Honeywell IRD 1020.1 User manual

1
Flame detection device for
oil and gas flames
INTRODUCTION
The IRD 1020.1 detector is used to supervise gas or oil
flames. This flame monitoring device should be connected
to a Satronic oil burner control box. Monitoring is based on
the infra-red flicker principle, in other words, the flickering
infra-red light of the flame is detected. The steady radiation
from, for example, the glowing refractory layer on the inside
of the boiler, has no effect on the detector. The IRD 1020.1
replaces the IRD 1020 and 920.
When exchanging the IRD 1020, care must be taken that the
corresponding IRD 1020.1 with the same imprint (blue or
white) is used (see page 3 and 4).
When exchanging the IRD 920, care must be taken to wire
the sensor correctly (see page 3), and the existing holder
must be exchanged with the magnetic holder M93.
For replacement of the IRD 920 with IRD 1020.1 is the
sensor cable also needed.
The infra-red flicker detector can be used with any one of the
following control boxes:
IRD 1020.1 DKG 972
DLG 974, 976
DMG 970, 971, 972, 973
TFI 812.2
MMI 810, 811, 812, 815, 816, 962
TMG 740-2, 740-3
SGU 930, 930i
IRD 1020.1 D DVI 980, 982
MMG 810, 811
FFW 930
DKG 972
DLG 974, 976
DMG 970, 971, 972, 973
TFI 812.2
MMI 810, 811, 812, 815, 816, 962
TMG 740-2, 740-3
SGU 930, 930i
CONSTRUCTIONAL FEATURES
The infra-red sensor and the pre-amplifier are hermetically
sealed in glass and along with the electronics form an
integrated unit in the flame detector. Wiring is by way of a
plug connection. The sensitivity control and two LED’s for
indication of the flame signal are situated on the rear of the
flicker detector.
Infra-red flicker detector IRD 1020.1
TECHNICAL DATA
Supply voltage 220 / 240 V (-15... +10%)
50 Hz (50 - 60 Hz)
or 110/120 V (-15... +10%)
50 - 60 Hz (±5%)
Nominal current input approx. 4 mA
Power consumption 1 VA
Ambient temperature -20°C to +60°C
Insulation standard IP 41
Mounting attitude any
Weight 40 g
Flame viewing attitude side-on or end-on according
to type
Spectral response 800 - 1100 nm
(with daylight filter) maximum 950 nm
Frequency range 15 Hz.... 250 Hz (-12 dB)
Sensitivity adjustment range approx. 1 : 20 (26 dB)
Switch-on delay < 3.5 sec.
(after connecting
operating voltage)
Response time < 0.1 sec.
Cut-out time < 1 sec.
Approved ambient parameter max. 95% at 30°C
- for operation -20°C... +60°C
- for storage -20°C... +80°C
Build-up of ice, penetration of
water and condensing water are inadmissible
Approvals according
to European standards EN 298, as well as all other
relevant Directives and
standards
EN1C-0118SZ20 R1005

2
TECHNICAL FEATURES
1. Flame detection
- Yellow- as well as blue-burning oil- and gas flames can be
monitored.
- The flame detector is suitable for operation where the
ambient temperature is within the range -20°to +60°C.
- The flickering detector IRD 1020.1 becomes active not
before a minimum threshold-level of steady light is
exceeded. That guarantees that neither electromagnetic-
nor ignition-spark noise are affecting the IRD.
- Sensitivity is adjustable.
- LED 1 is a warning indicator for the pre-purge phase as
well as normal operation. LED 2 indicates the actual status
of the detector: On or off.
- During pre-purge, LED 1 indicates possible stray light,
which may be produced either by a flickering or by
a steady light source, before the detector switches on
(LED 2).
- When the burner is operating normally, LED 1 acts as a
warning indication of the flame signal current sensitivity
being set too low - it begins to flicker or extinguishes
before the detector switches off.
- The compact size makes it possible to mount the detector
on any burner. For this reason the IRD mounting flange
M93 has the same dimensions and fixing holes as the FZ
flange M74. This magnetic flange provides the switch-off
facility specified in the European standard. The IRD 1020.1
therefore only functions with the M93 flange.
2. Installation instructions
- The detector probe should be fitted so that it receives the
light which pulsates most strongly. This can be achieved
by positioning the detector as close as possible to the
flame or by directing it at a particular zone of the flame (e.g.
by using a sighting tube).
- No stray light must be allowed to fall on the detector (e.g.
through cracks or from a sight glass). Pulsating stray light
(e.g. from fluorescent lighting or light bulbs) could cause
the system to switch to lockout. Due to the very high
sensitivity of the detector, it should not be exposed
directly or indirectly (reflections) to the ignition spark.
- The infra-red flicker detector should be fitted in such a way
that the ambient temperature cannot under any
circumstances rise above 60 °C. At higher temperatures,
there is a risk of incorrect operation and the life expectancy
of the unit could be reduced. In addition, care should be
taken that the detector is not subjected to unusually harsh
vibration and receives no hard knocks.
- It is necessary for the magnetic IRD M93 flange to be
mounted on a flat surface to avoid any mechanical stress
which could otherwise damage it.
COMMISSIONING AND MAINTENANCE
During commissioning and after servicing, the flame
monitoring system should be checked for faultless operation
as follows:
1. Check that the detector is connected properly. Wrong
connections are a risk to safety, and could cause damage
to the detector unit or burner system.
2. Adjust to maximum sensitivity and start the burner: If the
LED indicator is lit after the start impulse, carefully adjust
the sensitivity control until LED 1 extinguishes. No LED
should light up during the pre-purge phase.
3. When the burner is operating normally, carefully turn
back the sensitivity control until LED 1 begins to flicker.
Increase the setting again by one or two increments until
both LED’s are lit. If LED 1 does not flicker even at
position 1: Leave potentiometer at position 1-2. This
adjustment should be carried out when the flame signal
current is weakest (at a cold-start, shortly after flame
establishment or after stabilisation).
4. The flame detection device requires no maintenance of
any kind, and as it is classed as safety equipment, no
attempt should be made to open the housing.
5. Because the nature of the flame can change in time due
to the accumulation of dirt, the indicators on the detector
should be checked periodically.
Please note:
Burner operating normally = both LED’s on
Burner in pre-purge phase = both LED’s off
For safety reasons the sensitivity must not be set
higher than necessary.
Safety Checks:
1. Shut off the fuel supply when the burner is in the "run"
position. The indicator LEDs should extinguish and the
control box go to lockout.
2. Start the burner with the fuel supply shut off. The control
box must go to lockout at the end of the safety time due
to absence of flame.
3. Remove the detector from its mounting flange during a
pause, fit onto it a second flange M93. Start the burner
with straylight on the detector (e.g. by a cigarette-lighter,
bulb or a neonlight. Daylight or a torch is not suitable).
The control box must go to lockout due to stray light
either immediately or at the end of the pre-purge,
depending on the model.
Test switch-off facility:
1. Remove the detector durning the "run" position from its
special M93 flange. The control box must go to lockout
due to the activated switch-off facility.
IRD 1020.1

