Forney IDD-II User manual

www.forneycorp.com
BURNERS IGNITERS DAMPERS CONTROLS
IDD Flame Detector Heads
Standard Models: IDD-II, IDD-IIL, IDD-IIU, and IDD-Ultra
Publication 372000-05 Rev K

This manual contains information for the IDD Flame Detector Heads from Forney Corporation, 16479 N.
Dallas Parkway, Suite 213, Addison, Texas.
All personnel should become thoroughly familiar with the contents of this manual before attempting to
install, operate or maintain the system. Because it is virtually impossible to cover every situation that
might occur during operation and maintenance of the equipment described in this publication, personnel
mentioned herein.
accomplished under Forney supervision.
PROPRIETARY NOTICE
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.
Additional copies of this publication may be purchased from Forney. When ordering or requesting cost
information, refer to the publication number appearing on the title page. Address to the attention of the
Sales Department, Forney Corporation, 16479 N. Dallas Parkway, Suite 213, Addison, Texas 75001.
IDD Flame Detector Heads Manual
372000-05 Rev K
i
INTRODUCTION

IDD Flame Detector Heads Manual
372000-05 Rev K
ii
REVISIONS
REVISIONS DATE COMMENTS
AInitial Release
B
C 4/2003
D 6/2004
E
6/2004
F
10/2006
G
07/2013
Add CEX and Ultra versions of detector heads,
update graphics.
H
08/2013
Correct graphics with cable support brackets.
J
09/2015
Update logo and address.
Remove IDD-UV and IDD-UltraCEX
K
12/2020

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

Section 1 System Description
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1.2 Safety
Section 2 Installation
2.1 Installation Procedure
2.2 Detector Wiring
Section 3 Commissioning
3.1 Initial Checkout
3.1.1 Operational Checkout
Section 4 Operation
Section 5 Troubleshooting
Section 6 Maintenance
Section 7 Storage
Section 8 Return or Repair Service
Section 9 Parts
TABLE OF CONTENTS
IDD Flame Detector Heads Manual
372000-05 Rev K
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Dimensional drawing – IDD Standard housing
Detector Sighting
Detector Location VS. Secondary air rotation
IDD Direct Mount Arrangement
IDD Swivel Mount Arrangement
IDD Direct Mount with Cooling Chamber
IDD Swivel Mount Arrangement with Cooling Chamber
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Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
LIST OF FIGURES
IDD Detector Head Troubleshooting
IDD Detector Head Assembly Parts
Table 1
Table 2
LIST OF TABLES
1
2
3
5
6
10
11
11
11
12
13
14
15
16
17
2
6
7
8
9
9
9
10
13
17

IDD Flame Detector Heads Manual
372000-05 Rev K
1
SECTION 1
DESCRIPTION
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detector–ULTRA) heads utilize a silicon carbide cell. The complete assembly is potted with non-repairable
epoxy.
Detector Head Typical
Application
Spectral
Response Sensor Housing
IDD-II Oil and Coal IR 700 to 3300 nm /HDGVXO¿GH Standard
IDD-IIL Lignite IR 700 to 3300 nm /HDGVXO¿GH Standard
IDD-IIU 8Q¿OWHUHGIRU2LO
& Coal IR 400 to 3300 nm /HDGVXO¿GH Standard
IDD-Ultra Natural Gas UV 200 to 425 nm Silicon carbide Standard

IDD Flame Detector Heads Manual
372000-05 Rev K
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Figure 1 Dimensional drawing – IDD Standard housing
MECHANICAL SPECIFICATIONS
1.1
ATTRIBUTE STANDARD MODELS
Models IDD-II, IDD-IIL, IDD-IIU, IDD-Ultra
Approvals Factory Mutual (FM)
Housing Rating NEMA4
MECHANICAL
Size 1.75 x 6.25 inches
(44.5 x 158.8 mm)
Weight 1.3 lbs (0.59kg)
Mounting 1.0 inch NPT male pipe
Viewing Angle (non-restricted) 120 degrees
Recommended Viewing Angle 3 to 5 degrees

