SIGHT PIPE
CONNECTION
1 23/32 HEX
[43.7]
MATERIAL : ALUMINUM ALLOY A 380
FINISH: BODY AND CAP ARE GREY POWDER COAT,
LOCK RING IS BLACK POWDER COAT
Mounting Flange (ordered separately)
60-2919-1 (NPT)
60-2919-2 (BSP)
Warning! - Risk of electrostatic discharge. Make sure that all personnel and equipment are
correctly grounded when installing, or handling the InSight II scanner in potentially explosive
atmospheres.

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FIGURE 3. TYPE 95DSS3-1CEXSS, -1CEX-2, SCANNERS, OPTIONAL FLAME-PROOF HAZARDOUS AREA HOUSINGS
Note: Model 95DSS3-1CEX includes the 95DISP-1 Display.
Models 95DSS3-1CEXSS and 95DSS3-1CEX-2 include the 95DISP-1-SS Display.
Model 95DSS3-1WICEX includes the Infrared Transmitter.
Model 95DSS3-1CEX-ND includes the 61-7347-1 blank cover
Scanner P/N Material Mounting Flange P/N
95DSS3-1CEXSS Stainless Steel 60-2692SS (NPT)
60-2693SS (BSP)
95DSS3-1CEX-2 Aluminum 60-2692-4 (NPT)
60-2693-4 (BSP)
Mounting Flange
(ordered separately)
(Quantity 2)
Warning! - Risk of electrostatic discharge. Make sure that all personnel and equipment are
correctly grounded when installing, or handling the InSight II scanner in potentially explosive
atmospheres.

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MODEL LISTING
Notes:
1. Hazardous area ratings (Class I, Class II and ATEX) certified by FM unless otherwise noted.
2. Hazardous area requirements for InSight II scanners with electrical connectors:The plastic "Loc Fast" retainers
provided with the 59-546-xxx and 59-547-xx cables must be installed over the quick disconnect connectors.
3. ATEX Certification number FM09ATEX0051X, IECEx cert# IECEx FMG 09.0008X
4. ATEX Certification number FM09ATEX0026X, IECEx cert# IECEx FMG 08.0008X
5. In order to maintain the NEMA 4X / IP66 rating, suitable NEMA 4X / IP66 connectors, fittings, or conduit must
be used.
PART
NUMBER
(see note 6)
SENSOR Alpha
Numeric
VFD
Display
Infrared
Trans-
mitter
12-PIN
CONNECTOR
8-PIN
CONNECTOR
HOUSING
RATING
(see note 1)
AGENCY APPROVALS
UL
C/US
FM DIN-
DVGW
DIN-
CERTCO
CE AGA ABS In
Metro
95DSS3-1 IR & UV (order
sepa-
rately)
(order
sepa-
rately)
YES YES NEMA 4X, IP66
CLASS I DIV. 2
GROUPS
A, B, C & D
CLASS II
DIV. 2
GROUPS
F & G
(see note 2)
YES YES YES YES YES YES YES YES
95DSS3-1WOC
(see note 5)
NO NO NO NO NO
95DSS3-1WINC YES NO .II 3 G Ex nA nC
IIC T4 IP66
II 3 D Ex tD A22
IP66 T135 °C
Ta= -40°C to -65°C
(see notes 2,3)
NO NO NO
95DSS3-1CEX
(includes
95DISP-1)
IR & UV YES NO NO NO NEMA 4X, IP66 YES YES YES YES YES YES YES YES
95DSS3-
1WICEX
(includes
95WIDISP-2)
IR & UV NO YES
II 2 G Ex d IIC T6
IP66
II 2 D Ex tb IIIC
T85°C
Ta=-40°C to +65°C
(see note 4)
95DSS3-
1CEX-ND
(includes
61-7347-1)
IR & UV NO NO
95DSS3-
1CEXSS
(includes
95DISP-1-SS)
(see note 5)
IR & UV YES NO NO NO
II 2 G D Ex d IIC T6
IP66
Ta=-40°C to +65°C
(certified by CESI)
YES NO YES YES YES NO NO NO
95DSS3-1CEX-2
(includes
95DISP-1-SS)
(see note 5)
IR & UV YES NO NO NO
II 2 G D Ex d IIC T6
IP66
Ta=-40°C to +60°C
(certified by CESI)
NO NO NO NO NO NO NO NO
95DISP-1
(display)
YES NO YES YES YES YES YES YES YES YES
95WIDISP-2
(IR transmitter
for wireless dis-
play) *
NO YES
61-7347-1
(blank cover) NO NO NO NO NO NO NO NO NO NO

