Forney IDDX User manual

www.forneycorp.com
BURNERS IGNITERS DAMPERS CONTROLS
IDDX Flame Detector Amplier Manual
Publication 372001-24 Rev. A

IDDX Flame Detector Amplier Manual
372001-24 Rev. A
i
NOTICE: Read this manual in its entirety before commencing work of any kind. Only
experienced personnel familiar with this type of equipment, should install, setup, and
service this equipment.
NOTICE: The equipment serial number should be referenced any time that contact
is made with Forney. The serial number can be found on the Forney Data Label/Plate
(mounted on the equipment).
NOTICE: If any of the procedures or instructions provided in this manual are unclear,
contact Forney for resolution. Forney Corporation offers complete, on-site service solutions
to ensure proper installation, programming, commissioning, and troubleshooting.
WARNING: Never use this equipment in any manner for which it was not designed.
Improper use can severely impact user safety. The Forney Corporation cannot be held
liable for any damages resulting from such use! Failure to heed this warning COULD result
in death or serious injury.
TECHNICAL RELEASE LOG
REV MODIFICATION DATE
A Original Release 04/2021

PM IDD9000 Flame Amplier
372001-02 Rev Kv
TABLE
OF
CONTENTS

0.1 Introduction
0.2 Proprietary Notice
0.3 Safety Awareness
0.4 Personal Protective Equipment (PPE)
0.5 Typical Safety Alert Symbols and Action Icons
0.6 Additional Documentation
Section 1 Equipment Description
1.1 Summary
Operating Modes
1.2 Dimensions
1.3 Technical Data
1.4 Codes, Standards, and Agency Approvals
Section 2 Equipment Installation
2.1 Location
2.2 Required Site-Service Connections
2.3 Wiring
2.3.1 Amplier Upgrade Wiring Tables
Section 3 Setup and Conguration
Mode
IDD Channel Tuning
Flame Failure Response Time Delay for Modes 1
Self-Check Cycle Time for Modes 1
Saving Conguration
Functions Unavailable While Tuning
Analog Outputs
Amplier Shutdown/Failure
Section 4 Service and Troubleshooting
4.1 Service
Coordination
Handling
Storage
4.2 Troubleshooting
Section 5 Aftermarket
5.1 RMA / Warranty
5.2 Parts and Accessories
Section 6 Appendix
6.1 Common Acronyms
6.2 Common Regulatory Agencies
TABLE OF CONTENTS
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iii
iii
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iv
iv
iv
1
1-2
3-5
6
7
8
9
9
9
10
10
12
13
13-19
20
21
22
23
23
23
24
24
24
24
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27
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IDDX Flame Detector Amplier Manual
372001-24 Rev. A

iii
INTRODUCTION
0.1
PROPRIETARY NOTICE
0.2
SAFETY AWARENESS
0.3
This manual serves as a guideline to service technicians for the basic installation, setup, and troubleshooting
of the IDDX Flame Amplier, manufactured by Forney Corporation: 16479 Dallas Parkway, Suite 600,
Addison, TX 75001.
All personnel should become thoroughly familiar with the contents of this manual prior to installing,
setting-up and servicing this equipment. Because it is virtually impossible to cover every situation that
might occur during operation and maintenance of the equipment described in this publication, personnel
are expected to use good engineering judgment when confronted with situations that are not specically
mentioned herein.
The contents of this publication are proprietary data of Forney Corporation. Reproduction or use of any
part of the publication for purposes other than the support of the equipment for which it is published is
permissible only if expressly authorized in writing by Forney.
Safety is YOUR responsibility and must always be primary concern. The guidelines covered in this
manual will greatly improve your ability to safely install and maintain this equipment. It is the equipment
owner’s responsibility to ensure that the concerned personnel fully understand and abide by all site-
specic Health, Safety, and Quality protocols. Safety summaries and procedures can never replace good
common sense!
IDDX Flame Detector Amplier Manual
372001-24 Rev. A

PERSONAL PROTECTIVE
EQUIPMENT (PPE)
0.4
All involved personnel should follow their site-specic Health, Safety, and Quality guidelines.
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IDDX Flame Detector Amplier Manual
372001-24 Rev. A
TYPICAL SAFETY ALERT
SYMBOLS AND ACTION ICONS
0.5
ADDITIONAL DOCUMENTATION
0.6
ALL labels in this manual should be carefully observed, read, and understood. Standard labels are as
follows:
IDD Detector Manual
DANGER Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE Provided to notify personnel of potential damage to equipment. This
label can also contain important operational information and/or tips
that may be useful. These labels are not related to personal injury.