IDD Flame Detector Heads Manual
372000-05 Rev K
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Temperature Rating
Operating:
IDD-II, IDD-IIL and IDD-IIU
32oF to 140oF (0oC to 60oC)
IDD-Ultra
32oF to 250oF (0oC to 121oC)
Storage:
-25oF to 140oF (-32oC to 60oC)
Cooling / Sealing Air
Front Mount:
10 scfm @ 6-inches w.c.
(16m3/hr @ 152Kg/m2)
Fiber Optic:
15 scfm @ 6-inches w.c.
(25m3/hr @ 152Kg/m2)
Maximum Cooling Air Temp
IDD-II, IDD-IIL and IDD-IIU
120oF (49oC)
IDD-Ultra
170oF (77oC)
ELECTRICAL
Input Voltage +50Vdc for cell bias
+12 to +15Vdc logic
Output Voltage 0.1 to 0.8 Vac peak to peak
Power Consumption 0.12 VA maximum
Cable Rating 4 conductor, shielded, 20-gauge stranded
wire
Maximum Cable Length 1320 feet (402.3 meters)
Connector MS3112E10-6P
SAFETY
1.2
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hot furnace gas.

IDD Flame Detector Heads Manual
372000-05 Rev K
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WARNING: Do Not Open When Energized
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glasses to prevent eye injury caused by airborne particles in cooling/seal-air supply or wind
box.
CAUTION: The detector head contains sensitive electrical components. Ensure that all
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the I/O cable.
CAUTION: Disconnect the cable from the detector by hand, but do NOT twist the connector
barrel. Twisting could cause the wires to become disconnected from solder connections
inside the connector barrel.

IDD Flame Detector Heads Manual
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combustion zone is within the detector’s line of sight.
The IDD detectors are usually located on the boiler in a position that minimizes radiant or conducted heat
to the detector. In some cases, supplementary cooling chambers may be required. Typical installations
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optic) for ease of maintenance and a support bracket for the four-conductor cable. Cable support brackets
are not used with supplemental cooling chambers or CEX versions.
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equipment from Forney Corporation.
The location and sighting instructions listed in the following sections are general guidelines for the location
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• The physical mounts are adequate to support the weight of the detector head in the position required
for operation.
• The ball valve lever of the cooling-air line moves through its entire operating range without obstruction
from any structure, cable, or hose.
• The cooling-air hose and I/O cable do not interfere with the operation of any moving components at the
boiler front. The I/O cable does not contact hot surfaces capable of melting its insulation.
• The cable must not run close to any cable or equipment carrying high voltage to keep interference to
minimum.
SECTION 2
INSTALLATION
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Note: An acceptable detector location must ensure:
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IDD Flame Detector Heads Manual
372000-05 Rev K
6
1. The best results are obtained when the detector is aimed so that the detector’s line of sight intersects
the burner center at a slight angle (e.g. 5 degrees) and sees a maximum of the primary combustion
zone, as shown in Figure 3. If only one detector is used per burner, the line of sight should also
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as air register blades, interfering vanes, or other hardware should be cut away or notched so they do
not fall within the detector’s line of sight as shown in Figure 3.
INSTALLATION PROCEDURE
2.1
Note: Always check with the burner manufacturer before you trim the register blades.
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Figure 2 Detector Sighting
4. AN ACCEPTABLE DETECTOR LOCATION MUST ENSURE THE FOLLOWING:
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IDD Flame Detector Heads Manual
372000-05 Rev K
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Figure 3 Detector Location VS. Secondary air rotation
6. The preferred method for mounting surface mounted detectors requires the use of a swivel mount,
shown in Figures 6, 8, 10 and 12. 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
detector). The sight pipe should be arranged to slant downward so that dirt and dust will not collect
inside.
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position in place by tightening the three hex head cap screws located on the swivel mount ring.
FLAME MUST COMPLETELY COVER SIGHT OPENING
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close to the periphery of the throat where the ultraviolet radiation is at a maximum. (See Figures 3 and 4)
Having determined an appropriate location for the sight tube, cut a clearance hole for a 2 inch pipe
through the burner plate. If register vanes interfere with the desired line of sight, the interfering vane(s)
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below.
Note: Always check with the burner manufacturer before you trim register vanes.
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
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Figure 4 IDD Direct Mount Arrangement
IDD Flame Detector Heads Manual
372000-05 Rev K
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8. The detector lens must be kept free of contaminants (oil, ash, soot, dirt) and the detector housing
temperature must not exceed its maximum heat rating. Excessive temperatures will shorten detector
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Arrangement Drawings.
The detector mounting may be made with provision for purge air through only the 3/8” inlet or the 1” wye
connection. Normally purge air is provided through the 1” wye and the 3/8” inlet is plugged.
It is good practice to use the sealing coupling (P/N 9114793 NPT, 9114782 BSP) on all installations to
insure against unwanted furnace pressures from damaging the detector lens. When a sealing coupling
is used, the 1” wye connection is used for the purge air and the 3/8” opening is plugged. The sealing
coupling is located in front of the detector, behind the 1” wye/valve.
Under normal conditions, with clean burning fuels and moderate ambient temperature conditions, purge
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be required for fuels that produce high levels of ash or soot, or for hot environments to maintain the
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Refer to Parts section at the end of this manual for applicable part numbers of items shown in arrangement
drawings.
Cable support bracket is required on Standard IDD when a cooling chamber is not used.
CAUTION: To ensure safe and reliable detection it is the responsibility of the commissioning
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Note: If freezing temperatures are expected at the detector head, Forney recommends heat tracing the
detector sight tube. Contact Forney for additional details.