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6. UL Functional Safety Listed Primary Safety Control 5AC0 EN/IEC 61508, Parts 1-7 (2010) up to SIL3. ANSI/
UL 1998 (2008) Class 2
* For use with wireless handheld commissioning tool, p/n 95WIHH-2, see bulletin 133-735
SPECIFICATIONS
MECHANICAL:
Housing Material: Standard Models and Model CEX-2: Cast aluminum with gray polyester powder coat finish
Model CEXSS: 316 stainless steel w/zinc primer, gray epoxy midcoat, polyurethane topcoat
Housing Weight: Standard Models: 5.9 lbs. (2.69kg); CEX-2 Model: 13.2 lbs (5.98 kg)
Model CEXSS: 21.3 lbs. (9.66 kg); All other CEX Models: 7.1 lbs (3.22 kg
Environmental: NEMA 4X, IP66, Class I Division 2, Groups A, B, C & D, Class II
Division 2, Groups F& G (refer to agency approvals table)
Mounting: Requires one threaded mounting flange, ordered separately (see below).
For fiber optic mount, refer to bulletin CU-117
Cooling / Purge Air Requirements:
Source: Clean, dry, cool
Volume: 4 SCFM (113 l/min) at 3/8” threaded mounting flange, or 1 inch “Y” fitting, mounted on
scanner sight pipe. Temperature near the upper limit of the scanner operating range and/or use with
dirty/dusty fuels may require up to 15 SCFM (425 l/min).
Pressure: Adequate to overcome furnace or windbox pressure
Operating Temperature Rating: -40°F to + 150°F (-40°C to +65°C)
Storage Temperature Rating: -40°F to + 185°F (-40°C to +85°C)
Humidity: 0% to 95% relative humidity, non-condensing
STANDARD MOUNTING FLANGE:
Material/Weight: Cast aluminum with gray polyester powder coat finish. Contains an integral
heat-insulating female thread insert / 0.62 lbs (0.28 kg)
Flange Threads: P/N 60-2919-1 1" NPT female pipe mount with 3/8” NPT female cooling air connection.
P/N 60-2919-2 1" BSP female pipe mount with 3/8” BSP female cooling air connection.
OPTIONAL MOUNTING FLANGE, STAINLESS STEEL:
Material/Weight: 316 Stainless steel (without heat-insulating threaded insert), with zinc primer, gray epoxy
midcoat, polyurethane topcoat / 1.86 lbs. (0.84 kg).
Flange Threads: P/N 60-2692SS 1" NPT female pipe mount with 3/8” NPT female cooling air connection.
P/N 60-2693SS 1" BSP female pipe mount with 3/8” BSP female cooling air connection.
OPTIONAL MOUNTING FLANGE, CAST ALUMINUM:
Material/Weight: Cast aluminum (without heat-insulating thread insert), with grey polyester powder coat
finish / 0.5 lbs (0.23 kg)
Flange Threads: P/N 60-2692-4, 1" NPT female pipe mount with 3/8" NPT female cooling air connection.
P/N 60-2693-4, 1" BSP female pipe mount with 3/8" BSP female cooling air connection.
ELECTRICAL:
Input Power: 24 Vdc, +10%, -15% supply current: 0.35 A, 8.5 VA, Hold Time must be 20 msec
Min. Fireye power supply 60-2685 is recommended
Electrical Connection: 8-pin and 12-pin screw type quick-disconnect, (model 95DSS3-1)
Relay Output: 2FLAME RELAYS, SPDT (N.O. and N.C.)
FAULT RELAY, SPST (N.O.)
Contact Rating: Minimum: 10 mA @ 5 Vdc
Maximum: 100 mA @ 30 Vdc; 100 mA @ 50 Vac
Analog Output: Two, 4-20 mA dc current, referenced to 24Vdc common, Max. connected 1oad: 750 ohms