SECTION 1
EQUIPMENT DESCRIPTION
The Forney IDDX ame amplier is a ame detector amplier designed for use with Forney IDD series of
ame detectors. The IDDX Flame amplier is suitable for use in a variety of industries such as oil, coal,
gas, etc. and across several applications such as gas-red industrial burners, utility burners, waste fuel
burners, duct burners and igniters.
The IDDX ame amplier is a stand-alone intelligent controller which includes two printed circuit boards
(PCB) assembled and packaged in a covered chassis suitable for mounting on a standard DIN rail.
The IDDX ame amplier may be installed in any orientation (horizontal or vertical DIN rail). The IDDX
amplier must be installed in a controlled environment (protected from dust & excessive heat). Screw
terminals are provided for electrical connections with external equipment.
The IDDX ame amplier provides power control, signal conversion, and processing control for Forney
IDD detectors (IDD II, IDD IIU, IDD IIL, Ultra). The IDDX is designed to work with any one of the following
Forney ame detectors:
Detector Forney Part Number
IDD II 3832121
IDD IIU 3832122
IDD IIL 3832123
IDD Ultra 3832129
Power printed circuit board (PCB) receives 24VDC input power from an external power source and
provides 5 VDC, 12 VDC, 15 VDC, & 50 VDC power for various circuits. The 15Vdc supply, powers IDD
detector heads directly while 50VDC provides bias voltage for the IDD detectors. Both 15 VDC and 50
VDC output to ame detector are protected by self-resetting fuses (PTC) .
The IDD ame detector produces an analog data signal whose amplitude and frequency vary with
light intensity. This signal is amplied using an adjustable gain amplier (0 through 15) and fed to
microprocessor for signal processing. Microprocessor runs FFT algorithm to provide signal intensity at
different frequencies. At regular intervals, the microprocessor compares those values with congured
tuning parameters from memory. When the count value exceeds the corresponding value from memory,
the microprocessor sets a ag to indicate ame presence.
SUMMARY
1.1
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The count values provide a direct measure of infrared or ultraviolet light intensity striking the respective
sensors. Accordingly, an analog output signal (4-20 ma) is provided to drive ame intensity meters or for
use in a control system. Analog output is driven by internally generated 15 Vdc and is protected by a self-
resetting fuse (PTC). The minimum and maximum scale values are user adjustable based on customer
requirements.
The IDDX amplier includes a self-check feature for ame detection system. Once ame is detected,
at user selected interval, IDDX runs a self-check routine to validate proper functioning of the system.
During self-check, 50 VDC Bias voltage to detector is removed for a brief period while processor monitors
detector signal to drop below ame relay drop out set point. If the ame signal from detector fails to
drop below the drop out set point, CPU triggers fault LED to lit, Flame relay to deenergize, Fault relay
to deenergize and locks out IDDX amplier in fault state until manually reset by technician by pressing
RESET push button.
Fault relay is normally energized to provide fail safe output and deenergizes on detection of fault. Thus,
fault relays contacts are in closed state until any fault is detected. The IDDX amplier checks for broken
wire or disconnected IDD detector head or loss of 15 VDC power to detector and triggers fault alarm when
such condition persist.
Any fault detected by rmware in the IDDX amplier, generates a corresponding error message that can
be downloaded to the Termiex/ SmartDisplay®. Any failure will be continually broadcast until reset
pushbutton is pressed.
The IDDX Flame Amplier faceplate has six (6) status LEDs to display real-time
operating conditions:
Flame (Green) Steady when the Flame Relay is in “ON” state.
Alarm (Red) Steady when the Detector faults; off otherwise.
WDT (Green) Flashing every second indicates normal operation; off during processor