Cable support bracket is required on Standard IDD when a cooling chamber is not used.
Figure 5 IDD Swivel Mount Arrangement
Figure 6 IDD Direct Mount with Cooling Chamber
Figure 7 IDD Swivel Mount Arrangement with Cooling Chamber
IDD Flame Detector Heads Manual
372000-05 Rev K
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IDD Flame Detector Heads Manual
372000-05 Rev K
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in a conduit to protect it from damage and to prevent moisture ingress. Take precautions to keep the
detector cable away from any high inductive wiring associated with high inductive loads or high voltage,
or high energy spark ignition systems.
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DETECTOR WIRING
2.2
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IDD Flame Detector Heads Manual
372000-05 Rev K
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Before commissioning, complete all of the installation instructions.
SECTION 3
COMMISSIONING
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1. Verify the operation of the detector head as follows:
a) Remove mounted IDD detector head.
b) Connect it to the four-conductor cable.
c) Place a light source 1 to 4 feet from the surface of the detector. Use a Tungsten light source for
IR detector heads and a UV light source for the IDD-Ultra.
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voltmeter (DVM) or oscilloscope to be 0.1 to 8.0 vac, peak to peak.
e) Remove all light supplied to the detector cell, and verify loss of signal.
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INITIAL CHECKOUT
3.1
Operational Checkout
3.1.1

SECTION 4
OPERATION
IDD Flame Detector Heads Manual
372000-05 Rev K
12
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decreases, it causes a change in resistance of the cell substrate. This resistance change in turn creates
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burner and the sighting of the primary combustion zone.
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sighting may cause detector failure due to a weak or non-existent signal.

IDD Flame Detector Heads Manual
372000-05 Rev K
13
If the detector head malfunctions, ensure that the procedures described in the commissioning section
have been performed successfully.
Refer to Table 1 for Troubleshooting information.
TABLE 1: IDD Detector Head Troubleshooting
SECTION 5
TROUBLESHOOTING
Symptom Probable Cause Remedy
No signal output
Supply voltage to head not
present.
Verify +50 vdc and +12 to +14.5
vdc to detector.
Detector head assembly not
functional. Replace detector.
Overheated detector head.
Verify surface of detector is less
than 140° F (60°C). Correct high
temperature as necessary.
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signal.
Aim the detector at the base
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Check alarm Noise on output signal.
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grounded.
Check for broken cable wire.
Replace detector.
Reroute cable if not in a shielded
cable tray.
Weak detector (PPS) output
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signal
Aim the detector at the base
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7DUJHWÀDPHLQWHQVLW\LVZHDN Consult engineering.

IDD Flame Detector Heads Manual
372000-05 Rev K
14
The IDD detector head is a non-repairable device and requires no maintenance other than periodically
cleaning the cell surface. The appropriate cleaning schedule is determined by the quality and cleanliness
of the cooling-/seal-air source. Forney recommends the use of a non-oily cleaning solution and a soft
lint-free cloth for lens cleaning.
SECTION 6
MAINTENANCE

IDD Flame Detector Heads Manual
372000-05 Rev K
15
Store the IDD detector head in its shipping box until used.
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SECTION 7
STORAGE