3
CONNECTION OF IRD 1020.1 TO SATRONIC BURNER CONTROL BOXES
IRD 1020.1
IRD 1020.1
IRD 1020.1
blue
black
brown
blue
black
brown
blue
black
brown
IRD 1020.1 TERMINALS
1
2
3
4
5
6
7
1 2
brown black blue
Possible faults
1. LED’s light up during the pre-purge phase (control
box switches to lockout):
a) Sensitivity set too high
b) Stray light
c) Ignition spark visible to detector (directly or reflection).
Correct by preventing direct sight of ignition spark.
d) Interference from ignition cable (lay cables some
distance apart, or possibly screen the detector).
2. No indication from LED’s after establishment of flame:
a) Incorrect or faulty wiring
b) Sensitivity set too low
c) Detector positioned wrongly (receives no light)
d) Detector or viewing window dirty
e) Defective detector
f) IRD flange M93 defective (cracks or other mechanical
defects)
g) wrong IRD flange, special magnetic IRD flange M93
is needed.
IRD 1020.1
Control box type TFI 812 DKG 97. DMG 97.
DLG 97.
Terminal no. 8 8 8
Terminal no. 1 1 2
Terminal no. 9 9 9
Control box type MMI
Terminal no. 8
Terminal no. 2
Terminal no. 9
Control box type TMG 740 SGU 930(i)
Terminal no. 8 N
Terminal no. 1 15
Terminal no. 20 1
SENSITIVITY –CHARACTERISTIC OF IRD 1020.1 (BLUE, WHITE)
IRD-Type Sensitivity Characteristic
blue standard For Gas- or dual fuel burner
Immune to Ignition spark detection
white increased For Gas- or dual fuel burner for difficult to detect flame
Immune to Ignition spark detection

4
ORDERING INFORMATION
ITEM DESIGNATION ITEM NO.
Flame sensor Flicker detector IRD 1020.1 side-on right blue 230V 16531
Flicker detector IRD 1020.1 side-on right white 230V 1653104
optional Flicker detector IRD 1020.1 end-on viewing blue 230V 16532
Flicker detector IRD 1020.1 D end-on viewing blue 230V 16552
Flicker detector IRD 1020.1 end-on viewing white 230V 1653204
Flicker detector IRD 1020.1 end-on viewing blue 115V 16572
Flicker detector IRD 1020.1 side-on left blue 230V 16533
Mounting flange Flange M93 230V 59093
Sensor cable Plug type, 3-wire, 0.6 m with tag wire ends 7236001
The above ordering information refers to the standard version.
Special versions are also included in our product range. Specifications subject to change without notice.
FLICKER DETECTOR IRD 1020.1
VARIANTS
35
3
26
4.5
15.1
48
ø20.5
4
17
14
104
29 50 44
ø13.5
21.8
HOLDER M93
Satronic
IRD 1020.1
Satronic
IRD 1020.1
Satronic
IRD 1020.1
Item no.
Light entrance from right blue 16531 230 Volt
white 1653104 230 Volt
End-on light entrance blue 16532 230 Volt
white 1653204 230 Volt
blue 16572 115 Volt
blue 16552 230 Volt
(1020.1 D version)
Light entrance from left blue 16533 230 Volt