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
Operator Interface: P/N 95DISP-1, 95DISP-1-SS, Alpha -Numeric Display with five pushbutton keys.
P/N 95WIDISP-2 Infrared Transmitter, used in conjunction with
P/N 95WIHH-2 Hand-held communications tool.
Cable Specification: P/N 59-546 (8-conductor), P/N 59-547 (12-conductor):
Multi-core, 8 and 12 conductor (color coded), 18- AWG, with foil wrap and overall
braided shield and drain wire. PLTC-ER rating. Maximum cable length 1000 feet (305 meters)
Cable Jacket: PVC / black (flame-retardant, RoHS compliant)
Temperature Rating: -40°F to +221°F (-40°C to +105°C)
P/N 59-546 Nominal O.D. 0.44" (11.2 mm), maximum O.D. 0.48” (12.2mm)
P/N 59-547 Nominal O.D. 0.52" (13.2 mm), maximum O.D. 0.56” (14.2mm)
INSTALLATION NOTES
The InSight II flame scanners determine the presence or absence of flame by monitoring the fre-
quency spectrum of the flame. The scanner should initially be mounted so that the primary combus-
tion zone is within the scanner’s line of sight.
The location and sighting instructions listed in the following sections are rough guidelines for the
location of the scanner. The scanner provides feedback via its VFD or wireless display to assist in the
adjustment and proper alignment of the flame scanner. Refer to the setpoint procedures described in
this bulletin.
Note: An acceptable scanner location must ensure the following:
Reliable main flame and/or ignitor flame detection at all air flow and furnace loads (ranges of fuel
firing).
Rejection of the ignitor flame if too short, or in the wrong position to ignite the main flame reliably,
thus prohibiting the delivery of fuel to the burner.
INSTALLATION PROCEDURE
WARNING: Protective filtered lenses should be worn when viewing flame. Infrared and
ultraviolet energy from the flame can be damaging to the eyes.
1. The best results are obtained when the scanner is aimed so that the scanner’s line of sight inter-
sects the burner center at a slight angle (e.g. 5 degrees) and sees a maximum of the primary com-
bustion zone, as shown in Figure 4. If only one scanner is used per burner, the line of sight
should also intersect the igniting flame.
2. For installations where separate scanners are used to monitor main and ignitor flames, the main
flame scanner should be sighted so it does not detect the ignitor flame.
3. The scanner should have an unrestricted view of flame as far as possible. Physical obstructions
such as air register blades, interfering vanes, or other hardware should be cut away or notched so
they do not fall within the scanner’s line of sight as shown in Figure 6.
Note: Always check with the burner manufacturer before you trim the register blades.

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
FIGURE 4. SINGLE BURNER SCANNER SIGHTING
4. Consideration must be given to burner secondary air rotation, some burners have clockwise
(CW) air rotation and others have counterclockwise (CCW) air rotation. If combustion air enters
the furnace with a rotational movement of sufficient velocity to deflect the ignitor flame in the
direction of rotation, position the scanner 10 to 30 degrees downstream of the ignitor as shown
in Figure 5 and close to the periphery of the burner throat (See Figure 4).
FIGURE 5. SCANNER LOCATION VS. SECONDARY AIR ROTATION
5. Having determined the approximate location for the sight pipe, cut a clearance hole for a 2 inch
pipe through the burner plate. Look through the hole. If register vanes interfere with the desired
line of sight, the interfering vane(s) should be trimmed to assure an unrestricted viewing path at
all firing levels as indicated in Figure 6.
Note: Always check with the burner manufacturer before you trim register vanes.
FIGURE 6. IF POSSIBLE, FLAME SHOULD COMPLETELY COVER SIGHT OPENING
6. The preferred method for mounting surface mounted scanners requires the use of a swivel
mount, P/N 60-1664-3 (NPT), shown in Figures 7, 8, and 9. Center the swivel mount over the
two inch hole in the burner plate and secure using three hexed cap screws (not provided). Install
the sight pipe on the swivel mount. If a swivel is not used, insert the end of the sight pipe into
the hole, align the hole to the desired viewing angle and tack weld (welding must be adequate to
temporarily support the weight of the installed scanner). The sight pipe should be arranged to
slant downward so that dirt and dust will not collect inside.
CAUTION: Use no more than one foot of one inch diameter sight pipe. Increase the sight
pipe diameter one inch for every additional foot of sight pipe length used to avoid restricting
the scanner’s field of view.
When a satisfactory sighting has been confirmed by operational testing, secure the swivel
mount’s ball position in place by tightening the three hex head cap screws located on the
swivel mount ring.
PRIMARY
COMBUSTION
ZONE
AIR REGISTER
BLADES
SCANNER
LINE OF
SIGHT
BURNER
THROAT
FLAME
ENVELOPE
BURNER
CENTER LINE
BASE
IGNITOR
SCANNER
MAIN BURNER
CCW ROTATION
IGNITOR
SCANNER
MAIN
CW ROTATION
BURNER
BUT THISNOT THIS NOT THIS
OR THIS
Obstruction
Obstruction