internal fault except when detector is disconnected.
P1 (Green) Steady when Prole Select Input 1 is ON; off otherwise.
P2 (Green) Steady when Prole Select Input 2 is ON; off otherwise.
Self-CHECK (Green) Blinking on every period value set on Self check timer; off otherwise.
NOTICE: Analog output is generally representative of the ame intensity and
are intended for display on the operator console only. Analog output signal is not
representative of quality of combustion and must not be used as ‘loss of ame’ input to
safety control loop of the Burner Management System.
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Operating Prole Select Inputs:
Two (2) prole select inputs are available for selecting up to four (4) different proles, numbered from
0 to 3 stored in its non-volatile memory. Each prole select input is sourced (5 VDC) from the detector
itself and must be wired to a potential free contact controlled by BMS or other control system. Do not
connect external power to prole select input terminals.
The stored proles are intended to allow for easy switching between commonly used burner operating
conditions without requiring manual re-tuning of the ame amplier. Each prole contains a full set of
operating parameters see Table 210 Operating Proles.
The amplier reads the prole selected by the Prole Select input code and displays the Active Prole
number in the lower right corner of the Termiex / SmartDisplay®. The Active Prole can be changed
at any time other than while in the tuning loop by repositioning the Prole Select inputs. Any tuning
parameter changes can be saved only to the Active Prole. Example: Active Prole 0 is displayed as
“Set 0”.
Table 2-10 Prole Select Input Encoding
Prole Select 1
J12-TB 1
Prole Select 2
J12-TB2
ACTIVE PROFILE
OPEN OPEN Set 0
CLOSE OPEN Set 1
OPEN CLOSE Set 2
CLOSE CLOSE Set 3
Operating Modes
All operating proles are initialized via a prole ag and with the default settings shown.
Table 2-11 Operating Proles
Termiex Display Mode 1: IDD PPS only Setting Range
IDD GAIN 0 0 through 15
SPECTRAL RANGES 1
CORNER 1 80 Hz 12 -1024
CORNER 2 200 Hz 12 -1024
WEIGHT 1 1 1 through 9
Power PCB installed on the base includes terminals for wiring as well as LEDs
for troubleshooting
LED 4 (Yellow) Steady when 24 VDC input power is present.
LED 11 (Yellow) Steady when 15 VDC output power to Detector head is present.
LED 10 (Yellow) Steady when 5 VDC output power is present.
LED 1 (Yellow) Steady when 50 VDC output power to detector head is present.
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HD-01-EX Flame Detector
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A serial communication port is located on the front of the IDDX. This port enable communication be-
tween the microprocessors on the board and a hand-held Termiex/ SmartDisplay® via RS422 commu-
nication protocols.
Upon completion of installation, the user must connect the Termiex/ SmartDisplay® to the amplier
and revise the tuning parameters suitable to detect the presence and absence of target ame. Us-
er-supplied tuning parameters are stored and remain unchanged until overwritten with new tuning
parameters.
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372001-24 Rev. A
A serial communication port is located on the front of the IDDX. This port enable communication
between the microprocessors on the board and a hand-held Termiex/ SmartDisplay® via RS422
communication protocols.
Upon completion of installation, the user must connect the Termiex/ SmartDisplay® to the amplier
and revise the tuning parameters suitable to detect the presence and absence of target ame. User-
supplied tuning parameters are stored and remain unchanged until overwritten with new tuning
parameters.
Table 2-11 Operating Proles
Termiex Display Mode 1: IDD PPS only Setting Range
CORNER 3 1024 Hz 12-1024
CORNER 4 1024 Hz 12-1024
WEIGHT 2 1 1 through 9
IDD PICKUP- PPS 500 1-4095
IDD DROPOUT- PPS 100 1-4085
IDD ANALOG LOW- PPS 0 0-3000
IDD ANALOG HIGH- PPS 3000 0-4095
FFRT 3.8 Seconds 1,2,3.8
CHECK DELAY 120 Seconds 30 to 600 seconds
IDDX Flame Detector Amplier Manual