12

7. In larger multi-burner type applications such as power, kiln or refinery burners, it is recognized
that there may be several obstructions within the scanner overall range of view. The same princi-
ple of adjusting the scanner such that the flame is within the center of its field of view applies.
Use of a swivel mount allows the scanner to be adjusted to target the flame within the center of
the scanner range of view. (see obstructed view in figure 6 above)
8. For ease of use, the scanner should be installed on the sight pipe so the VFD display (if used)
can easily be read.
Note: Operation of the VFD display is independent of position.
9. The scanner lens must be kept free of contaminants (oil, ash, soot, dirt) and the scanner housing
temperature must not exceed its maximum rating of 150°F (65°C). Excessive temperatures will
shorten scanner life. Both requirements will be satisfied by a continuous injection of purge air at
either the 3/8” housing inlet or the 1” “Y” connection ahead of the swivel mount as shown in
Figures 7, 8 and 9.
Note: Internal scanner temperature is available via the VFD display. See “Status Menu” under
“Programming the Scanner.”
The scanner mounting may be made with provision for purge air through only the 3/8” opening as
shown in Figure 9 or for purge air through either the 3/8” opening or the 1” “Y” connection as shown
in Figure 8. In the latter arrangements, normally only one of the two connections is provided with
purge air and the other connection is plugged. When a sealing coupling is used as shown in Figure 7,
the 1" “Y” connection is used for the purge air and the 3/8” opening is plugged.
It is good practice to use the sealing coupling (P/N 60-1199 with NPT threads) on all installations to
insure against unwanted furnace pressures from damaging the scanner lens.
Under normal conditions, with clean burning fuels and moderate ambient temperature conditions,
purge air flow of approximately 4 SCFM (113 l/min) is generally adequate. Up to 15 SCFM
(425 l/min) may be required for fuels that produce high levels of ash or soot, or for hot environments
to maintain the scanner’s internal temperature within specification.
MECHANICAL ACCESSORIES
Surface Mounting Flange (Required)
Standard: Cast aluminum with gray polyester powder coat finish. Contains an integral heat-insulating female
thread insert (external heat-insulating nipple not required).
P/N 60-2919-1 1" NPT female pipe mount with 3/8” NPT female cooling air connection.
P/N 60-2919-2 1" BSP female pipe mount with 3/8” BSP female cooling air connection.
Optional: 316 Stainless Steel with zinc primer, gray epoxy midcoat and polyurethane top coat finish. Does not
contain heat-insulating insert.
P/N 60-2692SS 1" NPT female pipe mount with 3/8” NPT female cooling air connection.
P/N 60-2693SS 1” BSP female pipe mount with 3/8” BSP female cooling air connection.
Optional: Cast aluminum with grey polyester powder coat finish. Does not contain heat-insulating insert.
P/N 60-2692-4, 1" NPT female pipe mount with 3/8" NPT female cooling air connection.
P/N 60-2693-4, 1" BSP female pipe mount with 3/8" BSP female cooling air connection.
Swivel Mount (Optional)
The scanner swivel mount, P/N 60-1664-3 (NPT) (see Figure 9, Item A), is used to adjust the scanner
sighting angle after the scanner has been installed, The swivel mount is shown in Figures 7, 8, and 9.
Sealing Coupling with Quartz Window (Optional)
The sealing coupling, P/N 60-1199-x (see Figure 10, Item D), is used whenever a coupling or a seal
is required for scanner piping. The quartz window blocks furnace pressure, hot gases and soot from
coming in contact with the scanner and contaminating the lens. P/N 60-1199-1 has a 1" NPT thread,
p/n 60-1199-2 has a 1" BSP thread. When the sealing coupling is used, a 1 inch “Y” fitting must be
used downstream of it for connection of a purge air supply (plug 3/8”opening).

13

Orifice Kit (Optional)
An orifice may be used to restrict the scanner’s field of view aiding discrimination between the tar-
get flame and other flames in the combustion chamber. An orifice may also be used to reduce the
total amount of radiation reaching the scanner, thereby avoiding the chance of saturation. Orifice kit
(P/N 53-121) contains nine different orifice sizes, and two retaining clips. The orifice can be
installed either within the 60-1664 swivel mount, within the 60-1199 coupling, or within the 60-
2919-1, 60-2919-2 surface mounting flange. Refer to figures 11 and 12.
Cooling Cover/Vortex-Tube Cooler Kit (Optional)
For high ambient temperature applications, a Cooling Cover (p/n 60-2930-x) and Vortex-Tube
Cooler Kit (P/N 60-2720) are available. Refer to bulletins 133-749 and CU-103 for details.

14

FIGURE 7.
FIGURE 8.
FIGURE 9.
PART NUMBER
A. SWIVEL MOUNT 60-1664-3 (NPT)
60-1664-4 (BSP)
B. 1" WYE 35-200 (NPT)
C. 1” CLOSE NIPPLE 35-201 (NPT)
D. SEALING COUPLING W/QUARTZ WINDOW
60-1199-1 (NPT)
60-1199-2 (BSP)
E. 1” NIPPLE 35-127-2 (NPT)
F. 3/8" PLUG 35-202 (NPT)
G. SURFACE MOUNTING 60-2919-1 (1”NPT)
FLANGE 60-2919-2 (1”BSP)
C
EF
AB
D
G
22.25” (642mm)
PART NUMBER
A. SWIVEL MOUNT 60-1664-3 (NPT)
60-1664-4 (BSP)
B. 1" WYE 35-200 (NPT)
C. 1” NIPPLE 35-127-2 (NPT)
D. 3/8” PLUG 35-202 (NPT)
E. SURFACE MOUNTING 60-2919-1 (1”NPT)
FLANGE 60-2919-2 (1”BSP)
AB
C
D
E
22.0” (560mm)
PART NUMBER
A. SWIVEL MOUNT 60-1664-3 (NPT)
60-1664-4 (BSP)
B. 1” NIPPLE 35-127-2 (NPT)
C. 3/8" THREADED OPENING
D. SURFACE MOUNTING 60-2919-1 (1”NPT)
FLANGE) 60-2919-2 (1”BSP)
C
B
A
D
16.75” (426mm)

15

FIGURE 10.
FIGURE 11.
ORIFICES
Figure Qty. Part Number Description
11 1 53-121 Orifice Kit: Contains following items:
11A 1 53-121-2 Orifice: Diameter = 0.062"
11B 1 53-121-3 Orifice: Diameter = 0.078"
11C 1 53-121-4 Orifice: Diameter = 0.093"
11D 1 53-121-5 Orifice: Diameter = 0.109"
11E 1 53-121-6 Orifice: Diameter = 0.125"
11F 1 53-121-7 Orifice: Diameter = 0.187"
11G 1 53-121-8 Orifice: Diameter = 0.250"
11H 1 53-121-9 Orifice: Diameter = 0.375"
11I 1 53-121-10 Orifice: Diameter = 0.500"
11J 2 34-181 Orifice Retainer
PART NUMBER
A. SWIVEL MOUNT 60-1664-3 (NPT)
SWIVEL MOUNT 60-1664-4 (BSP)
B. SCANNER CABLE w/connector 59-547-xx
C. SCANNER CABLE w/connector 59-546-xx
D. SEALING COUPLING W/QUARTZ WINDOW
60-1199-1 (NPT)
60-1199-2 (BSP)
A
B
C
D
A-I. Orifices: 0.062" - 0.5" DIA
J. Orifice Retainer 34-181