Figure 1 – IDDX Flame Amplier
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HD-01-EX Flame Detector
372001-23 Rev. A
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DIMENSIONS
1.2
Figure 2 - IDDX Flame Amplier Dimensions in inches
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IDDX Flame Detector Amplier Manual

TECHNICAL DATA
1.3
Electrical
Mechanical
Power Supply: 24 VDC (+/-10%)
Steady State Current: 265 mA
Inrush Current: 1 A
Power Consumption: 6.5 Watt
External In-line Fuse:(Required)1 1A Fuse (Customer Furnished)
Terminal Size: 18 AWG
Heat Dissipation: 4 Watt
Flame Relay: 1 (fail safe)
Contacts: (External 500 mA Fuse
Required in series) SPST, 250VAC/5A
Conformal Coating: No
Relay Operating Cycle: > Min 20 X 106 Operations
Flame Failure Response Time
(FFRT): 1, 2, 3, 3.8 second (user adjustable)
Fault Relay: 1
Analog Output: One Sourced 4-20 mA, Load resistance <= 500 Ohm
Prole Selection Digital Inputs: 2 Self-Powered Inputs
Communication (Wired): RS-422 (Termiex)
Housing Material: Engineered Polymer
Weight: 0.62 lbs. (280 gms.)
Degree of Protection: IP20, NEMA 1
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HD-01-EX Flame Detector
372001-23 Rev. A
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CODES, STANDARDS,
AND AGENCY APPROVALS
1.4
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IDDX Flame Detector Amplier Manual
Environmental
Compatible Detector Heads
Ambient Operating Temperature: 32°F to 140°F (0°C to 60°C)
Ambient Storage and Transportation Temperature: 68°F to 122°F (20°C to 50°C)
Relative Humidity: RH 95% 104°F (40°C)
IDD-II Filtered IR Detector (700nm – 3300nm)
IDD-IIL Low Frequency IR Detector (700nm – 3300nm)
IDD-IIU Unltered IR Detector (400nm – 3300nm)
IDD-Ultra UV Detector (200nm – 425nm)
Table 1 - Codes and Standards
The IDDX Flame Amplier is designed to meet several industry codes and standards. Subsequently,
the CE, UL, IEC, FM, and ATEX approvals have been obtained.
Code/Standard Description
Enclosure Type IP 20
Factory Mutual
7610 Approval Standard for Combustion Safeguard and Flame Sensing System
ANSI/UL 94 Flame Resistant UL 94 Compliant
RoHS Directive 2002/95/EC

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IDDX Flame Detector Amplier Manual
The purpose of this section is to ensure that the IDDX Flame Amplier is installed using recommended
Forney practices.
• The IDDX Flame Detector Amplier must be installed in a cabinet rated to NEMA 12 ingress protection
or better to ensure it is protected from heat, dust, and moisture ingress.
•If installed in an unventilated cabinet, forced exhaust / colling air fans may be required depending on
ambient conditions and heat loading.
• Where ambient temperatures are expected to exceed specied limits, cabinet must be installed in a
controlled environment.
• Ensure that the IDDX Flame Amplier and associated cabling is located at a safe distance from high
voltage lines or other sources of electrical noise.
LOCATION
2.1
SECTION 2
EQUIPMENT INSTALLATION
NOTICE: Ensure that the supply voltage matches the information provided in section 1.3
Technical Data prior to connecting power to the unit.
REQUIRED SITE-SERVICE
CONNECTIONS
2.2
The IDDX Flame Amplier requires a 24VDC input from an instrument quality power supply. Forney
strongly recommends use of 24 VDC input power source with low output ripple voltage to keep power
supply induced noise to minimum.

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IDDX Flame Detector Amplier Manual
WIRING
2.3
Figure 8 – IDDX – WIRING DAIGRAM
Voltage Internal PTC Fuse Description
50V 10mA/0.5W Sensor Bias Supply
15V 50mA/30V/0.6W Sensor Logic Supply
15V 50mA/30V/0.6W 4-20mA

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IDDX Flame Detector Amplier Manual
Figure 9 – IDDX – Internal Self Resetting Fuse details
PINOUT SUMMARY:
PIN Signal Function
J4 Connector - 24V Supply
1 24VDC (+) Input Power Supply Positive Wire
2 COMMON Input Power Supply Negative Wire
3 Earth / Shield System Earth / Chassis Ground
J3 Connector - External DCS
1 GND Electrical Ground return for DCS
2 4-20mA IDD icker signal, 4-20mA return PPS
3 15V 15VDC + for DCS System
J11 Connector - Relay
1 ALARM COM Common for External BMS system
2 ALARM NO Normally Open for External BMS system
3 FLAME COM Common for External BMS system
4 FLAME NO Normally Open for External BMS system
J2 Connector – Reserved for Future Use
1 GND Electrical Ground return for System
2 B Reserved for Future Use
3 A Reserved for Future Use
J1 Connector - IDD Head Connector
1 Shield Chassis (cable shield)
2 GND Electrical ground return for detector
3 50V +50 VDC Bias/5mA
4 IDD IDD Detector signal
5 15V +15 VDC for IDD detector
J12 Connector - Master/slave and Prole Inputs
1 GND Electrical ground return for External system
2 P1 Binary 1, Add all for 0-3 Prole Select
3 P2 Binary 2, Add all for 0-3 Prole Select
J6 Connector - ISP
1 ICSP In system Programming to ash new rmware
J7 Connector - Termiex
1Termiex Connecting termiex for user interface
Refer to Application guide 372001-25 for detailed instruction when replacing Forney legacy amplifiers
with IDDX Flame Amplifier.