16

FIGURE 12.
ELECTRICAL ACCESSORIES (see note)
Note: Hazardous Area requirements for InSight II scanners with electrical connectors:
1. For hazardous locations, the plastic “Lok Fast” retainer provided with cable 59-546-xx and 59-
547-xx must be installed over the quick disconnect connectors.
Scanner Cables, P/N 59-546, 59-547
Fireye recommends P/N 59-546 (8-conductor) and 59-547 (12-conductor) color-coded multi-core
cables. This cable includes 18 AWG conductors and a flame-retardant, low smoke, zero halogen
PVC jacket. Refer to page 10 for full cable specifications. Refer to figure 13, 14 for color code and
connection information. This raw-stock cable is used as extension wiring between a junction box or
Wiring Harness Assembly (below) and the burner management system. The maximum total cable
length is 1000 feet (305 meters) per scanner.
Note: Model 95DSS3-1WINC requires p/n 59-497 (12-conductor) cable.
24 Volt DC Power Supplies
Fireye offers DIN rail mounted 24 vdc power supplies for use with the InSight II Integrated flame
scanner. Model 60-2685-25 can power up to five InSight II scanners, model 60-2685-4 and 60-
2685-50 can power up to ten InSight II scanners (see note 1). Refer to bulletins CU-100 and CU-118
for details.
Notes:
1. Listed output is when power supply is vertically mounted, and with an ambient temperature of
104F (40C) maximum.
PART NUMBER DESCRIPTION NOTES BULLETINS
60-2685-25 24 VDC Switching Power Supply, 100-240 vac 50/60 Hz. input, 2.5 A output
at 24 vdc. Powers up to five scanners.
Dimensions: 3.7"(95mm) high x 1.6" (40mm) wide x 4.3"(108mm) deep
1 CU-118
60-2685-50 24 VDC Switching Power Supply, 100-240 vac 50/60 Hz. input, 5.0A output
at 24 vdc. Powers up to ten scanners.
Dimensions: 4.5" (115mm) high x 2.0" (50mm) wide x 4.8" (121mm) deep.
1 CU-118
60-2539-12 DIN mounting rail, 12" (305mm)long
60-2539-24 DIN mounting rail, 24" (610mm)long
60-2539-36 DIN mounting rail, 36" (914mm)long
SWIVEL MOUNT
ORIFICE RETAINER
PURGE
ORIFICE
FIELD OF VIEW
FIELD OF VIEW
BALL
AIR SUPPLY 3/8” PLUG
1" SWIVEL MOUNT 60-1199-1,2 SEALING COUPLING

17

Scanner Cable with Female Connector, P/N 59-546-x, 59-547-x
Fireye offers the 59-546 (8-conductor) and 59-547 (12-conductor) cables in precut lengths with a
female factory installed connector. These assemblies are offered in several lengths ranging from 3-
meters (9 ft., 10 in.) to 90-meters (295 ft., 3 in.)
Table 1: SCANNER CABLES 59-546-x
PART
NUMBER DESCRIPTION
LENGTH
METERS FEET
59-546-3 8-Conductor 3-meter cable assembly with 8-pin female connector. 3 meters 9 feet, 10 inches
59-546-6 8-Conductor 6-meter cable assembly with 8-pin female connector. 6 meters 19 feet, 8 inches
59-546-9 8-Conductor 9-meter cable assembly with 8-pin female connector. 9 meters 29 feet, 3 inches
59-546-12 8-Conductor 12-meter cable assembly with 8-pin female connector. 12 meters 39 feet, 4 inches
59-546-15 8-Conductor 15-meter cable assembly with 8-pin female connector. 15 meters 49 feet, 2 inches
59-546-30 8-Conductor 30-meter cable assembly with 8-pin female connector. 30 meters 98 feet, 5 inches
59-546-45 8-Conductor 45-meter cable assembly with 8-pin female connector. 45 meters 147 feet, 7 inches
59-546-60 8-Conductor 60-meter cable assembly with 8-pin female connector. 60 meters 196 feet, 10 inches
59-546-90 8-Conductor 90-meter cable assembly with 8-pin female connector. 90 meters 295 feet, 3 inches
59-546 8-Conductor cable without connector. Sold by the foot for use as extension
cable from a junction box.
- As required
Table 2: SCANNER CABLES 59-547-x
PART
NUMBER DESCRIPTION
LENGTH
METERS FEET
59-547-3 12-Conductor 3-meter cable assembly with 12-pin female connector. 3 meters 9 feet, 10 inches
59-547-6 12-Conductor 6-meter cable assembly with 12-pin female connector. 6 meters 19 feet, 8 inches
59-547-9 12-Conductor 9-meter cable assembly with 12-pin female connector. 9 meters 29 feet, 3 inches
59-547-12 12-Conductor 12-meter cable assembly with 12-pin female connector. 12 meters 39 feet, 4 inches
59-547-15 12-Conductor 15-meter cable assembly with 12-pin female connector. 15 meters 49 feet, 2 inches
59-547-30 12-Conductor 30-meter cable assembly with 12-pin female connector. 30 meters 98 feet, 5 inches
59-547-45 12-Conductor 45-meter cable assembly with 12-pin female connector. 45 meters 147 feet, 7 inches
59-547-60 12-Conductor 60-meter cable assembly with 12-pin female connector. 60 meters 196 feet, 10 inches
59-547-90 12-Conductor 90-meter cable assembly with 12-pin female connector. 90 meters 295 feet, 3 inches
59-547 12-Conductor cable without connector. Sold by the foot for use as extension
cable from a junction box.
- As required

18

SCANNER DISPLAYS (for standard / non-CEX models)
Scanner Display, P/N 95DISP-1, 95DISP-1-SS
P/N 95DISP-1 is a two-line by sixteen-character alpha-numeric VFD Display with a five-pushbutton
keypad. The 95DISP-1 is installed by the user onto the end of the standard scanners enabling the user
to view and change the operating parameters and setpoints at the scanner itself. The 95DISP-1-SS is
factory installed into the 95DSS3-1CEXSS and 95DSS3-1CEX-2 scanners.
Infrared Transmitter, P/N 95WIDISP-2
P/N 95WIDISP-2 is an Infrared Transmitter, installed by the user onto the end of the scanner instead
of a display. The 95WIDISP-2 transmitter provides infrared wireless communications to a model
95WIHH-2 hand-held remote communications tool.
Hand-Held Remote Communications Tool, P/N 95WIHH-2
P/N 95WIHH-2 is hand-held infrared remote communications tool. It contains an alpha-numeric dis-
play and pushbutton keys enabling the user to view and change the operating parameters and set-
points of an InSight II scanner when standing in line-of-sight of the scanner. The InSight II scanner
must be fitted with the optional 95WIDISP-2 infrared Transmitter.
Blank Cover, P/N 61-7347-1
P/N 61-7347-1 is a Blank Cover used to maintain environmental ratings when neither the 95DISP-1
nor 95WIDISP-2 is installed. With the 61-7347-1 installed, the operator interface must either be via
"Fireye Explorer" pc software, or by temporarily installing a 95DISP-1 or 95WIDISP-2.
Refer to bulletin CU-116 for 95DISP-1, 95DISP-1-SS, 95WIDISP-2, and 61-7347-1 installation
instructions.
Note: Model 95DSS3-1CEX includes the 95DISP-1 Display.
Models 95DSS3-1CEXSS and 95DSS3-1CEX-2 include the 95DISP-1-SS Display.
Model 95DSS3-1WICEX includes the 95WIDISP-2 Infrared Transmitter.
Model 95DSS3-1CEX-ND includes the 61-7347-1 Blank Cover.
SCANNER WIRING
To reduce electrical noise interference, take precautions to keep the scanner cable away from any high
inductive wiring associated with high inductive loads or high voltage, high energy spark ignition sys-
tems.
CAUTION: The flame scanner requires 24 Vdc power for operation. Connection to a 24 Vac
or 120 Vac power source will damage the scanner. Refer to wiring diagrams.
External 0.5 Amp slow-blow fuses are recommended to protect Flame Relay and Fault Relay
contacts
All wiring to the scanner should be rated at 105°C. For runs less than 1000 feet, the use of
Fireye Scanner Cable, P/N 59-546, (8 wire) and P/N 59-547, (12 wire) is recommended. For
runs in excess of 1000 feet, consult the factory.
CAUTION - Damage to electronic components through electrostatic discharge (ESD)
Note: Before touching the internals of the InSight II scanner installers can discharge any static built
up on their body by touching the outside of the scanner housing if the ground is already attached. If
the scanner isn’t already grounded, the installer could touch a nearby object that is earthed.