The purpose of this section is to ensure that the IDDX Flame Amplier is properly setup and congured,
using recommended Forney practices.
The amplier tuning mode can be reached using either the handheld Termiex/SmartDisplay® or the
Forney Terminal Emulator Software (TES) installed on a laptop computer. Table 3-1 Keypad Commands
summarizes the keypad commands available in the IDDX Flame Amplier rmware program.
The three key sequence “/13” (slash, one, three) is pressed to enter the tuning loop. The amplier is tuned
in the active mode only.
Note:
•During tuning, any changes that cause loss of ame indication will be transmitted to the main ame
relay following the FFRT delay.
•While tuning, if the main ame relay drops, the system will not re-initiate Flame-on status until the
user exits the tuning loop. If the ame lamp indicator is on when the tuning loop is exited, the system
will then return to flame-on status.
SECTION 3
SETUP AND CONFIGURATION
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IDDX Flame Detector Amplier Manual
Table 3-1 Keypad Commands
Function Termiex / SmartDisplay®
Key strokes
Terminal Emulator Software
(TES) Button
Enter the tuning loop / 1 3
Slash one three Cong
Do self-check now ?
Question mark Self Test

Mode
The rst screen displayed in the tuning loop allows selection of the operating MODE. Each Channel of
the amplier can use a single IDD detector. The numeric key 1 is pressed to set IDD MODE. Press F4,
“NXT” to continue.
IDD Channel Tuning
If MODE 1 is selected, a sequence of IDDX channel tuning screens will follow. If available, use the USB
oscilloscope to facilitate IDD tuning. An oscilloscope with FFT is more effective in determining the lower
and upper corner frequencies; pick-up and dropout points; and analog output low and high points.
IDD Gain
To avoid saturation, the gain must be set to midrange or below. If the ame signal is clipped by excessive
amplication, its spectrum is corrupted, making the ame on/off decision unreliable.
Factory default is a gain value = “0”. Under most installations this should be sufcient gain for operation
of the amplier. The “weight factor” multiplier explained in the next section will also set output gain. If lack
of gain is realized, then gain setting should be increased.
Note:
Any ame detector connected to the unselected mode input will receive power but is not monitored for
signal level or tested during self-check
Note:
Gain setting should be as low as possible, typically 0, to ensure safety. As boiler load increases
raw signal strength will increase. If this signal strength is too high, then gain will need to be reduced.
Figure 3-2 & 3-3 will apply so as not to saturate the amplier. “<<” need to be avoided as this a high
signal strength near saturation.
• The IDDX Flame Amplier allows a maximum of 10 minutes of use while in the tuning loop before a
time-out will occur. At a time-out, the tuning loop is exited and the system returns to active operation,
any unsaved changes that were entered will be lost.
• Upon time-out, completion of tuning or unplugging the Termiex, the IDDX returns to normal operating
mode. This is indicated by the WDT LED starting to ash. Pressing the reset button ensures the IDDX
has returned to normal operation.
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IDDX Flame Detector Amplier Manual

For best tuning and operation, adjust the gain up or down, so the most LEFT arrows are showing and no
RIGHT arrows are visible. Use the F1, “DEC” and F2, “INC” keys on the Termiex to make adjustments.
The correct GAIN setting has the signal strength indicator “>” extending from the left side to the approximate
center of the display while the burner is operating. The GAIN value is stored as a number from 0 to 15,
where 15 corresponds to the maximum GAIN of 32x. Gain setting should be as low as possible, typically
0, to ensure safety.
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IDDX Flame Detector Amplier Manual
Gain Value Multiplying Factor
0 0.65
1 1
2 1.3
3 2
4 2.6
5 3.25
6 4
75
8 5.2
96.5
10 8
11 10
12 10.4
13 16
14 20.8
15 32
Table 3-2 IDD Gain Range