19

FIGURE 13. WIRING DIAGRAM, MODEL 95DSS3-1 INSIGHT II FLAME SCANNER
Notes:(see page 21)
FLAME
RELAY 1
(Note 1)
FLAME
RELAY 2
(Note 1)
FAULT
RELAY
(Note 2,3)
Red
Black
Tan
Yellow
Brown
Blue
Violet
Orange fuse
fuse
1
2
3
8
7
6
4
5
FIREYE CABLE 59-546-xx
COLOR CODE
CABLE
QUICK-DISCONNECT
TO BMS
INPUT
(Notes 5,6)
fuse
INPUT
POWER
24VDC
REMOTE
FILE SELECT
1
4-20mA FR1
OUTPUT
Referenced
To 24 VDC (-)
4-20mA FR2
OUTPUT
Referenced
To 24 VDC (-)
REMOTE
FILE SELECT
2
REMOTE RS-485
COMMUNICATIONS
*Blue/Red
Black/Orange
Red/White
Yellow/Black
Brown/Orange
Blue/Black
Black/Yellow
Red/Black
9
8
5
6
7
3
4
2
1
(+)
(+)
(+)
(-)
(-)
(-)
B
A
SW1
SW2
(Note 10)
(Note 10)
(Note 4)
(Note 7)
(Note 4)
Type 95DSS3-1
FIREYE CABLE 59-547-xx
COLOR CODE
24VDC
INPUT
POWER
TO BMS
METER
(Notes 5,8,9)
Orange/Black
INTERNAL
TERMINAL
BLOCKS (Note 11)
1
2
3
8
7
6
4
5
9
8
5
6
7
3
4
2
1
* wire color code format:
Blue/Red
Primary color Stripe color
Orange/Black
Black/Yellow
Brown/Orange
Blue/Black
Red/Black
Yellow/Black
Red/White
Black/Orange
Blue/Red
Orange
Violet
Blue
Brown
Yellow
Tan
Black
Red
8-Pin 8-Pin
9-Pin 12-Pin

20

FIGURE 14. RETROFIT WIRING DIAGRAM, MODEL 95DSS3-1WINC INSIGHT II SCANNER USING INSIGHT I CABLE
Notes: (see page 21)
FLAME
RELAY 1
(Note 1)
FLAME
RELAY 2
(Note 1)
FAULT
RELAY
(Note 2,3)
White/Black
Red
Pink fuse
1
2
3
8
7
6
4
5
FIREYE InSight I CABLE
59-497-xx
COLOR CODE
CABLE
QUICK-DISCONNECT
TO BMS
INPUT
(Notes 5,6)
fuse
INPUT
POWER
24VDC
REMOTE
FILE SELECT
1
4-20mA FR1
OUTPUT
Referenced
To 24 VDC (-)
4-20mA FR2
OUTPUT
Referenced
To 24 VDC (-)
REMOTE
FILE SELECT
2
REMOTE RS-485
COMMUNICATIONS
*Black/Red
White/Blue
Violet
Grey/Red
Brown
Blue/Red
Yellow
9
8
5
6
7
3
4
2
1
(+)
(+)
(+)
(-)
(-)
(-)
B
A
SW1
SW2
(Note 10)
(Note 10)
(Note 4)
(Note 7)
(Note 13)
Type 95DSS3-1WINC
24VDC
INPUT
POWER
TO BMS
METER
(Notes 5,8,9)
Orange
INTERNAL
TERMINAL
BLOCKS (Note 11)
1
2
3
8
7
6
4
5
9
8
5
6
7
3
4
2
1
Orange
Yellow
Brown
Blue
Grey
Violet
White
Black
Green
Red
Blue
White/Black
8-Pin
White/Red
* wire color code format:
Black/Red
Primary color Stripe color
J
K
M
L
H
G
B
A
9-Pin
C
D
12-Pin
White/Red
E
F
(NOTE 13)